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RELATED APPLICATION
This application claims priority to U.S. Provisional Application Ser. No. 61/451,513 (entitled INTEGRATED NETWORKED ASSET MANAGEMENT, filed Mar. 10, 2012) which is incorporated herein by reference.
BACKGROUND
Managing ice merchandisers to keep them stocked with bags of ice has been performed by drivers of ice trucks, who visit sites and check the ice merchandisers visually to determine whether more bags of ice should be added. This process leads to wasted effort when the ice merchandisers do not need more ice. It also may lead to delay in refilling ice merchandisers and result in lost sales if not refilled quickly enough.
One proposal to begin to address such problems has been to add weight sensors under the ice merchandiser to weigh the entire ice merchandiser. This retrofit solution is not able to offer level information on more than one product inside the merchandiser and its components, all external, may be negatively impacted by adverse weather conditions or subject to tampering or vandalism.
SUMMARY
A system for an ice merchandiser having a compressor in a compressor enclosure to cool the ice merchandiser includes a sensor disposed within the ice merchandiser, and a communications component disposed within the compressor enclosure and coupled to the sensor to receive signals from the sensor representative of the amount of ice in the ice merchandiser, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection.
In one embodiment, the sensor includes a camera and a heating element proximate a lens of the camera.
In another embodiment, an ice merchandiser is fitted with at least one weight scale that sits in the bottom of the ice merchandiser to measure the weight of ice bags placed upon it. The scale in one embodiment covers substantially the entire floor of the chest. The scale provides an output to a system outside a cooled volume of the ice merchandiser. The system takes the output and provides a signal on a network representative of the weight, and correspondingly, the ice supported by the scale.
In some embodiments, multiple scales may be used in the chest side by side to measure the weight of different sized bags of ice placed upon the scales.
In further embodiments, temperature sensors and contact switches may be coupled to the system to provide signals representative of temperature inside and outside of the chest, as well as whether a chest door is open or not.
The system may provide signal processing to provide signals representative of the sensed parameters to the network. In one embodiment, the system includes a device having an IP address to facilitate exposing the sensed information via a website like interface. A wireless modem may be included.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system to detect stocking of ice in an ice merchandiser according to an example embodiment.
FIG. 2 is a top view of components in a compressor container for the ice merchandiser of FIG. 1 .
FIG. 3 is a side block diagram illustrating further details of a sensor system within the ice merchandiser of FIG. 1
FIG. 4 is a block schematic diagram of an example heater.
FIG. 5 is a block flow diagram illustrating functions performed in accordance with an example embodiment.
FIG. 6 is an example interface to interact with the system of FIG. 1 .
FIG. 7 is a block diagram a system for performing functions and communications according to an example embodiment.
DETAILED DESCRIPTION
In the following description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural, logical and electrical changes may be made without departing from the scope of the present invention. The following description of example embodiments is, therefore, not to be taken in a limited sense, and the scope of the present invention is defined by the appended claims.
The functions or algorithms described herein may be implemented in software or a combination of software and human implemented procedures in one embodiment. The software may consist of computer executable instructions stored on computer readable media such as memory or other type of storage devices. Further, such functions correspond to modules, which are software stored on a storage device, hardware, firmware or any combination thereof. Multiple functions may be performed in one or more modules as desired, and the embodiments described are merely examples. The software may be executed on a digital signal processor, ASIC, microprocessor, or other type of processor operating on a computer system, such as a personal computer, server or other computer system.
FIG. 1 is a block diagram of a system 100 to detect stocking of ice in an ice merchandiser 110 according to an example embodiment. One or more different types of sensors may be placed inside the ice merchandiser 110 in various embodiments. In one embodiment, a sensor includes a camera 115 placed to obtain images, such as still images or video images of items, such as bags of ice placed on one or more platforms 120 , 122 inside of the ice merchandiser 110 . In one embodiment, platform 120 is used to hold bags 124 of one size, and platform 122 is used to hold bags 126 of a different size.
In one embodiment, the camera has a lens that provides field of view 128 that is wide enough, such as at least 70 degrees in one embodiment that is sufficient to enable someone to determine whether the items need restocking. One or more further sensors may be included, such as a temperature sensor 130 disposed within the ice merchandiser 110 to measure the temperature within the ice merchandiser. Sensor 130 may also include multiple sensors to sense further parameters, such as humidity in further embodiments.
In one embodiment, the platforms 120 and 122 may comprise load cells, forming weight scales that sit in the bottom of the ice merchandiser to measure the weight of ice bags placed upon them. The scales may be used with or without the camera, and the camera may also be used without the scales in various embodiments. In one embodiment, one scale is used that covers substantially the entire floor of the chest and measures the pressure on each of four feet supporting the scale off the floor of the chest. In further embodiments, the scale provides a linear analog output representative of weight. The output may be provided to circuitry either inside, or outside the ice merchandiser 110 , such as within a compressor enclosure 140 housing a compressor 142 and fan 144 in various embodiments, where the output may be converted to standardized signal such as a linear zero to five volt signal representative of the weight of ice bags on the scale.
The scale has a low profile such that it does not adversely impact the cooling volume of the ice merchandiser for holding ice bags. The scales are sized to fit within the ice merchandiser, and to ensure that they cover enough of the floor to accurately measure the amount of ice stacked on them. In some embodiments, some space is left between walls of the ice merchandiser and sides of the scale to ensure that the scales are not adversely affected by interference from the wall. The space is also small enough to ensure that bags of ice are properly accounted for by the scale without falling between the scale and walls. Such a sized scale is said to substantially cover a desired portion of the ice merchandiser floor. As can be seen, there is some tolerance permitted.
In some embodiments, multiple scales may be used in the chest side by side to measure the weight of different sized bags of ice placed upon the scales. In an ice merchandiser with two doors, one door may be used for bags of one weight having a first scale, and the other door may be used for bags of a different weight having a second scale. Thus, two weights are provided to the system for publishing via the network connection. In some embodiments, the system may provide alerts regarding a need for restocking one side or the other of the ice merchandiser when the weight falls below a desired level. In various embodiments, the alerts may be provided via text messages, email, voicemail or other mechanisms including various social media. Information regarding the ice merchandiser may be accessible from at least mobile devices, computer systems, and other devices capable of providing information.
In further embodiments, temperature sensors and contact switches may be coupled to the system to provide signals representative of temperature inside and outside of the chest, as well as whether a chest door is open or not. FIG. 2 is a top view block diagram of components in the compressor enclosure 140 . A compressor electrical enclosure 210 contains circuitry for controlling the compressor and fan, as in standard compressor designs. In some embodiments, sensors are provided to sense temperature within the compressor enclosures 140 , external temperature, and compressor power draw. Still further sensors may be included in further embodiments.
A communications enclosure 215 is included, and contains circuitry for controlling the sensors that have been added to the ice merchandiser 110 in various embodiments. The circuitry has an IP address and modem, and provides data to a network such as the Internet, representative of the sensed parameters, such as images, weight, temperature, humidity or other parameters that may be sensed, and correspondingly, the ice supported by the scale. In one embodiment, a web enabled sensor appliance, such as a Maverick IP Sensor Appliance by Mamac Systems, incorporates a web server, analog/digital inputs and relay outputs. The appliance operates with any 24 VAC transformer, and may be plugged into a hub/router. Any web browser can be used to enter the default IP address to receive the data.
FIG. 3 is a side block diagram illustrating further details of the sensor 115 within the ice merchandiser 110 of FIG. 1 . A circuit board 310 has a camera 315 mounted on it, along with a light emitting diode 320 (LED) near the camera and corresponding lens of the camera. In one embodiment the camera 315 and LED 320 are enclosed in a transparent camera enclosure 325 . The camera enclosure 325 may be made of polycarbonate materials in one embodiment, and the volume enclosed may be heated sufficiently by the LED 320 to remove or prevent moister from condensing or freezing on the lens of the camera 315 , allowing a clear field of view of the items stocked in the ice merchandiser 110 . In further embodiments, the LED 320 may be positioned very close to the lens to obviate the need for the enclosure 325 . The proximity of the LED 320 to the camera may thus vary in different embodiments, but should be within a distance to allow it to perform the function of providing a clear field of view. In addition, the LED 320 may serve to illuminate the items for viewing. In still further embodiments, the camera may include circuitry to allow for imaging without the use of visible light.
The circuit board 310 may further include control circuitry 330 which can be used to control the camera and LED, and communicate with the circuitry in the electrical enclosure 210 in various embodiments. The processing of data may be split between such circuitry in various embodiments, or only one set of circuitry may perform all the functions. In still further embodiments, one or more sensors, such as temperatures sensor 335 may be included on the circuitry board 310 .
FIG. 4 is a block schematic diagram of an example heater 400 that may be used to provide a clear field of view for the lens of the camera. The heater may include a substrate having fine resistive heating wires to provide heat when powered via circuitry. The substrate may be adhesive, with the wires on or embedded, similar to add on rear windshield heaters for automobiles. The heater 400 be positioned proximate the lens of the camera or in the field of view of the lens on or embedded within the transparent camera enclosure 325 . The heater may be positioned outside the field of view on the camera enclosure 325 if it provides sufficient heat to create a clear field of view when images are obtained.
FIG. 5 is a block flow diagram 500 illustrating sensed parameters and components involved in data flow in various embodiments. Internal conditions 510 represent conditions inside of the ice merchandiser 110 in one embodiment. Internal conditions may include measurements from two scales at 512 and 514 , the camera 516 , and internal temperature 518 . External conditions 520 may include compressor enclosure or hood temperature 522 , compressor power draw 524 , a maintenance log 526 , and power loss indications 528 .
The information collected corresponding to these conditions is then communicated via the communications module 215 at 530 . The module 215 may be a 3 G, 4 G, WIFI, or other type of wireless communications module in various embodiments that is coupled to the internet represented at 532 . The information is then provided to server 534 , and back via a network 536 , such as the internet, to a provider of the items at 538 . The provider 538 may be an ice company in one embodiment responsible for restocking the ice merchandiser. One or more user interfaces may be provided on a personal computer, smart phone, tablet, or other device enabling a person responsible for restocking to determine whether or not an ice merchandiser needs restocking, and with what types of items. The information may distinguish between different sized bags of ice, such as 10 lbs or 20 lbs.
FIG. 6 is an example interface 600 to interact with the system of FIG. 1 . In one embodiment, the server 534 processes the information and creates a user interface allowing viewing of the information in various forms. Multiple different parameters may be published and viewable via interface 600 . A web type interface, or any number of other media, such as social media, including email and other forms of electronic communication may be used. Still further, the system may provide visible and audio alerts proximate the ice merchandiser.
In example interface 600 , images are shown at 610 , 612 , 614 . The images may be thumbnail images that are linked to higher quality images in further embodiments. The newest image is indicated at 614 , with prior images available to the left side of the display. In one embodiment, clicking on the latest image may initiate communications back to the system 100 to provide a real time image.
A graph 620 illustrates desired parameters over time. In some embodiments the time frame may be selected by the user in a common manner. Illustrated on graph 620 are internal ice merchandiser temperature 622 and ambient temperature 624 , which varies significantly over the few days that are shown. As desired, the internal temperature 622 is fairly constant. Note that a winter environment is like occurring in this representation as the ambient temperature dips below the internal temperature. While temperature is shown on the graph, other parameters may be shown in further embodiments. In addition, a link to multiple settings 630 may be provided to enable the user to change timing of when data is periodically provided, or change any other control points used to control the system 100 , including the compressor and fan in some embodiments.
Some example control points and corresponding notes are shown in the following TABLE 1:
TABLE 1
Product
Product Level Measured
Level
Within ±5%
Product Level Differentiation
by Merchandiser Side
Compressor Status
Defrost Monitoring and
Control
Electric Current Draw
Monitoring
Power Outage Monitoring
Compressor Hood
Temperature Change
Monitoring
Maintenance Tracking and
Alerts
Interior Case Temperature
Temperature Change
Monitoring
Merchandiser Door Status
Open Door Alarm Set Points
FIG. 7 is a block diagram a system for performing functions and communications according to an example embodiment. FIG. 7 is a block diagram of a computer system or circuitry which may be used to process and publish sensed data and information according to an example embodiment. In the embodiment shown in FIG. 7 , a hardware and operating environment is provided that is applicable to any of the circuitry, servers and/or remote clients shown in the other Figures. It should be noted that many devices to provide the functions described herein may be formed with far fewer components than described below. Components may be included or excluded as desired and appropriate for the functions to be provided.
As shown in FIG. 7 , one embodiment of the hardware and operating environment includes a general purpose computing device in the form of a computer 700 (e.g., a personal computer, workstation, or server), including one or more processing units 721 , a system memory 722 , and a system bus 723 that operatively couples various system components including the system memory 722 to the processing unit 721 . There may be only one or there may be more than one processing unit 721 , such that the processor of computer 700 comprises a single central-processing unit (CPU), or a plurality of processing units, commonly referred to as a multiprocessor or parallel-processor environment. In various embodiments, computer 700 is a conventional computer, a distributed computer, or any other type of computer.
The system bus 723 can 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 system memory can also be referred to as simply the memory, and, in some embodiments, includes read-only memory (ROM) 724 and random-access memory (RAM) 725 . A basic input/output system (BIOS) program 726 , containing the basic routines that help to transfer information between elements within the computer 700 , such as during start-up, may be stored in ROM 724 . The computer 700 further includes a hard disk drive 727 for reading from and writing to a hard disk, not shown, a magnetic disk drive 728 for reading from or writing to a removable magnetic disk 729 , and an optical disk drive 730 for reading from or writing to a removable optical disk 731 such as a CD ROM or other optical media.
The hard disk drive 727 , magnetic disk drive 728 , and optical disk drive 730 couple with a hard disk drive interface 732 , a magnetic disk drive interface 733 , and an optical disk drive interface 734 , respectively. The drives and their associated computer-readable media provide non volatile storage of computer-readable instructions, data structures, program modules and other data for the computer 700 . It should be appreciated by those skilled in the art that any type of computer-readable media which can store data that is accessible by a computer, such as magnetic cassettes, flash memory cards, digital video disks, Bernoulli cartridges, random access memories (RAMs), read only memories (ROMs), redundant arrays of independent disks (e.g., RAID storage devices) and the like, can be used in the exemplary operating environment.
A plurality of program modules can be stored on the hard disk, magnetic disk 729 , optical disk 731 , ROM 724 , or RAM 725 , including an operating system 735 , one or more application programs 736 , other program modules 737 , and program data 738 . Programming for implementing one or more processes or method described herein may be resident on any one or number of these computer-readable media.
A user may enter commands and information into computer 700 through input devices such as a keyboard 740 and pointing device 742 . Other input devices (not shown) can include a microphone, joystick, game pad, touch screen, mobile phone, mobile pad, satellite dish, scanner, or the like. These other input devices are often connected to the processing unit 721 through a serial port interface 746 that is coupled to the system bus 723 , but can be connected by other interfaces, such as a parallel port, game port, wireless, or a universal serial bus (USB). A monitor 747 or other type of display device, including a touch screen, can also be connected to the system bus 723 via an interface, such as a video adapter 748 . The monitor 747 can display a graphical user interface for the user. In addition to the monitor 747 , computers typically include other peripheral output devices (not shown), such as speakers and printers.
The computer 700 may operate in a networked environment using logical connections to one or more remote computers or servers, such as remote computer 749 . These logical connections are achieved by a communication device coupled to or a part of the computer 700 ; the invention is not limited to a particular type of communications device. The remote computer 749 can be another computer, a server, a router, a network PC, a client, a peer device or other common network node, and typically includes many or all of the elements described above I/O relative to the computer 700 , although only a memory storage device 750 has been illustrated. The logical connections depicted in FIG. 7 include a local area network (LAN) 751 and/or a wide area network (WAN) 752 . Such networking environments are commonplace in office networks, enterprise-wide computer networks, intranets and the internet, which are all types of networks.
When used in a LAN-networking environment, the computer 700 is connected to the LAN 751 through a network interface or adapter 753 , which is one type of communications device. In some embodiments, when used in a WAN-networking environment, the computer 700 typically includes a modem 754 (another type of communications device) or any other type of communications device, e.g., a wireless transceiver, for establishing communications over the wide-area network 752 , such as the internet. The modem 754 , which may be internal or external, is connected to the system bus 723 via the serial port interface 746 . In a networked environment, program modules depicted relative to the computer 700 can be stored in the remote memory storage device 750 of remote computer, or server 749 . It is appreciated that the network connections shown are exemplary and other means of, and communications devices for, establishing a communications link between the computers may be used including hybrid fiber-coax connections, T1-T3 lines, DSL's, OC-3 and/or OC-12, TCP/IP, microwave, wireless application protocol, and any other electronic media through any suitable switches, routers, outlets and power lines, as the same are known and understood by one of ordinary skill in the art.
On the upper left part of the above picture is a signal conditioner that takes voltage signals entering the system on the lower part of the picture and converts them to a zero to five volt range compatible with the web enabled sensor appliance just below it. A model on the upper right couples the server to a wireless network. Wires from the sensors may follow the path of the condenser tubing placed on top of the ice merchandiser, and the entire device may fit inside the container for the condenser and include an antenna on top of the container as shown. | A system for an ice merchandiser having a compressor in a compressor enclosure to cool the ice merchandiser includes a sensor disposed within the ice merchandiser, and a communications component disposed within the compressor enclosure and coupled to the sensor to receive signals from the sensor representative of the amount of ice in the ice merchandiser, wherein the communications component is configured to convert the received signals to a digital format and publish the signals via a network connection. | 5 |
This application claims the benefit of U.S. Provisional Application No. 60/339,078, filed Oct. 30, 2001.
FIELD OF INVENTION
The present invention relates to methods and apparatus for producing carbon nanotubes, by vaporizing carbonaceous material, and metallic catalytic materials in a high temperature environment produced by a plasma, and, more particularly, to the production of single walled nanotubes “SWNTs” using a radio frequency generated plasma as the heat source to vaporize the carbonaceous and catalytic materials.
BACKGROUND OF THE INVENTION
Because of their unique structure, physical and chemical properties the recently discovered fullerene nano-tube (Single-Walled Nano-Tubes; SWNT) materials have been investigated for many applications. Indeed this is one material from which the application development has out-paced its mass availability. The most added-value applications that are being developed using nanotubes include Field Emission Devices, Memory devices (high-density memory arrays, memory logic switching arrays), Nano-MEMs, AFM imaging probes, distributed diagnostics sensors, and strain sensors. Other key applications include: thermal control materials, super strength (100 times steel) and light weight reinforcement and nanocomposites, EMI shielding materials, catalytic support, gas storage materials, high surface area electrodes, and light weight conductor cable and wires. Carbon fibers and whiskers, both of which are carbon forms other than nanotubes, have been synthesized for many decades, and have revolutionized structural materials in almost every application where lightweight and high strength are desirable qualities. Much smaller than fibers or whiskers, carbon nanotubes were discovered only recently [S. Ijima; Nature, 354, p56 (1991)].
However, to utilize this unique material in applications a high volume industrial process that can produce these nanotubes at low cost and with the required purity and physical properties (controlled length and chirality) needs to be developed. The approach is to use low cost solid starting raw materials such as carbonaceous materials “derived from Coal” both as a source of carbon and as a source of some if not all the catalyst for the growth of the SWNT. For additional catalyst materials also solid catalyst can be used. Currently, SWNT are produced on a discrete run basis by the vaporization of metal-graphite composites either in an electric arc discharge [S. Iijima and T. Ichihashi, “Single-Shell Carbon Nanotubes of 1-nm Diameter,” Nature 363, 603–605 (1993) and D. S. Bethune, C. H. Kiang, M. S. deVries, G. Gorman, R. Savoy, J. Vasquez, R. Beyers; Nature, 363, 605–607 (1993); D. S. Bethune, R. B. Beyers, C. H. Kiang, “Carbon Fibers and Method for Their Production”, U.S. Pat. No. 5,424,054 (1995).], or by laser pulses [P. Nikolaev, A. Thess, R. E. Smalley, “Catalytic Growth of Single-Walled Nanotubes by Laser Vaporization,” Chem. Phys. Lett. 243, 49 (1995)]. In the arc discharge process, a carbon anode loaded with catalyst material (typically a combination of metals such as nickel/cobalt, nickel/cobalt/iron, or nickel and transition element such as yttrium) is consumed in arc plasma. The catalyst and the carbon are vaporized and the SWNT are grown by the condensation of carbon onto the condensed liquid catalyst. Sulfur compounds such as iron sulfide, sulfur or hydrogen sulfides are typically used as catalyst promoter to maximize the SWNT yield. When using the existing method based on arc discharge, it is difficult to increase the amount of vaporized carbon, and it is difficult to control the process parameters of the arc. In the arc the carbon rods act as the feed materials and the source (electrodes) for arc discharge. Accordingly, it is difficult to control separately these functions. This result in limited production of carbon nanotubes and in a product that is highly contaminated with other clustered carbon materials, causing the high cost of mass production. The cost of SWNT is determined by the production rate, yield, raw materials cost. The raw materials consist of carbon source, catalyst and promoters. The use of solid carbon particulate such as coal as source of carbon and some if not all of the catalyst and promoter could lead to tenfold savings in raw materials costs. The use of plasma source of intense heat can result in complete vaporization of the solid feed materials, and very high rate of production. The separation of feed materials from the source of heat gives full control of the process to maximize yield. This creates the opportunity for effective and inexpensive mass production of carbon nanotubes.
SWNT are synthesized using a gas catalytic process wherein carbonaceous material is vaporized by the application of heat under conditions appropriate to produce the SWNT. Although the mechanism is poorly understood, it is theorized that the gas synthesis process can be generally divided into three separate sub-processes. One of the sub-processes is nano-catalyst formation process, which involves the vaporization of metal catalyst and the subsequent formation of active metal nanoparticulates. Another step is sublimation/vaporization of carbon to form carbon cluster in the gas phase. This step might be eliminated if gaseous carboneous source is used. The final sub-process is the carbon nano-tube growth process, which involves the dissolution of the carbon clusters into the metal catalyst nanoparticulates, and subsequent growth of SWNT from the carbon supersaturated catalyst. This mechanism seems to be the most accepted mechanism. In the nano-catalyst formation process, parameters such as surface tension of the catalyst nanoparticulates, nanoparticulate size, shape, density and its distribution parameters are of importance to control the diameter of nanotubes and the yield. For the SWNT growth process, important parameters will include carbon vapor density and carbon saturation in catalysts, the residence time of the nanotube-growing catalyst in the gas at appropriate temperature.
Current modes of SWNT production involve the use of catalyst-packed graphite rods [D. S. Bethune et.al], or catalyst impregnated graphite rod [X. Lin, X. K. Wang, V. P. Dravid, R. P. H. Chang, J. B. Ketterson, “Large Scale Synthesis of Single-Shell Carbon Nanotubes, Appl. Phys. Lett., 64(2), 181–183 (1994).], which are consumed in a DC electric arc to produce SWNT-containing soot. A variation of the packed rod technique utilizes the catalyst as a molten metal in a small crucible onto which a graphite rod is arced, thereby co-vaporizing carbon and catalyst to form several grams of SWNT per operation [S. Seraphin and D. Zhou, “Single-Walled Carbon Nanotubes Produced at High Yield by Mixed Catalysts,” Appl. Phys. Lett. 64, 2087–2089 (1994).] has also been developed. The product of the arc-based production methods contains SWNT that are coated with amorphous carbon, as well as other contaminants including amorphous and graphitic carbon particles, carbon-coated metal catalyst particles, and traces of fullerenes-C 60 , –C 70 , etc. Separation schemes have been devised to remove the contaminant [H. J. Dai, A. G. Rinzler, P. Nikolaev, A. Thess, D. T. Colbert, and R. E. Smalley, “Single-Wall Nanotubes Produced by Metal-Catalyzed Disproportionation of Carbon Monoxide,” Chem. Phys. Lett. 260, 471–5 (1996)], which allow limited (1–10%) recovery of pure tubes. Relatively pure SWNT have been produced [A. Fonseca, K. Hernadi, P. Piedigrosso, J. -F. Colomer, K. Mukhopadhyay, R. Doome, S. Lazarescu, L. P. Biro, P h. Lambin, P. A. Thiry, D. Bernaerts, J. B. Nagy, Synthesis of Single- and Multi-Wall Carbon Nanotubes Over Supported Catalysts, Appl. Phys . A67, 11–22 (1998).; K. Hernadi, A. Fonseca, J. Nagy, D. Bernaerts, A. Lucas; Carbon, 34, 1249–1257 (1996); H. M. Cheng, F. Li, X. Sun, S. D. M. Brown, M. A. Pimenta, A. Marucci, G. Dresselhaus, and M. S. Dresselhaus, “Bulk Morphology and Diameter Distribution of Single-Walled Carbon Nanotubes Synthesized by Catalytic Decomposition of Hydrocarbons,” Chem. Phys. Lett. 289, 602 (1998); H. M. Cheng, F. Li, G. Su, H. Y. Pan, L. L. He, X. Sun, and M. S. Dresselhaus, “Large-Scale and Low-Cost Synthesis of Single-Walled Carbon Nanotubes by the Catalytic Pyrolysis of Hydrocarbons,” Phys. Lett. 72, 3282 (1998).] by use of gaseous carbon sources decomposed over catalyst particles either supported on inert solids or floating in gas reaction media. Several tens of grams of high-yield SWNT samples were produced whose properties varied greatly depending on the reagent gas used and the method of catalyst particle preparation. Laser vaporization of catalyst/carbon composite rods has produced over 50% yield (relative to initial carbon input) of SWNT, however, with a slower production rate compared to arc process. While some of these methods for SWNT production produce high-yield products and others are touted as “Large-Scale” processes, none produce high yield SWNT on a continuous basis with control over all production variables.
Williams and et al [K. A. Williams, M. Tachibana, J. L. Allen, L. Grigorian, S-C. Cheng, S. L Fang, G. U. Sumanasekera, A. L. Loper, J. H. Williams, and P. C. Eklund, Chemical Physics Letters, (310) 1–2, 31 (1999).] have investigated the production of SWNT from untreated bituminous coal, and they showed that SWNT can be produced, but with twofold to fourfold reduction in the purity. It was interestingly found that transition metal impurities such as pyrite in bituminous coal may actually contribute a synergistic catalytic effect and it might be possible to produce SWNT from pyrite rich bituminous coal without adding any catalyst. However, the presence of sulfur dramatically decreases the yield.
In case of coal as the particulate solid carbon source, the best coal for SWNT feedstock is one that has a high fixed carbon content and low volatile component. Two ways to use the coal have been investigated in the present invention. One, as a comparison, is to form conductive rods to be used in the arc process, and the other way is to use the coal as powder feed in the plasma reactor. Initial attempts to make rods from untreated coal failed due to excessive evolution of gas in the rods resulting in cracking of the rods during carbonization. Furthermore, for powder feed it is essential to have free-flowing powder. Accordingly, volatile component of the coal also had to be removed. Since pretreatment is required, just about any coal can therefore be used and treated to obtain its fixed carbon content. Removing the volatile component can improve the yield of SWNT production as a result of the decrease in oxygen content.
Accordingly, the present inventors have developed methods that incorporate the most successful aspects of existing SWNT production to establish the feasibility of using solid carbon such as coal including anthracite, as a source of carbon, together with a catalyst, as a way to potentially reduce the cost and produce high yield SWNT.
Moreover, the present inventors have shown that using hydrogen in the presence of iron sulfide or sulfur catalyst promoter significantly increases the yield of SWNT when using particulate solid carbon such as coal as the carbon source.
A quantitative treatment addressing physiochemical mechanisms and transport processes associated with SWNT synthesis has also been proposed by the present inventors to improve production and materials development. The composition of solid carbon or of coal, size, concentration of the metal catalyst from the coal and the concentration of the carbon clusters, together with the temperature profile as they relate to yield of SWNT production was used as an input into the physiochemical mechanistic model.
The technical feasibility of efficiently using particulate solid carbon such as coal as the carbon source to produce SWNT, in substantially continuous reactor has been demonstrated as described herein.
Although relatively large production of multi-walled carbon nanotubes is carried out in Japan (Showa Denko) where they have built and operated a 5 meter long, with 1 meter diameter reactor, the reactor is thermally controlled with an upper operating temperature of 1200° C. Under these conditions only multi-walled nanotubes MWNT can be produced, but SWNT can not be produced economically.
One objective of the present invention is to develop an improved scaled-up reactor where key process parameters can be controlled independently for the economical production of high yield of SWNT using particulate solid carbon source including such as coal based materials.
High-temperature plasma offers a convenient and advantageous source for the vaporization of carbon. It is relatively easy to produce and control, and carbonaceous and solid catalyst materials can be injected into a flowing-gas fed plasma. The flow of gas and the ability to control the volume, temperature and location of the plasma make production and collection of nanotubes with controlled properties on a continuous basis easier than in arc based reactors. Hot plasma is formed when the temperature of ions, electrons and internal particles corresponds to the thermal equilibrium conditions, at pressure of about 100 Torr and more, this temperature may be as high as 5,000 to 20,000 K. At pressure of less than 100 Torr, the temperature of ions, electrons and internal particles corresponds to non-equilibrium cold plasma and runs around 100 to 1,000 K. Hot plasma generated by using high frequency induction coils is called ICP (Inductively Coupled Plasma) and cover wider region as compared to plasma generated by DC arc discharge method, which allows preventing mixing in possible impurities from the electrode materials. Using the Hot ICP plasma method, it becomes possible to vaporize larger quantities of carbon powder and catalyst and mass-produce the carbon nanotubes. Several approaches to using plasma to vaporize coal and metal catalyst precursors for SWNT production were investigated by the inventors.
There are several approaches to create hot plasma. In one approach the plasma is created by an electric arc between electrodes located in a tube through which a flowing stream of gas is maintained. This is typically called “Plasma Spray Torches”. The plasma torch can be viewed as modified arc discharge described above except the electrodes are non-consumable. The flow of gas forces the plasma plume out of the tube. Powders are introduced either into the gas stream or are injected just in front of the torch tube. The powder is rapidly heated, and the high velocity gas stream causes the molten particles to splatter onto an object to be coated or collected in a bag filter. Different gases torch design and applied power account for the temperature of the plasma and therefore determine the rate at which powder can be fed into the torch and the temperature of the emitted particles. The inventors tested this type of plasma spray systems for SWNT production using solid carbon and catalyst feed materials. Samples of ball-milled carbonized coal/catalyst powders were introduced into a Metco model 7M-plasma sprayer. Argon/helium gas mixtures were used in the experiment, and the powder was introduced into the plasma by a powder feeder that injects a stream of argon with entrained powder into the plasma directly in front of the torch.
With most metals and ceramics that are used in coatings, the metal powder is melted enough to adhere to the object that is being coated. For SWNT production, the carbon/catalyst powder must be vaporized for the reaction to occur, and the products must be cooled in an inert atmosphere. Therefore, the torch was adjusted to produce the hottest plasma, and certain experiments were run in an argon-filled container. TEM analysis of the products of these experiments showed little change in the starting material, indicating that the transfer of heat from the plasma to the powder was insufficient to vaporize the powder. This result was due to short residence times of the powder in the plasma and/or the plasma was not hot enough.
Another experiment used an experimental plasma torch that introduced the coal/catalyst powder directly into the plasma by entraining the powder in the gasses used to feed the torch. Again, it was found that short exposure time of the powder to the hot zone of the plasma was too short to cause vaporization of the fed materials and as a result no carbon nanotubes were formed.
The available plasma spray torches are designed to melt metal and ceramic powders at high feed rates and to eject the molten powders at a high speed. They are not designed to completely vaporize the powders and the high velocities cannot be reduced to increase the thermal transfer to the powder.
Independent adjustment of the parameters that control plasma temperature and residence time of the powder feed in the plasma may allow vaporization of carbon powders and therefore could produce nanotubes.
Yet another approach to create hot plasma is by high frequency induction coupling. ICP torches are used to atomize and ionize analytical samples to do electronic emission spectroscopy, mass spectral analysis, and are used in reactors to produce sub-micron sized metal powders. They can attain temperatures of well over 10,000° K, and are known to atomize materials with a high degree of efficiency and reproducibility. These qualities make ICP reactors attractive for nanotube production. Other key advantages of the ICP reactor concept are the ability to process tens of grams per minute, and the continuous nature of the feed. The ICP plasma reactor concept is being investigated for example at the Institute of Laser Plasma Physic at the Heinrich-Heine University in Dusseldorf Germany to produce nanopowders [P. Buchner, D. Lützenkirchen-Hecht, H. -H. Strehblow und J. Uhlenbusch: Production and characterization of nanosized Cu/O/SiC composite particles in a thermal rf plasma reactor, Journal of Materials Science 34 (1999), 925–931]. An inductively coupled plasma (ICP) reactor (rf generator: f=3.5 MHz, max. rf plate power 35 kw; plasma gas: argon at 400–1000 MPa) is used to produce ultrafine metal, ceramic, and composite powders (particle size ca. 10 nm) starting from metallic and ceramic precursor powders (grain size approx. 10 μnm). An attractive feature of this reactor system is the high production rate (up to 100 g/h). The inventor developed similar equipment. The ICP reactor offers high production rates with the use of powder reactants, and more importantly, with a continuous collection of product. However, it is not known whether this system can be used to vaporize solid carbon and metal particles to produce single walled nanotubes. It is known that it is possible to produce multi-walled carbon nanotubes in such system, however this product can be produced at much lower temperature than single walled nanotubes.
Y. Tanaka, Y. Matsumoto, K. Mizutani reported the production of fullerene and multi-walled carbon nanotubes [JP 2546511, Oct. 23, 1996] using carbon powder exposed to hot plasma generated using high frequency induction coil. However, they did not produce single walled nanotubes and it is not obvious that the conditions of the hot plasma can be changed sufficiently to produce such product. They also did not vaporize catalyst in their process, and it is not obvious that conditions for the hot plasma can be achieved to vaporize metal catalyst and solid carbon simultaneously to produce sufficient clusters of carbon and nanometal catalyst to grow single walled nanotubes.
A clear understanding of the general chemical mechanism of SWNT formation however, is required in order to optimize any production scheme for SWNTs with higher yield and desirable quality of SWNTs. In particular, this includes the rationalization of the role of sulfur, oxygen and hydrogen-containing impurities in the coal-derived raw starting material. The design of new processes that offer alternatives to the arc process, viable production schemes, which would enable continuous production of SWNTs in high yields, is practically impossible without preliminary quantitative assessment of the required process parameters, largely based on this mechanistic consideration. Thus, the feasibility of SWNT synthesis in Inductively Coupled Plasma (ICP) reactors and in Plasma Torch (PT) reactors was estimated based on the knowledge of the kinetic mechanism derived in the course of parametric studies by inventors of the arc production process.
The main result revealed in the detailed parametric study of the arc process of SWNT formation is that the kinetics are very reminiscent of the kinetics of fullerene formation in the arc, which was previously studied in detail [A. V. Krestinin, A. P. Moravsky, “Mechanism of Fullerene Synthesis in the Arc Reactor” Chem. Phys. Lett. , v.286, 479–485 (1998)]. Therefore, a brief explanation of the main conclusions drawn from the mechanism of fullerene formation and from the quantitative description of the fullerene arc process is necessary, followed by consideration of the applicability of these results to SWNT arc synthesis and its quantitative analysis.
In fullerene arc synthesis the pure carbon vapor flowing from the narrow arc gap is idealized as a turbulent jet of cylindrical symmetry, which is described in the framework of a semi-empirical theory [G. N. Abramovich, Applied Gas Dynamics, Science, M., 1969] of heat and mass transfer in a free turbulent jet. These turbulent transfer phenomena entirely control the dynamics of carbon vapor mixing with helium gas and the resulting cooling. The diffusion of helium into the arc gap clearance is negligibly small under the narrow gap conditions. This turbulent jet model made it possible to find an analytical relationship between the essential parameters of the arc process. These include the rate of soot formation V soot , the original carbon vapor temperature T o and velocity U o , the helium pressure in the reactor P, the gap width h o and electrode diameter 2r o , and finally, the characteristic time for turbulent mixing and cooling of carbon vapor τ mix . The value of τ mix turns out to be uniquely linked to the value of the fullerene yield, obtained under various arc currents, helium pressures and inter-electrode gap, and thus enable prediction of the yield from the available process parameters. An optimal value for τ mix corresponds to the maximum fullerene yield, and this value must be retained constant at any variation of a parameter among those listed above, by appropriately adjusting the values of other parameters in accordance with well proven [Krestinin et. al.] relationship τ mix =r o 1.5 /U o h o =2r o 2.5 P/V soot RT. So, the rate of cooling (τ mix ) is the main and the only parameter determining the fullerene yield.
The inventors have established that the yield of SWNTs in the arc process varies with the change of helium pressure, arc current and rod feed rate in the same manner as the yield of fullerenes in the fullerene synthesis considered above. The pressure, current and feed rate dependencies of the SWNT yield all pass through a maximum, which has the same value for all three cases, thus implying existence of a unique set of parameters for optimal production of SWNTs. Therefore, it was concluded with a high degree of certainty that formation of SWNTs is a fast gas process that is kinetically governed by the same hydrodynamic factors, namely, the rate of cooling of mixed carbon/metal vapor. The same analytical approach, described above, seems applicable to mixed carbon/metal vapor condensation under arc conditions, since the metal component content in the vapor is low enough to consider its influence on gas dynamics parameters as a small perturbation.
The existence of a unique optimal set of externally controlled parameters for SWNT production in the arc, and of an analytical relationship between those parameters, means that there exists a set of internal parameters that are optimal for the process. The internal parameters include at least the process temperature, carbon and metal vapor density, the rate of vapor cooling, and can only be controlled indirectly. These factors govern the production rate of SWNTs by influencing he mechanism of mixed vapor condensation. The process can be effected at any of its kinetic stages, such as during the build up or steady state performance of metal catalyst particles during their positioning and deactivation, or during separate conversions of carbon vapor that results in soot formation, etc. Other experimental schemes that are potentially capable of intense generation of mixed carbon/metal vapor in hot plasma environment, such as ICP and PT techniques, will produce SWNTs if the values of these process governing factors are maintained the same as in the optimal arc process. In other words, it is a plausible assumption that in any hot plasma carbon/metal system, it is necessary to maintain certain temperature profile and vapor density, pertinent to optimal arc process, to eventually obtain SWNTs. This was the approach pursued by the inventors; to as closely as possible mimic the temperature and vapor density conditions found in the arc, while designing ICP and PT experimental setups intended for obtaining SWNTs on a much larger scale than the arc process.
A simple way to assess experimental conditions and geometry required for viable ICP and PT processes consists of reproducing the useful power density of the arc in the hot plasma region of ICP and PT reactors, and proportional scaling up of the amount of carbon and metal powders fed into the plasma. Assuming that all carbon and metal particulates are vaporized in the hot plasma plume or ball, the reaction zone will have the appropriate temperature and vapor density. The cooling rate can be adjusted by regulating the inert carrier gas (argon) flow rate. For example, the typical value for the useful power density of the SWNT producing arc can be estimated as ca. 2 kw/cm 3 . This value ensures complete vaporization of ca. 0.3 g of carbon and catalyst metal particles per minute. The condensation process of this initially ca 3700 K hot vapor, taking place during ca. 1 ms during fast mixing of the vapor with buffer gas yields ca. 15 mass. % of SWNTs in the condensed soot. To scale up the SWNT production rate of an ICP reactor by a factor of 10, the hot plasma ball of the ICP reactor should be ca. 10 cm 3 (10 times that of the arc hot zone) in volume. The induction coil used to generate the plasma should be capable of developing ca. 20 kw power in the argon gas at 200–700 Torr in the ICP reactor, and the carbon/metal powder feed rate should be ca. 3 grams/minute (the ICP experiments were carried out at various feed rates and 1.5 gram/minute appeared optimum). The standard LEPEL T-40 radio frequency generator can meet this power requirement, while using a 20 mm in inner diameter quartz tube for a reactor to create a plasma ball constrained within 10 cm 3 , which were the actual tube size and power levels employed by the inventor and demonstrated that the predicted yields could be obtained.
The ICP reactor and overall carbon vaporization rate can be further scaled up, in contrast to the arc process. For example, an ICP reactor employing 200 kw power in the induction coil and a flow-through tube 44 mm in inner diameter was capable of vaporizing under hot plasma conditions up to 100 g/min of pure graphite powder in a fullerene producing process, yielding ca. 6% of fullerenes in the product [Tanaka et. al.]. Up to 1 MW RF power supplies are commercially available, so potential capabilities of the ICP method for high rate SWNT production far surpass those of the arc which is presently the main process for bulk SWNT manufacturing. When combined with the possibility to use such low cost raw material as coals, the ease of scaling the ICP method makes it ideal for the development of an industrial scale SWNT production process.
Therefore, considering the foregoing, a need remains for improved methods of producing single-wall carbon nanotubes, with very high purity and homogeneity in processes with improved conversion efficiency of feedstock to single walled nanotubes (SWNT). The combination of RF hot plasma system, and the use of solid feed materials at the specific operating conditions could be a practical method to mass produce the SWNT product.
SUMMARY OF THE INVENTION
This invention relates to the method of effective mass production of single-wall carbon nanotubes of high purity, homogeneity at high yield from solid carbon materials such as coal. In the reaction of this method, single-wall carbon nanotubes are produced in a reaction zone at high temperature created by hot plasma such as RF plasma.
An ICP reactor system was designed for SWNT production from solid carbon such as coal. This system offers the advantages of powder feedstock, continuous production and high throughput. The successful design utilizes a closed system as shown in FIG. 1 . The high frequency power supply was a Lepel model T-40 ( 11 ) that powered a multi-turn water-cooled induction coil ( 12 ) wrapped around a water-cooled ( 13 ) reaction tube ( 14 ). A vibratory powder feeder ( 15 ) was used to shake coal/catalyst powder into the stream of argon that was maintained at a pressure of 300 torr. The powder entered the plasma ( 16 ), was vaporized and condensed into nanotubes and other products, which were collected in the trap ( 17 ). The pressure of the reactor is maintained using vacuum pump ( 18 ). The powder feeder is installed above the reactor ( 14 ) and its operation was flawless even though ultrafine powder was used. An alternative feeding mechanism is to fluidize the powder from the bottom into the hot plasma zone as shown in the schematic in FIG. 2 . In this case the pressure control ( 28 ) and product collection ( 27 ) will be from the top. This approach allows for the control of the residence time of powder feed in the hot zone.
In case of coal as source of solid carbon two Premium Coal samples selected by the present inventors for comparison were a low volatile bituminous coal (Pocahontas, Va.) and a high volatile bituminous coal (Pittsburgh, Pa.). The two coal samples were carbonized at 1000° C. for 4 hours under argon atmosphere. Commonly, the temperature was increased slowly at 5° C./minute under a slow flow of argon while pulling a light vacuum. Outgassing occurred from about 200–700° C. After most of the gasses had left the sample, a vacuum of several millitorr was applied while continuing heating at 7° C. under a slow flow of argon. Conditions of 1000° C. and millitorr vacuum were maintained for one hour. Carbonization of the high-volatile bituminous coal (Pittsburgh) produced shiny gray-black cakes with lots of voids, with a weight loss of 31.6%, which correspond closely to reported data of 37% volatile material. It appears that during heating, the high-volatile coal becomes molten, and gasses that are evolved create a brittle, sponge-like cake. Carbonization of the low volatile coal (Pocahontas) produced a more compact brick of granular, black carbon that was more friable than the high-volatile material. Weight loss was 18.2%, which compares well to reported data of 18%. The carbonized coals were ground in a mill-style laboratory grinder and sieved to 50–125 micron particle size. The carbonized coal powder was ball-milled with micron sized metal catalyst powder to produce starting materials for feed powder for plasma-based reactors or for making rods for arc discharge reactor for comparison. Choice of catalyst was made based on previous SWNT production experience of the inventors. Cobalt: nickel catalyst with a 3:1 atomic ratio was used with 2.5 atomic % metal content in the finished product (powder for plasma-based reactors, and rods for arc discharge reactor).
The arc discharge rods were made by mixing the treated coal/catalyst powder with pitch binder, then pressing 1×1×7.5 cm rods. The rods were then carbonized at 1000° C. in argon for two hours. The resultant rods had a density of approximately 1.7 g/cc, which is considered being very competitive to commercial carbon rods. The 3:1 Co:Ni metal catalyst content was 11.5 wt %, which corresponds to 2.5 atomic % metal. Similar rods were prepared from graphite/catalyst powder mixtures for comparison.
For plasma based reactor the mixture of the graphitized coal and/or graphite with the metal catalyst was used as is. This eliminates the rod fabrication step, which is expensive.
The cold plasma can easily be initiated by ionizing gas by high frequency field without powder feed. The power can then be adjusted to obtain hot plasma. When the powder is feed intense plasma is generated because of the vaporization and the ionization of the metal catalyst. The plasma then stabilizes and spreads down the tube, FIG. 1 ( 14 ). The powder feed can almost be seen by observing the higher intensity of the plasma where the powder vaporizes. This system was operated under different power conditions, pressure and with different size feed. Ultrafine solid carbon or coal (1–5 μm size) was required to vaporize all of the carbon based material in the short residence time employed in operating this reactor. The product can be collected and sampled from the filter bag or trap, FIG. 1 ( 17 ).
TEM micrographs of the collected product from ICP reactor are shown in FIG. 3 . As can be seen, SWNTs were produced, and to our knowledge this is the first time that SWNTs from solid carbon or coal were produced in a plasma chemical system. Typically fine powder or multi-walled nanotubes (MWNT's) are produced in similar reactors. The intensity of the plasma, the residence time of the powder in the hot zone of the reactor chamber, the size of the powder feed, and the gas composition are all important parameters to control the type of product produced. The main effect of all these parameters is to ensure the vaporization of the carbon. Of course, if carbon in the hot zone is vaporized, the metal catalyst in the hot zone will also vaporize. The quenching rate and concentration of the vaporized product will dictate the type of nanotubes produced. In accordance with our invention, the ability to control the gas flow rate in our designed ICP system allowed us to control the concentration of metal catalyst resulted in very small and nano-size catalyst metal particles only to be formed, promoting the selective formation of only SWNTs.
Characteristics of the SWNTs were estimated from a large number of TEM images. The bundle diameters of the SWNTs produced from coal using the ICP technique were found to be about 8 nm. This bundle diameter is smaller than those obtained in the arc process (˜10 nm) and smaller than the bundle diameter obtained by Williams et al (˜13 nm) of SWNTs produced from coal in the arc process. Smaller bundles are easier to disperse. From the side-wall fringes, in the TEM micrographs, the diameter of the individual SWNT was estimated to be ˜1.25 nm. This diameter is larger than the SWNT produced by Williams et al (˜1.0 nm), but is smaller than the SWNT diameter produced in the arc process (˜1.35 nm). The catalyst metal nanoparticles, which appear as dark regions in the TEM, FIG. 2 , were about the same size as the metal particles produced in the arc using graphite as the carbon precursor (average 24 nm).
None of the TEM images evaluated contained any evidence of multiwalled tubes, indicating that the nanotube product synthesized in accordance with our invention is only SWNT.
For production rate and scale up, it can be envisioned that this process is easy to scale up, being nearly continuous, and can be automated.
TEM is currently the most reliable method of analysis, since high resolution is required to discern individual nanotubes types, and to identify the bundle size and the SWNT dimension. Several analytical techniques are now available for determining the yield the SWNT. However it should be emphasized that the problem of evaluating the purity of SWNT sample is a difficult problem, and currently there is no protocol for comparison of SWNT yields in samples prepared by different techniques. This is especially true because of the inhomogenity in the samples. Two particular techniques are to some degree have been accepted by different groups working in this field. These two techniques are Raman spectroscopy and Thermogravimetric techniques. The thermogravimetric analysis (TGA) is used to decompose the sample in air, thereby selectively oxidizing the various particulate components of the soot sample. The nanotubes are more resistant to oxidation, and a weight percent measurement can be made. In addition, the amount of metal catalyst particles can also be readily analyzed from the weight of residue after the carbon materials are combusted. Raman spectroscopy gives a quantitative assessment of the types of SWNT in the sample. These analytical tools are complementary to the TEM analysis, and provide a less expensive and more rapid quantitative characterization of SWNT products. Both from TGA analysis and Aerial density measurement indicated that the yield of SWNT produced in the present system is comparable to the arc discharge method. However, the production rate is 12 times the rate of the arc process in only 20 mm diameter reactor. This result is very encouraging for further improvement and scale up.
We determined that initial problems with getting sufficiently hot plasma could be overcome by increasing the pressure of the argon atmosphere. In a preferred example, run conditions that were found to produce SWNTs were 400 torr Ar at a flow rate of 2.0 I/minute. Carbonized coal with 2–100 micron particle size was ball milled with 2.6 atomic % mixture of cobalt/nickel catalyst metals with Co:Ni ratio of 3:1 (atomic). This powder mixture was fed into the reactor (20-mm diameter) at a rate of 1.5 grams/minute. More optimization may improve nanotube yield, because the operating variables in this system are quite few and it is designed so that their optimization can potentially result in a practical and commercial method to produce large volume and low cost SWNTs. In addition, this technique takes real advantage of the low cost of powder carboneous materials like coal as the source of raw materials by using its natural powder form with simple pretreatment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a general schematic of RF plasma flow reactor for the production of single wall carbon nanotubes with solid gravity feed of reactant, and hot plasma zone ( 16 ) in which the solid feed is vaporized for the growth of single-wall carbon nanotubes.
FIG. 2 shows a general schematic of RF plasma flow reactor for the production of single wall carbon nanotubes with solid reactant feed from the bottom by fluidization. The high frequency power supply was a Lepel model T-40 ( 21 ) that powered a multi-turn water-cooled induction coil ( 22 ) wrapped around a water-cooled ( 23 ) reaction tube ( 24 ). A continues powder feeder ( 25 ) is used to feed the carbon/catalyst powder, that can be fluidized with a stream of inert fluidizing gas ( 29 ) such as argon. The fluidized powder ( 30 ) enters the plasma ( 26 ), was vaporized and condensed into nanotubes and other products, which were collected in the trap ( 27 ). The pressure of the reactor is maintained using vacuum pump ( 28 ). The fluidization of the powder feeder into the plasma allows for the control of the residence time powder feed in the hot zone.
FIG. 3 shows TEM micrograph of the product according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with the present invention there is provided a novel method of producing fullerenes comprising Single Walled nanotubes (SWNT's), which comprises providing a source of carbon and a catalyst comprised essentially of a transition metal of the iron group of the periodic table of elements and sulfur in a reaction zone having a SWNT forming atmosphere comprised essentially of a plasma forming gas and subjecting the carbon and catalyst to plasma heat in the reaction zone. The heat causes the carbon and catalyst to vaporize producing a carbon and metal containing vapor that is quenched therein to condense the vapor resulting in the formation of the SWNT product outside of the heated reaction zone, where it is recovered.
In a preferred embodiment the SWNT atmosphere contains an inert gas advantageously argon or helium and optionally some hydrogen gas. The SWNT forming atmosphere is preferably maintained at a pressure in the range of 10 Torr to 760 Torr (0.013 to atmosphere).
In a preferred embodiment the metal catalyst is comprised essentially of one of iron, cobalt, or nickel powder or any mixture of these powders.
In a preferred embodiment the reaction zone is heated in an Inductively Coupled Plasma (ICP) system in a reaction chamber, wherein the SWNT atmosphere is maintained. Carbon is introduced to the plasma ball as a flow of the powder to provide more surface area and faster vaporization.
The catalyst mixture is also fed into the plasma ball preferably as a powder. The desired catalyst component ratio may be provided by supplying pure components in the desired ratio or by alloying and combining them in the desired ratio or by combining them in several convenient mixtures or alloys that when fed to the plasma ball combine to form the desired composition of SWNT forming atmosphere.
In a preferred embodiment an ICP reactor capable of developing 0.2–5 kw/cm 3 power density in plasma volume is used to vaporize carbon/metal feed powder and produce SWNTs. Preferably the power density is in the range 1–3 kw/cm 3 to ensure complete vaporization of carbon and metal powder particles in the plasma ball.
In a preferred embodiment, the linear size of carbon powder particles is in the range 1 μm -150 μm. More preferably, carbon particles are of 1–5 μm size that ensures more complete vaporization at a given plasma power density and residence time and/or allows using lower power density and shorter residence time. For the same reason it is expedient to use fine and ultrafine metal powders of the particle size 0.05–10 μm and preferably 0.5–2 μm.
In a preferred embodiment the feed rate of mixed carbon/metal powder specified for 1 kw power developed in plasma is in the range 0.01÷0.1 g/min. kw, at which rate complete vaporization of carbon is achieved depending on powder particle size and residence time of particles in the plasma zone.
In a preferred embodiment, the plasma forming gas flux is in the range of 0.01–10 l/min. cm 2 , preferably 0.1–0.5 l/min. cm 2 to ensure appropriate residence time of powder in the reaction zone and temperature profile along the reaction coordinate.
In a preferred embodiment, the pressure of the plasma forming gas lies in the range 50-760 Torr and preferably in the range 200–400 Torr to maintain the hot plasma regime of reactor operation, which ensures the vaporization of raw materials and efficient formation of SWNTs.
The following examples describe the preferred embodiments of the present invention, with description of the apparatuses, processes, procedures and results of particular and representative runs and products and comparative examples been given. The detailed description falls within the scope of, and serves to exemplify the more generally described process set forth above. The examples are presented for illustrative purposes only, and are not intended as a restriction on the scope of the invention.
EXAMPLE 1
SWNT are typically made from graphite rods that are drilled coaxially and tightly packed with a mixture of catalyst and graphite powder. Graphite rod with 5/16″ (8 mm) diameter was center drilled and packed with catalyst. The catalyst was 3:1 Co:Ni metal catalyst content was 11.5 wt %, which corresponds to 2.5 atomic % metal. The rods were vaporized by arcing the rods in an inert gas atmosphere using an arc reactor made of quartz chamber. From our extensive previous experience with graphite rod starting materials, the approximate conditions to produce SWNT from the catalyst-packed graphite were known. A gap is maintained by adjustment of the stepper motor speed. Pressure of helium, rod feed rate and current are maintained constant by instrument control. The voltage is allowed to vary, but remains relatively stable while equilibrium conditions of rod consumption are maintained. A single rod is consumed in about 60 minutes producing about 5 grams of products, and the products were recovered for each run. This equipment is currently the most successful for making SWNT from graphite starting materials, and is the apparatus of choice for testing SWNT production. A key feature of this Quartz Arc reactor for SWNT production is the rotating cathode. This feature was found to be critical in maximizing the yield of SWNT and smoothing the operation of the arc. SWNT gets destroyed or deteriorated if they remaining near the arc. Rotating the cathode avoids this situation. Furthermore, slag build up on the cathode with time, which results in uneven and variable gap distance with time. Again the cathode rotation maintains the slag to a minimum and as result a smooth operating condition is maintained.
The usual yield of nanotubes in the soot from these rods is on the order of 10–20 wt % nanotubes with the remainder of the product being carbon-coated catalyst metal particles that are 5–50 nm in diameter, and amorphous carbon. The key operational parameters for the graphite-catalyst powder packed graphite rods are given in Table 1.
TABLE 1
Operating Arc Discharge Parameter For Packed
Graphite-Catalyst Powder Graphite Rods
Packed Graphite Rods
Dimensions (mm)
8 × 200 (cylindrical)
Cross-section (mm 2 )
49.5
Density (g/cc)
1.9
Current (amperes)
96
He pressure (torr)
450
Feed rate (mm/minute)
1.5
Approx. voltage
22–23
The products from the arc runs were collected and analyzed by Transmission electron microscopy (TEM). Arial measurements from TEM micrographs of the products indicate yields of about 15–18 wt % SWNT were obtained. In terms of production rate of the arc process, as pointed out, a rod can be burned in about 60 minutes, producing about 5 gm of products. The production rate in the small laboratory reactor is therefore 0.083 grams/minutes. Since there is a limitation (yield decreases with larger diameter rods) in the diameter of the rod used then scale up can be by increasing rod length, and duplicating reactors. Nevertheless these rates, while they are adequate for existing demand, are very low for practical applications.
EXAMPLE 2
Coal composite rods were made by mixing the treated coal/catalyst powder with pitch binder, then pressing 1×1×7.5 cm rods. The rods were then carbonized at 1000° C. in argon for two hours. The resultant rods had a density of approximately 1.7 g/cc, which is considered being very similar to commercial carbon rods. Cobalt: nickel catalyst with a 3:1 atomic ratio was used with 2.5 atomic % metal content in the finished rods. Coal composite rods were arced in the Quartz reactor described in example 1. The composite coal rod was installed in the lower electrode (anode), and is moved via a stepper motor to contact the broad upper electrode (cathode). A gap is maintained by adjustment of the stepper motor speed. Pressure of helium, rod feed rate and current are maintained constant by instrument control. The voltage is allowed to vary, but remains relatively stable while equilibrium conditions of rod consumption are maintained. A single rod is consumed in about 40 minutes producing about 5 grams of products.
TABLE II
Operating Arc Discharge Parameter For Packed for
Packed Coal-Catalyst Composite Rods.
Composite rods
Dimensions (mm
10 × 10 × 76 (square)
Cross-section (mm )
100
Density (g/cc)
1.7
Current (amperes)
145
He pressure (torr)
450
Feed rate (mm/minute)
2.0
Approx. voltage
22–23
The key operational difference between the graphite-catalyst powder packed graphite rods and the composite coal-catalyst rods was the rate of burn or the feed rate required maintaining the gap voltage constant. Much higher burn rate was observed for the coal-catalyst composite rods. This of course is beneficial as it increases the production throughput, provided the product is of the same quality. The products from the arc runs were collected and analyzed by Transmission electron microscopy (TEM). The coal composite rods produced an abundant amount of SWNT. Arial measurements from TEM micrographs of the two products indicate yields of about 17 wt % SWNT were obtained which is very similar to the result of example 1.
A large number of TEM images were taken and the characteristics of the SWNT were estimated. The bundle diameter of the SWNTs produced from coal and from graphite was found to be about 10 nm. The side-wall fringes are well defined in the SWNT samples produced from coal compared to those produced from graphite. There also appears to be more amorphous carbon on the SWNTs produced from graphite, which could result in the poor side-wall fringes. From the side-wall fringes the diameter of the individual SWNT was estimated to be ˜1.5 nm. This diameter is larger than the SWNTs produced by Williams et al, and again can be explained by the differences in the catalyst used in both systems. Larger diameter SWNTs could be more desirable for gas storage for example. One striking difference between the product produced from coal to that produced from graphite is the size of the metal catalyst. The metal nanoparticles, which appear as dark regions in the TEM, were almost half the size (average 12 nm) when using coal as compared to metal nanoparticles produced from graphite (average 20 nm). This is a statistically significant difference and can possibly be a result of the presence of the sulfur in coal. Small catalyst is very useful in producing smaller bundles. Small bundles are easier to disperse.
In terms of production rate of the arc process, as pointed out, a rod can be burned in about 40 minutes, using the coal composite rods, producing about 5 gm of products. The production rate is therefore 0.125 grams/minutes. While this production rate is about 50% greater than the production rate of packed graphite rods, nevertheless these rates are very low for practical applications.
EXAMPLE 3
Carbonized coal with 2–100 micron particle size was ball milled with 2.6 atomic mixture of cobalt/nickel catalyst metals with Co:Ni ratio of 3:1 (atomic). This powder mixture was fed into the reactor system described in FIG. 1 ., at a variable rate from 1.5 grams/minute to 3 grams/minute. In a preferred example, run conditions that were found to produce SWNTs were 400 torr pressure, at an inert gas flow rate flow rate of 2.0 l/minute of argon. The induction coil used generated plasma at about 20 kw power. The standard LEPEL T-40 radio frequency generator was used. The reactor was a 20 mm inner diameter quartz tube, the created plasma ball was constrained within 10 cm 3 , which were the actual tube size and power levels employed in the experiments that demonstrated that the predicted yields could be obtained. The optimum feed rate where all feed was vaporized within the allowed residence time and plasma power conditions was found to be 1.5 gram/minute. A large number of TEM images were taken and the characteristics of the SWNTs were estimated. The bundle diameters of the SWNTs produced from coal using the ICP technique were found to be about 8 nm. This bundle diameter is smaller than those obtained in the arc process (˜10 nm). Smaller bundles are easier to disperse. From the sidewall fringes the diameter of the individual SWNT was estimated to be ˜1.25 nm. This diameter is smaller than the SWNT diameter produced in the arc process (˜1.5 nm). The catalyst metal nanoparticles, which appear as dark regions in the TEM FIG. 2 ., were about the same size as the metal particles produced in the arc using graphite as the carbon precursor (average 24 nm). Arial measurements from TEM micrographs of the products indicate yields of about ca. 15 mass. % of SWNTs in the condensed soot were obtained which is very similar to the result of example 1 and example 2.. However, the production rate was up to 1.5 grams/minute, which is 12 times the rate of the arc process in only 20-mm diameter reactor with the potential of easy scaling up to a continues system.
None of the TEM images evaluated contained any evidence of multiwalled tubes, indicating that the nanotube product synthesized in accordance with our invention is pure SWNT.
While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents which are both chemically and physically related may be substituted for the agents described herein while the same or similar results would be achieved. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims. | Single walled carbon nanotubes are selectively produced to the substantial exclusion of multi-walled carbon nanotubes by subjecting a mixture of solid hydrocarbon, such as coal, and a transition metal catalyst, to heat generated by an RF induction system sufficient to vaporize both the solid hydrocarbon and the catalyst, and thereafter collecting the single walled carbon nanotubes thereby formed. | 3 |
BACKGROUND OF THE INVENTION
The present invention generally relates to flow control devices and, more specifically, to liquid flow control devices for applications in which it is desired to reduce liquid flow at a disproportionate rate at higher pressures. While the preferred embodiment is described with regard to flow control between a reservoir and a livewell mounted on a boat, those of ordinary skill in the art will understand that the present invention has a much wider application, as further discussed below.
The terms "livewell" and "baitwell" are used in this disclosure interchangeably to describe either saltwater or freshwater boat-mounted holding tanks. The term "fresh water" as used below means water brought into the holding tank from outside the boat, whether saltwater or freshwater.
It is widely recognized that successful saltwater fishing with natural bait requires that the bait be kept alive and healthy. Since bait can be quite expensive and fragile, many fishing boats are equipped with means to maintain a continuous circulation of fresh water through the baitwell at all times, whether the boat is moving or not. In freshwater tournament fishing, such as bass and walleye events, the catch is kept in livewells. It is critical in these events to keep the catch alive or the fisherman will be penalized at weigh-in for any dead fish. Tournament catch are released after weigh-in.
A popular type of fishing boat livewell system is shown in FIG. 1. An inlet strainer or high-speed pickup 10 is mounted on boat hull 12, below waterline. The scoop may include a strainer to prevent the intake of waterborne solids. The scoop is connected to a seacock or shut-off valve 13. The outlet of the seacock is connected to the inlet side of pump 15. The pump outlet feeds water to livewell 17. Livewell 17 includes an overflow pipe 19.
When the boat is sitting still in the water or moving slowly, the pump is turned on to provide circulation. Water is drawn in through the inlet strainer and pumped to the livewell. Excess water is drained out overflow pipe 19, maintaining the livewell at a preset level and providing a continuous circulation of fresh water.
When the boat is underway, the pump is turned off and water flow is provided by the inlet strainer. As the boat speed increases, the water pressure acting at the inlet strainer increases due to the relative velocity between the boat and water. A substantial flow of fresh water can be provided in this manner. However, at high boat speeds, the resultant high dynamic pressure at the inlet strainer can produce excessively high pressure at the pump inlet and excessively high flow rate into the livewell. Both high pressure and high flow can cause problems, as now discussed.
Short pump service life is very common in this application. When high pressure acts on the inlet side of the pump, it can cause premature pump seal failure because low-cost marine centrifugal pumps have seals that are not designed for high pressure on the inlet side. Also, the high flow rate causes the pump impeller to rotate continuously, increasing seal wear and motor brush wear. As a result, many manufacturers choose to use expensive pumps which can better withstand the high inlet pressures and flows.
The high flow rates can create other problems. Unless the seacock is manually adjusted, the flow can exceed the overflow capacity, resulting in a flooded boat. Seacocks are generally not located in a convenient place to allow easy adjustment of flow. If the plumbing system has a fixed restriction so that no excess flow condition develops, then it is likely that the pump will be unable to provide adequate circulation when the boat is sitting still. Also, a restriction small enough for typical livewell applications, which may be about 1/4 inch in diameter in some cases, can easily clog with waterborne debris. Alternatively, if the overflow is increased in size to meet the flow demand at the highest boat operating speeds, it adds unacceptable cost and bulk to the plumbing system.
Accordingly, it is an object of the present invention to provide a flow control device which automatically adjusts to environments creating a high inlet pressure so that adequate flow may be provided, such as by using an inexpensive pump, during periods of relatively low inlet pressure, e.g., when a boat is sitting still or moving slowly, while also limiting flow and pressure to an acceptable level during periods of high inlet pressure, e.g., such as when a boat is running at its highest speeds.
It is another object of the invention to provide a flow control device which minimizes pump seal pressure, reduces induced impeller rotation speed, lessens motor brush wear and assures that an overflow system capacity is not exceeded.
It is yet another object of the invention to provide a flow control device which can utilize relatively large flow path dimensions at all operating pressures and flow conditions, allowing it to pass some suspended solid matter without frequent maintenance.
It is still another object of the invention to provide a flow control device which does not require moving parts, so as to provide long, trouble-free service life, and which can be manufactured using materials suitable for use in saltwater and freshwater, and for below waterline installation in boats.
SUMMARY OF THE INVENTION
The present invention provides a solution which addresses the objects described above, which overcomes disadvantages of prior art flow control devices, and which provides advantages not found in such prior art devices.
The present invention is a flow control device for variably resisting the flow of a liquid through a flow passageway. A housing communicates with the passageway. The housing has two ends, a sidewall, and an inlet and an outlet. A vortex generator or flow control means is mounted within the housing, and has a base and an annular flow guide radially spaced from the housing sidewall. The annular flow guide includes at least one, and preferably a plurality, of slots. Liquid entering the housing via the inlet is directed to the outside of the generator and through the slots thereby creating a vortex flow path within the generator as the liquid flows to the housing outlet, such that as the pressure of the liquid at the inlet increases the flow factor of the device decreases to lower the rate of increase in the liquid flow rate.
In a preferred embodiment, the housing is cylindrical and each of the inlet and the outlet is generally centrally disposed on one of the housing ends. Also, while again not a requirement to practice the present invention, the base of the generator may be axially spaced from the inlet end of the housing and the annular flow guide may extend axially from the base to the outlet end of the housing. Preferably, the slots are tangentially oriented relative to the annular flow guide. Also, preferably, the base extends radially beyond the annular flow guide, forming an annular flange with a plurality of passages. In a particularly preferred embodiment, the slots in the annular flow guide are displaced circumferentially from the passages in the annular flange. The annular flange may include beveled edges to direct the liquid flow at least in part in a preselected circumferential direction. Preferably, the slots are uniformly and generally symmetrically spaced about the circumference of the annular flow guide. The vortex generator may be cup-shaped, or take other suitable geometric configurations, and may be mounted, e.g., coaxially within the housing. Preferably, the diameter of the annular flow guide is greater than either of the diameters of the inlet or the outlet.
The present invention provides a flow control device which includes no moving parts.
In another preferred embodiment, the present invention consists of an assembly for transferring a liquid from a first reservoir to a second reservoir. This assembly includes a pump and a flow control device disposed between the first and second reservoirs. The flow control device located upstream of the pump, and has an effective flow area sufficient that the pump can deliver its full capacity liquid flow rate from the first reservoir to the second reservoir without substantial pressure drop across the flow control device. The flow control device also has a vortex generator such that as the inlet pressure to the device increases, the flow factor of the device decreases to lower the rate of increase in the liquid flow rate. The pump, such as a centrifugal or other pump, and flow control device may be incorporated into a unitary structure, or combined using separate parts. In a particularly preferred embodiment, the assembly is mounted on a marine vehicle and the second reservoir is a livewell.
In another embodiment of the present invention, a variable resistance flow control device is used to reduce the flow of a liquid through a flow passageway. The flow control device includes an inlet, an outlet and a flow control means. The inlet and the outlet each communicate with both the flow passageway and with the flow control means. The flow control means automatically responds to the flow velocity of the liquid through the inlet, such that as the inlet flow velocity increases the flow factor of the flow control means decreases to lower the rate of increase in the liquid flow rate.
In still another embodiment of the present invention, a variable resistance flow control device is used to reduce the flow of a liquid through a flow passageway. The flow control device includes an inlet, an outlet and a flow control means. The inlet and the outlet each communicate with both the flow passageway and with the flow control means. The flow control means automatically responds to the pressure of the liquid at the inlet, such that as the inlet pressure increases the flow factor of the flow control means decreases to lower the rate of increase in the liquid flow rate.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth in the appended claims. However, the preferred embodiments of the invention, together with its further objects and attendant advantages, will be best understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a diagrammatic view of a typical fishing boat livewell system;
FIG. 2 is an exploded view of the vortex flow and pressure limiter which constitutes a particularly preferred embodiment of the flow control device of the present invention;
FIG. 3 is a view showing an assembly of the components of the flow control device of FIG. 2;
FIG. 4 is a schematic view of the flow control device used in a livewell application;
FIG. 5 is a cross-sectional view of a preferred embodiment of the flow control device of the present invention;
FIG. 6 is a planar view of the annular flow guide of the vortex generator which forms part of the flow control device of the present invention;
FIGS. 7 (with flow control device) and 8 (without flow control device) show different prototype test configurations;
FIG. 9 is a graph showing flow rate versus inlet velocity for the prototype systems shown in FIGS. 7 and 8;
FIG. 10 is a graph showing pump inlet pressure (P pi ) versus inlet velocity (V b ) for the prototype systems shown in FIGS. 7 and 8;
FIGS. 11A and 11B are 2-dimensional illustrations of the prototype test configurations shown in FIGS. 7 and 8, using computational fluid dynamic software to show the analytical flow patterns in vector (FIG. 11A) and gradient (FIG. 11B) form which are developed when the slots of the annular flow guide are tangentially oriented, causing the flow to spin around the centrally-located outlet;
FIGS. 12A and 12B are illustrations similar to FIGS. 11A and 11B using computational fluid dynamic software, of the analytical flow patterns developed when the slots of the annular flow guide are radially oriented, allowing the flow to move directly toward the outlet with a minimal component of rotational velocity; and
FIG. 13 is a graph comparing the pressure drop versus flow rate for the radial and tangential/"vortex" slot configurations, showing that as flow rate increases, an increasing pressure drop difference develops with the tangential slot configuration, providing increased flow resistance.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The flow control device of the present invention is generally referenced as 20 in the drawings. Referring to FIG. 4, flow control device 20 is mounted between the high speed pickup/inlet strainer 10 and the pump 15. Tube 40 transports liquid from the pump to the livewell 17. Referring now to FIGS. 2 and 3, in a preferred embodiment, flow control device 20 consists of two basic parts: a housing 21 and an annular flow guide 26. Housing 21 consists of base portion 22 and cover portion 24. Base portion 22 has an inlet opening 23 and is joined to a cover portion 24 which has an outlet opening 25. Base 22 and cover 24 house annular flow guide or "vortex generator" 26. An o-ring seal (not shown) is preferably provided between base 22 and cover 24, and housing attachment screws 43 (shown in FIG. 5) are inserted through apertures 29a and 29b to attach base 22 to cover 24. It will be understood that these basic parts of flow control device 20 can be provided as shown, or formed in one or two integral pieces, as convenient.
Annular flow guide 26 is preferably provided with a number of tangentially oriented slots 27 on annular wall 26a which run axially, relative to the axis of flow control device 20. Bottom portion 26b preferably extends radially beyond flow guide 26, forming an annular flange portion 31 having passages 33 which are displaced circumferentially from slots 27. Annular flange portion 31 preferably includes beveled edges 28 to direct liquid flow at least in part a preselected circumferential direction, as detailed below. Axial slots 27 and beveled edges 28 are each preferably generally symmetrically spaced around the perimeters of annular wall 26a and bottom portion 26b, respectively, of flow guide 26. Slots 27 and beveled edges 28 are also preferably beveled in the direction of flow, as shown in FIGS. 2 and 6, for reasons described below.
In operation, when flow is directed into inlet opening 23, the flow is conducted to the annular space between the base 22 and annular flow guide 26. Axial slots 27 then direct the flow into the interior of annular flow guide 26. A uniform spacing of the slots 27 around the perimeter of flow guide 26 is desirable to create a uniform circular flow pattern. Outlet opening 25 is preferably located at the center of cover 24, which is also preferably at the center of flow guide 26. In the embodiment shown in the drawings (see especially FIG. 5), flow guide 26 is seated within base 22 such that bottom 26b of flow guide 26 is located sufficiently above the upper surface of inlet opening 23 to allow adequate flow through inlet opening 23. [preferable that it is non-restrictive]
Under low flow conditions, the flow velocity is low and flow can easily move radially inward toward outlet opening 25 and, therefore, through flow control device 20 with little restriction. This is the condition occurring when, using the livewell example, a boat is sifting still and the pump is turned on. Water is easily drawn through flow control device 20 by pump 15. The total open area of slots 27 is established by providing sufficient flow area to satisfy the pump with minimal restriction. The number of slots 27, overall height of flow guide 26 and total area required determine the width of slots 27. Since flow control device 20 must not clog with waterborne debris, the width of slots 27 must be sufficient to pass solid matter likely to flow through inlet strainer 10.
Continuing with the livewell example, as boat speed increases, the pressure at inlet opening 23 of flow control device 20 increases. This causes the velocity of the water to increase as it flows through slots 27 in annular flow guide 26. Tangential flow components create a circular flow pattern which gives rise to an increase in centrifugal force or pressure which makes it increasingly difficult for the flow to move radially inward, toward the center of outlet opening 25. The faster the boat moves, the faster the circular flow in flow control device 20. The result is that the resistance to flow through flow control device 20 increases as boat speed increases.
As seen in FIGS. 9 and 10, the flow and pressure downstream of flow control device 20 at high boat speeds are significantly reduced. The dimensions of flow control device 20 can be set so that the characteristics of inlet pressure versus flow rate through the device meet the pump requirements at zero-to-low boat speeds, for example, while limiting the flow and pressure to desired maximum levels at the highest boat speeds.
Referring to FIGS. 5 and 6, the key design parameters are:
Inlet diameter, D i
Base diameter, D b
Inside diameter of annular flow guide 26, D Ti
Outside diameter of annular flow guide 26, D To
Slot 27 height, H s
Slot 27 width, W s
Number of slots 27, N s
Location of slots 27
Outlet Diameter, D o
The resistance provided by flow control device 20 varies directly with D Ti and inversely with D i , W s , H s and D o . It has been found that the most effective performance occurs when slots 27 are positioned at equal spacing around the perimeter of flow guide 26, but other locations may also be used to provide advantageous performance.
A prototype of flow control device 20 was built and tested at various inlet conditions. The dimensions chosen for this prototype were selected such that a 360 GPH (gallons/hour) pump could draw full flow through flow control device 20 when the boat was still, while at high speeds there would be a significant reduction in pressure and flow compared to the flow and pressure that would occur without the use of flow control device 20. The prototype test configuration is illustrated in FIG. 7. The system is typical of systems used in boats. The objective of the test was to determine how much flow control device 20 reduced the system flow rate and pressure at the pump inlet for a given boat velocity. The first measurements were made with flow control device 20 installed. Pressure upstream of device 20, P i , pressure at the pump inlet, P pi , and flow rate, Q, were measured at operating flow rates between 300 and 3000 GPH. Total inlet pressure, corresponding to the dynamic pressure produced by a moving boat, was measured upstream of device 20. The equivalent velocity at the high speed inlet was calculated from Bernoulli's equation: ##EQU1## The test measurements produced the flow rate versus inlet velocity characteristic and pump inlet pressure versus inlet velocity characteristic for the system using the vortex generator of the present invention. Flow control device 20 was then removed and the measurements were repeated. In this case the pump inlet pressure and the pressure at the high speed inlet are the same. The total pressure due to boat velocity is therefore:
Total pressure due to boat velocity=1/2 ρ V b 2 =P i +1/2 ρ V s 2
where: ##EQU2## FIGS. 9 and 10 illustrate the benefits of flow control device 20 of the present invention. As boat speed increases, flow control device 20 reduces both flow rate and pump inlet pressure, compared to the values that would be present if device 20 were not used. As shown, at low boat speed, device 20 has little effect on either flow rate or pump inlet pressure, which is desirable to allow the pump to draw water freely through the high speed inlet. At higher boat speeds, however, the effect of flow control device 20 on both flow rate and pump inlet pressure becomes increasingly greater, which is again desirable to reduce the undesirable effects of excessive flow rate and inlet pressure on the pump and the livewell. For example, as shown in FIG. 9, at boat speeds of about 65 mph, the presence of flow control device reduces the flow rate by a fraction of near one half.
Using computational fluid dynamic software, an analysis was conducted to compare the performance of a tangential flow guide with a radial flow guide. The models were two dimensional representations of the prototype configuration. The only difference between the models was that the slots were oriented tangentially in one model (FIGS. 11A and 11B) and radially in the other (FIGS. 12A and 12B). These figures illustrate the analytical flow patterns which develop at the same high inlet velocity in each model. As shown, tangentially oriented slots 27 (as also shown, for example, in FIG. 6) cause the flow to spin around the centrally located outlet, while radially oriented slots 27 allow the flow to move directly toward the outlet with a minimal rotational velocity component. This difference in flow pattern results in a significant difference in flow rate versus pressure drop characteristic between the two configurations. FIG. 13 compares the pressure drop versus flow rate characteristic of the tangentially oriented and radially oriented slot 27 configurations. When flow rate is low, there is little pressure drop difference between radially and tangentially oriented slot configurations, but as flow rate increases an increasing pressure drop difference develops with the tangentially oriented slot configuration, providing increased flow resistance.
This means that device 20 has an increasing resistance to flow as boat velocity increases, which protects pump seals and reduces overflow capacity requirements. This lowers the cost of livewell system manufacturing since lower cost pumps and smaller overflow systems can be used. Pump life is extended. Operation is simplified also since device 20 automatically adjusts flow resistance with boat speed, eliminating the need for inconvenient manual seacock adjustments.
As used here and in the claims, the term "tangentially oriented" as it references slots 27 is defined as an arrangement and/or configuration of the slots such that flow exiting the slots tends to move circumferentially around the inside of annular wall 26a of flow guide 26 before traversing radially to outlet 25. The slots need not be oriented or the material between the slots need not be beveled at a true "tangent", but the orientation of the slots does at least form an oblique angle, relative to annular wall 26a, sufficient to cause circular flow.
As further used here and in the claims, "flow factor" means as follows. For typical orifice flow, which includes flow through round and slotted openings, Q=C f *√Δρ where "Q" is flowrate, "Δρ" is the pressure drop across the orifice, and "C f " is called the flow factor. For specific fluids and orifice geometries, C f is generally a constant since the flow pattern in the range of interest (usually the turbulent flow regime) through these devices remains similar even with changes in velocity. The flow control device of the present invention has a similar characteristic equation relating flow rate and pressure drop, but C f is not constant in the range of interest which is, again, turbulent flow. Instead, C f varies for flow control device 20 due to the changes in the flow pattern within vortex generator 26. At low flow rates in which flow is generally radial through the vortex chamber, C f remains generally constant as with simple orifice devices. However, at high flow rates, flow is generally tangential, with high centrifugal forces which add to the flow resistance, reducing C f . Thus, as the pressure a the inlet to device 20 increases, the flow factor decreases and, as a result, the rate of increase in the liquid flow rate through the device decreases.
Regarding the pump and/or livewell application described here, other configurations for flow control device 20 are contemplated. For example, device 20 may be built directly into the pump inlet chamber, conserving room in small bilges. The parameters for device 20, identified above, could easily be set for any pump capacity. Alternatively, device 20 may be incorporated into the high speed pickup, again reducing the installation space needed in the bilge.
The preferred embodiment has been described with reference to the drawings, in which the base of flow control device 20 is axially spaced from housing 21, and flow guide 26 extends axially spaced from housing 21, and flow guide 26 extends axially from base 22 and inlet 23 to cover 24 and outlet 25 so that the inlet and outlet liquid flow is colinear or parallel. However, it will be understood that this need not be the case. For example, for a given application the outlet passageway of flow control device 20 might run perpendicular or at another angle to the inlet passageway.
It will be understood that flow control device 20 may also find advantageous use in applications other than livewells. For example, flow control device 20 could be used in many different applications requiring flow limiters or system protection devices, where it is desired to minimize the effect of upstream pressure variations or downstream load variations on either pressure or flowrate. As one non-limiting example, the flow control device of the present invention could be used as a system protector in a hydraulic circuit, such that if a sudden load were placed on a hydraulic cylinder or a line failed, the vortex device would prevent an excess fluid condition from developing.
Of course, it should be understood that various changes and modifications to the preferred embodiments described herein will be apparent to those skilled in the art. Such modifications and changes can be made to the illustrated embodiments without departing from the spirit and cope of the present invention, and without diminishing the attendant advantages. It is, therefore, intended that such changes and modifications be covered by the following claims. | A flow control device for providing variable resistance to liquid flow through a flow passageway. A cylindrical housing communicates with the passageway. The housing has a sidewall, and an inlet and an outlet each disposed at two ends. A vortex generator is located within the housing, and has a base spaced from the inlet end of the housing and an annular flow guide radially spaced from the housing sidewall. The flow guide includes a number of slots. Liquid enters the housing through the inlet and is directed outside the vortex generator and through the slots. This creates a vortex flow path within the generator as the liquid flows to the housing outlet, so that as the pressure of the liquid at the inlet increases the flow factor of the device decreases to reduce the liquid flow rate through the device at higher inlet pressures. | 8 |
TECHNICAL FIELD
[0001] The present disclosure relates generally to medical devices, and more particularly, to medical devices for alleviation of jaw discomfort and/or headaches.
BACKGROUND
[0002] Many people suffer from pain in the joint located between the skull and the jaw. The joint is formed between the temporal bone of the skull and the mandible or jaw bone, and is commonly known as the temporo-mandibular joint or “TMJ”. The human body has two temporo-mandibular joints, one located on each side of the jaw in front of each ear. The TMJs move every time a person chews, talks, or swallows.
[0003] In greater detail, the TMJ is a paired joint articulating the mandibular condyle, articulator disc, and squamous portion of the temporal bone. The TMJ is capable of both glide and hinge movements. Specifically, the TMJ is formed by the mandibular condyle fitting into the mandibular fossa of the temporal bone. A separation of these two bones is accomplished by the articulator disc which is composed of dense fibrous connective tissue. Ligaments attach the articulator disc to the condyle, permitting rotational movement of the articulator disc during mouth opening and closure.
[0004] Displacement of the articulator disc introduces strain to the jaw muscles and causes muscle pain or fatigue around the jaw. In addition, articulator disc displacement often causes a painful clicking in the TMJ during certain jaw movements as the disc moves between normal and displaced positions. A number of other symptoms may occur as a result of a strained disc, including TMJ lock, shoulder, neck, and back pain, and headaches.
[0005] Conventional methods of treating temporo-mandibular joint disorders can be costly, physically cumbersome, involve invasive and irreversible treatment or be time consuming. Some conservative methods for treating TMJ discomfort include the use of an intra-oral splint, medication, and life style changes. One type of intra-oral splint is a stabilization apparatus which is used to help alter the posture of the mandible to a more open, relaxed, resting position. Another type of intra-oral splint is an anterior positioning apparatus. The anterior positioning apparatus attempts to decrease the compression load on the joint and alter the structural condyle disc relation. Both types of splints, however, cannot be used full time without risking displacement of teeth. Treatment by medication often involves the use of addictive drugs and/or anti-depressants and therefore can lead to misuse and abuse. In addition, medications often produce adverse side effects in the patient. Other conservative methods include chiropractic or physical therapy. Unfortunately, these methods require extensive time commitments and physical exertion by the patient.
[0006] More aggressive treatment of TMJ discomfort includes orthodontic treatment such as grinding down of teeth and various types of surgery. Orthodontic treatments, however, merely indirectly address TMJ pain by adjusting the dental articulation and overall bite of the patient. Furthermore, orthodontic approaches are invasive, irreversible, and expensive.
[0007] An alternative procedure and related apparatus for treatment of TMJ discomfort are disclosed in U.S. Pat. No. 5,769,891, the contents of which are incorporated by reference herein in their entirety. According to the disclosure in U.S. Pat. No. 5,769,891, a prosthesis is provided for insertion into the ear canal. The prosthesis has a rigid structural portion of a shape conforming to the ear canal when the jaw is in an open position. The prosthesis provides added support to the TMJ and associated secondary musculature to reduce strain in the TMJ area. In practice, this prosthesis is inserted into the ear canal with the jaw in either the open or closed position. Support is provided when the jaw is closed as the internal diameter of the ear canal is reduced. Another apparatus for treatment of TMJ discomfort is disclosed in U.S. patent application Ser. No. 12/075,046 (incorporated by reference). This apparatus likewise uses a substantially rigid structure providing support to the TMJ and associated secondary musculature.
[0008] Many people also suffer from severe headaches. In some instances, such headaches are related to defined TMJ disorders. In other cases, the headaches are not related to any discernable TMJ disorder. It has been found that the insertion of a substantially rigid prosthesis as disclosed in U.S. Pat. No. 5,769,891 and U.S. patent application Ser. No. 12/075,046 may provide relief for a sizeable percentage of people who suffer from headaches even where there is no discernable TMJ disorder. Without being limited to a specific theory, the present inventors believe that that support within the ear canal may reduce tension in surrounding muscles and ligaments, thereby relieving stress that may cause a tension headache.
[0009] While the prior rigid devices are believed to provide substantial benefits, they have to be sized for individual users or classes of users. Thus, a structure that is substantially self-adjusting for users of different sizes would be desirable.
SUMMARY OF THE DISCLOSURE
[0010] According to one aspect, the present disclosure provides an ear canal insert for treating TMJ disorders and/or headaches which acts directly on the TMJ and associated ligament and muscle structures to reduce stress and loads placed on the articulator disc located between the temporal bone and the mandible, as well as supportive muscles and ligaments near the TMJ. The insert includes an internal support and a deformable covering adapted to conform to the contours of the ear canal when the internal support and/or the deformable covering is expanded. In the expanded condition, the insert provides support to the TMJ and associated ligament and muscle structures. This support maintains the ear canal in an expanded circumferential condition generally approximating the ear canal when the jaw is open.
[0011] According to another aspect, the present invention provides an ear canal insert for treating TMJ disorders. The insert includes a deformable, covering of heat expansible material. The covering expands when exposed to body heat to conform to the contours of the ear canal. In the expanded condition, the insert provides support to the TMJ and associated ligament and muscle structures.
[0012] These and other aspects of the disclosure will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cut-away view illustrating an exemplary insert for insertion into an ear canal for treatment of TMJ discomfort incorporating an expansible endoskeleton frame disposed in embedded relation within a deformable cover;
[0014] FIG. 2 is a view illustrating insertion of the exemplary insert of FIG. 1 into the ear canal of a user;
[0015] FIG. 3 is a view similar to FIG. 2 showing the exemplary insert in the ear canal with the endoskeleton frame in expanded condition;
[0016] FIG. 4 is a side view of a TMJ in an unoccluded condition with the disc in the normal position;
[0017] FIG. 5 is a side view of a TMJ showing the disc in a displaced orientation;
[0018] FIG. 6 is a cut-away view illustrating another embodiment of an insert for insertion into an ear canal for treatment of TMJ discomfort incorporating an expansible endoskeleton frame disposed within a deformable cover with a solid wall hollow sound bore at the interior of the endoskeleton frame; and
[0019] FIG. 7 is a view similar to FIG. 6 illustrating another embodiment of an insert for insertion into an ear canal for treatment of TMJ discomfort incorporating an expansible cover with a solid wall hollow sound bore at the interior.
[0020] While the concepts of the instant disclosure are susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions and equivalents falling within the spirit and scope of the disclosure as defined by the appended claims and all equivalents thereto.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0021] Exemplary constructions and practices will now be described through reference to the drawings, wherein like elements are designated by like reference numerals in the various views. For purposes of illustration, FIG. 1 illustrates a prosthesis 10 adapted for insertion into an ear canal 12 as shown generally at FIGS. 2 and 3 . According to a contemplated practice, the prosthesis 10 includes a hollow deformable body 14 incorporating an interior sound transmission channel 16 extending in tunnel-like relation along the length of the prosthesis.
[0022] In the illustrated exemplary construction the deformable body 14 has a generally sleeve-like configuration surrounding the sound transmission channel 16 . According to one contemplated arrangement, the deformable body 14 is formed from silicone rubber or the like although other shape-conforming materials may likewise be used if desired. As shown, in the exemplary construction an endoskeleton frame 20 is disposed in embedded relation within the deformable body 14 . The endoskeleton frame defines a support member within the deformable body 14 . By way of example only, and not limitation, such a structure may be achieved by positioning the endoskeleton frame 20 about a mandrel corresponding generally to the size and shape of the desired sound transmission channel 16 and then casting the silicone rubber or other material forming the deformable body 14 around the mandrel and the endoskeleton frame 20 . Once the silicone rubber or other material forming the deformable body 14 has cured, the formed sleeve structure with the embedded endoskeleton frame 20 can be pulled off of the shaping mandrel. This results in a hollow sleeve structure in which the endoskeleton frame 20 is embedded in the deformable body in surrounding relation to the open sound transmission channel 16 .
[0023] According to one contemplated practice, the endoskeleton frame 20 is formed with an initial diameter which is compressible to assume a reduced size facilitating insertion into the ear canal 12 . As will be described further hereinafter, it may be desirable to carry out the insertion into the ear canal with the user's mouth open due to the expanded condition of the ear canal. However, insertion may also take place with the user's mouth in a closed condition if desired. As illustrated, the endoskeleton frame 20 may utilize a generally serpentine ring structure disposed in surrounding relation to the sound transmission channel 16 . As will be appreciated, such a structure may undergo substantial radial adjustment. However, it is likewise contemplated that any number of other configurations may be used if desired. By way of example only, and not limitation, various constructions for expansible endoskeletons are disclosed in US Patent Application 2007/0183613 in the name of Juneau et al. the teachings of which are incorporated herein by reference in their entirety.
[0024] In accordance with one contemplated practice, the endoskeleton frame 20 may be formed from a so called “shape memory alloy” such as a nickel titanium alloy or the like. Such materials may have a relatively malleable character at typical room temperatures and take on a substantially more rigid state upon being subjected to elevated temperature conditions such as exist in the human body. Accordingly, in practice the endoskeleton frame 20 may be compressed by a user prior to insertion into an ear canal and thereafter be allowed to expand back to a pre-deformed shape after insertion into the ear canal as it is exposed to body heat. Moreover, in the elevated temperature state, the endoskeleton frame of shape memory alloy is characterized by enhanced rigidity due to a martensitic solid phase transformation at such temperatures. As will be described further hereinafter, such enhanced rigidity provides a desirable level of support to the prosthesis 10 within the ear canal 12 .
[0025] While the use of a shape memory alloy may be desirable in some circumstances, it is likewise contemplated that other materials may be used which remain rigid at room temperature, but which nonetheless exhibit expansion at body temperature conditions. By way of example only, and not limitation, it is contemplated that one material that may be used in forming the endoskeleton frame 20 is a manganese/copper/nickel alloy or the like characterized by a relatively high coefficient of thermal expansion. By way of example only, one such material that may be used is a 72% manganese, 18% copper, 10% nickel alloy sold under the trade designation High Expansion 72 by Carpenter Technology having a place of business in Reading Pa. However, other alloys with relatively high coefficients of thermal expansion at body temperature conditions may also be used.
[0026] It is also contemplated that naturally resilient materials which are readily compressible but which bias outwardly in a spring-like manner following compression may be used in forming the endoskeleton frame 20 . By way of example only, and not limitation, resilient polymers such as nylon and the like which are suitable for machining or other formation practices to provide a serpentine ring structure or other structure as may be desired may be particularly desirable.
[0027] While the use of an expandable endoskeleton frame 20 with a resilient covering may be desirable for many applications, it is likewise contemplated that the covering itself may be substantially expandable upon application to body heat. This expansion may be in conjunction with corresponding expansion of an internal endoskeleton. Alternatively, expansion of the resilient covering may be substantially independent of any internal endoskeleton. In fact, it is contemplated that the internal endoskeleton may be eliminated entirely in some instances.
[0028] By way of example only, and not limitation, it is contemplated that in one exemplary practice the deformable body 14 may be formed from an open cell foam such as a polyurethane foam or the like which has been loaded with plastic microspheres or other expansible fillers adapted to expand and contract in a substantially reversible manner upon application and removal of heat. When such an insert is inserted into the ear canal 12 , the expansible fillers expand thereby causing the foam to expand and take on a more rigid character. Upon removal from the ear canal 12 , the microspheres then contract back to the original state. As will be described further hereinafter, in the expanded state, the prosthesis will hold the ear canal in an open condition thereby providing support to the adjacent muscles and ligaments associated with the proximate temporo-mandibular joint
[0029] It is also contemplated that the deformable body 14 may be formed from a foam material or the like characterized by a relatively high coefficient of thermal expansion at body temperatures such that the use of expansible fillers is not required. In this regard, body temperature sensitive foams or other materials which expand and take on enhanced rigidity may be particularly useful.
[0030] Regardless of the specific configuration of the prosthesis that may be used, the prosthesis operates by expanding within the ear canal so as to hold the ear canal in an open condition similar to the condition the ear canal has with the mouth in an open condition prior to insertion. This support within the ear canal provides corresponding support to the proximately positioned TMJ. FIG. 2 illustrates the insertion of a compressed prosthesis 10 into the ear canal 12 by a user. FIG. 3 illustrates the prosthesis 10 within the ear canal after insertion with the deformable body 14 expanded at least partially back to its pre-deformed state as a result of exposure to body heat and/or due to natural resiliency. As will be appreciated, the expansion of the deformable body 14 causes the deformable body 14 to press outwardly into generally conforming relation relative to the walls of the ear canal 12 . In this state, the prosthesis 10 acts to hold the ear canal open.
[0031] According to a potentially desirable practice, the length of the deformable body 14 is selected such that a distal end portion extends slightly past the bend in the ear canal known as the isthmus 22 . The isthmus 22 is in close proximity to the temporo-mandibular joint and is located approximately 20-22 millimeters from the outside of an adult ear. However, this distance may vary in different individuals. It is contemplated that using a deformable body having a length such that it extends substantially from the entrance to the ear canal into engagement with the isthmus facilitates providing desired support to the proximately positioned temporo-mandibular joint.
[0032] As illustrated, it is contemplated that at least one anterior projecting retraction element 40 may extend away from the deformable body 14 so as to project towards the exterior of the ear. Following insertion, at least a portion of the retraction element 40 may reside outside of the ear canal 12 . In this position, a wearer may grasp the retraction element 40 to facilitate removal of the prosthesis 10 .
[0033] The retraction element 40 is preferably substantially pliable to facilitate insertion and aid in removability while avoiding discomfort to the wearer. At the same time, the retraction element 40 should be characterized by sufficient strength to avoid breakage. By way of example only, and not limitation, it is contemplated that a suitable retraction element 40 may be formed from thermoplastic monofilament nylon adhesively bonded onto a surface of the endoskeleton frame 20 or a surface of the deformable body 14 . However, other suitable polymeric or non-polymeric materials may likewise be utilized if desired. The retraction element 40 may include a bulbous head portion 41 . Such a bulbous head portion 41 may enhance the ability of a wearer to grasp the retraction element 40 during removal of the prosthesis 10 from the ear canal 12 . In the event that the retraction element 40 is formed from nylon or other thermoplastic material, a suitable bulbous head portion 41 may be formed by selectively melting the terminal end of the retraction element 40 to form a melted polymer bead which is thereafter permitted to resolidify. The surface of the resolidified bead may thereafter be smoothed by sanding or other suitable treatment to remove irregularities so as to enhance comfort during use.
[0034] Referring now to FIGS. 4 and 5 , in the expanded condition the prosthesis 10 influences the relationship between the temporal bone 44 and the mandible 46 in each temporo-mandibular joint 48 , thereby relieving pain inducing stress in the temporo-mandibular joint 48 and related muscles, ligaments, and nerves. In this regard, it will be appreciated that one source of temporo-mandibular joint discomfort is a dislocated articulator disc 50 . As shown in FIG. 4 , when the jaw or mandible 46 is in an open or unoccluded position corresponding to the mouth being open, the articulator disc 50 is usually in a normal, unstrained position between the temporal bone 44 and a condyle surface of the mandible 46 . As is often the case with a person experiencing temporo-mandibular joint discomfort, the articulator disc 50 slips to a displaced position when the mandible 46 is subsequently closed, as illustrated in FIG. 5 . The displacement of the articulator disc 50 is often indicated by a clicking or popping noise as the mandible 46 moves between open and closed positions. In the displaced position, the articulator disc 50 is no longer between the condyle surface and the temporal bone 44 , and the articulator disc 50 and attached ligaments become strained. Strain on these members stresses the surrounding muscles, which may ultimately result in face, neck, and back pain.
[0035] To treat temporo-mandibular joint discomfort arising from a displaced articulator disc 50 , the prosthesis 10 is provided for reducing stresses and loads on the articulator disc 50 . The prosthesis 10 reshapes and holds the ear canal in a condition substantially corresponding to the condition when the mouth is open thereby providing a support structure which helps align the temporo-mandibular joint 48 and associated muscles and ligament structures so that the temporo-mandibular joint 48 has a normal rotational movement. Strain or compression on the articulator disc 50 is therefore reduced, thereby alleviating pain in the temporo-mandibular joint and associated structures. It may be desirable for the user's mouth to be held in an open condition during insertion of the prosthesis 10 such that the expandable prosthesis naturally conforms with the naturally occurring expanded condition the ear canal has when the mouth is open. However, the prosthesis 10 may also be inserted with the mouth in a closed position followed by expansion of the prosthesis causing the ear canal to open more fully.
[0036] It is to be understood a dislocated disc is only one cause of temporo-mandibular joint discomfort and that there are many other sources of such pain. Nerves, ligaments, and muscle groups (such as the masticatory musculature) are located proximal to the temporo-mandibular joint, and improper loading, strain, or alignment of these members provide potential sources of temporo-mandibular joint pain. Rather than being limited to disc dislocation situations, as outlined above, the prosthesis 10 addresses misalignment and stress in the temporo-mandibular joint and related structures by supporting these structures for normal rotational movement.
[0037] The prosthesis 10 alleviates temporo-mandibular joint discomfort by supporting the temporo-mandibular joint 48 and associated muscles, nerves, and ligaments for proper rotation of the mandible between open and closed positions. By inserting the prosthesis 10 into the ear canal, the prosthesis will thereafter expand to urge the walls of the ear canal outwardly to take on the shape when the mandible 46 is open and disc 50 is in the normal position. That is, the ear canal 12 is expanded and held open as if the mandible 46 is open. In the expanded condition the sound transmission channel 16 is also held in an open condition such that hearing is not impaired. Thus, a natural body orifice is used to reposition the mandible 46 without requiring surgery or other painful and invasive techniques.
[0038] As noted above, the example of a dislocated disc is merely illustrative of a temporo-mandibular joint condition addressed by the present device and is in no means meant to limit the scope of the present invention. Accordingly, it will be appreciated that the present device addresses stresses and misalignments in not only the disc but also any muscles, ligaments, and nerves associated with the temporo-mandibular joint. As noted previously, the reduction in strain to the muscles and ligament structures is also believed to be beneficial in reducing headaches.
[0039] As will be appreciated, in the embodiment of FIG. 1 , the expansion of the endoskeleton 20 acts to hold the sound transmission channel 16 in an open condition by virtue of spreading radially outwardly. The endoskeleton 20 also provides resistance against compression within the ear canal. FIG. 6 illustrates an alternative embodiment wherein elements corresponding to those described previously are designated by like reference numerals within a 100 series. Specifically, in the embodiment of FIG. 6 , the prosthesis 110 includes a substantially rigid hollow tube or sound bore 160 of a material such as acrylic or the like that extends along the length of the deformable body 114 at the interior of the endoskeleton frame 120 . In this construction, the interior of the hollow sound bore 160 defines the sound transmission channel 116 . The hollow sound bore 160 also provides an interior support for the endoskeleton frame to limit compression during insertion. The sound bore 160 may be contoured to conform generally with the curvatures of the ear canal. In this regard, shapes such as illustrated in U.S. Pat. No. 5,769,891 and U.S. patent application Ser. No. 12/075,046 may be particularly useful.
[0040] In use, the rigid hollow sound bore 160 may aid in inserting the prosthesis 110 into the ear canal. Specifically, the rigid hollow sound bore 160 defines an additional support member providing a degree of axial rigidity even when the deformable body is in a substantially flexible state. Further, the solid wall construction of the sound bore aids in maintaining the sound transmission channel 116 in an open condition at all times. Thus, there is no interference with hearing during the period prior to expansion.
[0041] The exemplary prosthesis 110 illustrated in FIG. 6 also includes at least one anterior projecting retraction element 140 including a bulbous head portion 141 extending away from the deformable body 114 so as to project towards the exterior of the ear as previously described. The retraction element 140 may be adhesively bonded onto a surface of the endoskeleton frame 120 , a surface of the sound bore 160 or a surface of the deformable body 114 .
[0042] FIG. 7 illustrates still another exemplary embodiment wherein elements corresponding to those described previously are designated by like reference numerals within a 200 series. In the embodiment of FIG. 7 , the prosthesis 210 is devoid of an expanding endoskeleton frame. Rather, expansion is provided by the material forming the deformable body 214 . As noted previously, such material may include shape conforming temperature sensitive foams and the like which expand upon exposure to body heat. Such expansion causes the deformable body 214 to press outwardly on the walls of the ear canal thereby holding the ear canal open in a condition corresponding to the condition of the ear canal when the jaw is open. As shown, the exemplary prosthesis 210 includes a support member in the form of a substantially tubular sound bore 260 of solid wall construction formed from a material such as acrylic or the like that extends along the length of the deformable body 214 . In this construction, the interior of the hollow sound bore 260 defines the sound transmission channel 216 .
[0043] In use, the rigid hollow sound bore 260 may aid in inserting the prosthesis 210 into the ear canal by providing a degree of axial rigidity even when the deformable body is in a substantially flexible state. Further, due to the solid wall construction of the sound bore, the sound transmission channel 216 remains open at all times. Thus, there is no interference with hearing once the deformable body 214 has expanded. The sound bore 260 may be contoured to conform generally with the curvatures of the ear canal. In this regard, shapes such as illustrated in U.S. Pat. No. 5,769,891 and U.S. patent application Ser. No. 12/075,046 may be particularly useful.
[0044] The exemplary prosthesis 210 also includes at least one anterior projecting retraction element 240 including a bulbous head portion 241 extending away from the deformable body 214 so as to project towards the exterior of the ear as previously described. The retraction element 240 may be adhesively bonded onto a surface of the sound bore 260 or a surface of the deformable body 214 .
[0045] It will be appreciated that the foregoing description provides examples of the disclosed apparatus and method of use. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to examples herein are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure or claims more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the claims entirely unless otherwise indicated.
[0046] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by the context.
[0047] Accordingly, this disclosure contemplates the inclusion of all modifications and equivalents of the subject matter recited in the appended claims as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is contemplated unless otherwise indicated herein or otherwise clearly contradicted by the context. | An expansible ear canal insert for treating TMJ disorders and headaches which acts directly on the TMJ and associated ligament and muscle structures to reduce stress and loads placed on the articulator disc located between the temporal bone and the mandible, as well as supportive muscles and ligaments near the TMJ. The insert is adapted to expand by application of body heat. In the expanded condition, the insert provides support to the TMJ and associated ligament and muscle structures. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/006,723 titled “METHOD AND SYSTEM FOR TWISTING BUILDING CONSTRUCTION,” filed Jan. 29, 2008, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of structural engineering, and, in particular, to methods and systems for designing, building, and/or providing structural support for buildings having a twisting external appearance.
[0004] 2. Background of the Technology
[0005] Certain architectural fashions have led to desirability for tall buildings that twist. However, such related art twisting towers are notoriously expensive, at least in part because the inclined columns and alignment of openings in the core wall for most designs creates large torsions that usually lead to the necessity for very thick core walls and/or some form of external bracing. The twisting inclined columns are also typically very difficult to build because these features generate more twisting force as the load is applied. As a result, related art designs have increased costs related to risk, design details and increased material quantities.
[0006] Essentially, two approaches have been taken in the related art. FIGS. 1A-1B show representative perspective and overhead views, respectively, of a building B 1 constructed using a first approach, in which support columns C 1 are angled to connect corresponding portions of pairs of floors F 1 and F 2 . The radius of twist between floors in FIGS. 1A-1B of about 45° is much greater than in a typical related art building, and the columns C 1 are not likely to be designed to connect to the extreme corners of twisting floors, as shown in FIGS. 1A-1B . The angle and position of columns C 1 shown in FIGS. 1A-1B are merely intended to be representative and to illustrate the problem. Among other problems, the approach depicted in FIGS. 1A-1B typically results in a torsional force being generated about the building through the angled columns. As the load on the floors F 1 , F 2 increases, the torsional force increases, thereby placing torsional force on the building B 1 (including on the core structure) in the twisting direction. Resolution of the torsional force results in an increase in structural material quantities (within the core, or secondary bracing system) that increases the cost of the structure significantly beyond that of typical building structures of comparable size. Further, the aesthetic appeal of buildings using the design depicted in FIGS. 1A-1B may be negatively impacted due to the increased inconvenience and space occupied by the structure as a result of a requirement for additional structural elements beyond that of typical building structures of equivalent size.
[0007] FIGS. 1C-1E show representative perspective and overhead views, at differing floor levels, of a building B 2 constructed using a second approach, in which support columns C 2 are vertical through the entire height of the building and connect pairs of floors F 3 and F 4 . The radius of twist between floors in FIGS. 1C-1E of about 45° is much greater than in a typical related art building, and columns C 2 may be located further from the center of twisting floors than shown in FIGS. 1C-1E . The positions of columns C 2 shown in FIGS. 1C-1E are merely intended to be representative and to illustrate the problem. Among other problems, the approach illustrated in FIGS. 1C-1E results in column locations varying between floors F 3 , F 4 , effectively “rotating” through rooms within the floors F 3 , F 4 as viewed through successive floors, thereby resulting in differing room layouts, relative to column locations, on each floor (a problem potentially further exacerbated with smaller angles of rotation than the angle shown in FIGS. 1C-1E ). Further, the floors require additional material to achieve the cantilevers beyond the columns which are providing the appearance of the twist. If efficiency is desirable, the magnitude of difference between the floors may be restricted due to limited cantilever lengths. This approach can be thus aesthetically unappealing because the articulation of the form is limited.
[0008] FIGS. 2A-2C contain representative diagrams and indications of typical forces affecting straight buildings ( FIG. 2A ), a comparison between such forces and the first approach discussed above ( FIG. 2B ), and a comparison between such forces and the second approach discussed above ( FIG. 2C ), further to the figures and discussion with respect to FIGS. 1A-1E .
[0009] FIGS. 2D-2K present various cutaway and other views and renderings of example related art buildings of the first approach outlined above.
[0010] Related art solutions to the problem have typically involved use of additional braced frames, thicker core walls, and/or traditional cantilevers, and thus contain a compromise on either economy or planning flexibility.
[0011] Twisting residential buildings have become desirable, but current known structural engineering solutions require compromises and are deficient, as stated above. Thus, currently, many projects are not realized in their original envisaged form, due to these problems. Because of the above identified problems, as well as others, buildings of the related art are not popular in design, There remains an unmet need in the art for methods and systems for designing, constructing, and providing structural support for twisting buildings that overcome the torsional and aesthetic problems of the related art.
SUMMARY OF THE INVENTION
[0012] Aspects of the present invention overcome the above identified problems of the related art, as well as others, by providing methods and systems for designing, building, and/or providing structural support for twisting buildings, such that these buildings may be erected using conventional vertical and horizontal elements. Aspects of the present invention avoid reductions in the interior space or disruption of general interior symmetry that would otherwise occur in the related art due to the need for additional structural material and/or design compromises. The methods and systems of aspects of the present invention thereby provide a new dimension for enabling architects to create economically feasible twisting towers and other building shapes, based on the basic methods and systems disclosed herein.
[0013] In aspects of the present invention, the methods and systems include at least three features:
[0014] a) Alternate floor plates. Every floor is supported from below and above.
[0015] b) Cantilever forces resisted by diaphragm action. The floor plates are supported from fin walls, or trusses, which cantilever from a central core. The push-pull from the cantilever forces balance within each diaphragm level. The twist is created by translating the fin walls or trusses around the core.
[0016] c) Lateral Support. The lateral forces are resisted by a core wall only. The alternate floor arrangement means that penetrations through the floor do not align, which means that lintel beams are deep and effective.
[0017] Aspects of the present invention provide at least the following at least the following features: alternating the floor plates at about 180 degrees (plus the desired twist angle), or design of two mutually supporting floor plates (A&B) which alternate with respect to height; full depth cantilevers, placed in division walls, to support floors above and below; and floor diaphragms used to resolve cantilever bending forces in place of traditional back-spans for cantilevers
[0018] Aspects of the present invention allow the twisting building to be constructed at equivalent costs to traditional buildings of approximately the same size.
[0019] Example aspects of the present invention will now be described in accordance with the above advantages. It will be appreciated that the examples described in the following detailed description are merely illustrative of the invention. Many variations and modifications will be apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE FIGURES
[0020] In the drawings:
[0021] FIGS. 1A-1B show representative perspective and overhead views, respectively, of a building constructed using a first related art approach, in which support columns are angled to connect corresponding portions of pairs of floors;
[0022] FIGS. 1C-1E show representative perspective and overhead views, at differing floor levels, respectively, of a building constructed using a second related art approach, in which support columns are vertical through the entire height of the building and connect pairs of floors;
[0023] FIGS. 2A-2C contain representative diagrams and indications of typical force issues affecting buildings of the related art;
[0024] FIGS. 2D-2K present various cutaway and other views and renderings of example buildings of the first related art approach;
[0025] FIGS. 3 and 4 show perspective and overhead views of a representative twisting round profile building provided for illustration purposes, in accordance with aspects of the present invention;
[0026] FIG. 5A shows a view of the central core for the building of FIGS. 3 and 4 ;
[0027] FIGS. 5B and 5C show renderings of the core of FIG. 5A , in accordance with aspects of the present invention;
[0028] FIG. 5D presents modeled results stress for the core of FIG. 5A , in accordance with aspects of the present invention;
[0029] FIGS. 6A and 6B present overhead views of a generally almond shaped floor profile, in accordance with aspects of the present invention;
[0030] FIGS. 7A-7C show features and views of a generally tear-drop shaped profile for floors a various aspects of implementation relating thereto, in accordance with aspects of the present invention;
[0031] FIG. 8 shows cantilever walls of varying length, in accordance with aspects of the present invention;
[0032] FIGS. 9-11 show perspective and overhead views of a pentagon-shaped profile for floors in a twisting building, in accordance with aspects of the present invention;
[0033] FIGS. 12-12C show perspective views of an exemplary building designed in accordance with aspects of the present invention;
[0034] FIG. 13 shows a rendering of a 100° twist as applied to a conventional building with a generally tear-drop shaped cross-sectional profile and vertically aligned doors, in accordance with aspects of the present invention;
[0035] FIG. 14 shows a rendering of a 60° increasing twist as applied to a conventional building with a generally tear-drop shaped cross-sectional profile and vertically aligned doors, in accordance with aspects of the present invention;
[0036] FIG. 15 shows a rendering of a 60° twist (only the tip columns rotate) as applied to a conventional building with a generally tear-drop shaped cross-sectional profile having vertically aligned doors, in accordance with aspects of the present invention;
[0037] FIGS. 16A and 16B show a rendering of a central core in which the doors are aligned vertically and staggered on alternating floors, respectively, in accordance with aspects of the present invention;
DETAILED DESCRIPTION
[0038] FIGS. 3 and 4 show perspective and overhead views, respectively, of a representative twisting structure B 3 having generally circularly shaped floor plans, which are provided for illustration purposes, in accordance with aspects of the present invention. As shown in FIG. 3 , floors F 30 , F 31 , and F 32 each are shown with five thin walls W 30 , W 31 , W 32 and a central core C 30 . Openings (e.g., doors) D 30 are positioned in core C 30 between each sequential pair of floors (e.g., between floors F 30 and F 31 ). While five cantilever walls for each floor are shown in the variation of FIGS. 3 and 4 , as few as three walls for each floor may be sufficient for other variations. Such variations may be convenient for residential use buildings, where the cantilever walls can be coordinated with the desired apartment layouts, but also may be suitable for any other use building where the partition of the space is suitable, or open trusses are used in the cantilever positions allowing passage through the cantilevers.
[0039] The arrangement, as shown in FIGS. 3 and 4 , may be realized in a variety of structural materials such as a reinforced concrete, post-tensioned concrete, and steel framing with concrete on steel deck floors, among others. The choice of structural material is dependent on the scale and dimensions of the structure and associated requirements. The use of the terminology ‘cantilever walls’ refers to the wall positions where a structural concrete cantilever, or steel truss cantilever may be placed.
[0040] As shown in FIG. 3 , alternative pairs of floors (e.g., F 30 , F 32 ) have nearly aligned cantilever walls (e.g., W 30 , W 32 , respectively). For each floor (e.g., F 30 ), walls for that floor (e.g., W 30 ), along with walls for the floor below that floor (e.g., W 31 ), together support the floor (e.g., F 30 ).
[0041] As further shown in FIG. 4 , the cantilever walls W 30 a , W 31 , W 30 b are subject to shear forces and cantilever bending forces by virtue of gravity and their attachment to central core C 30 and floor F 30 . The walls W 30 a , W 30 b support floor F 30 from above, as shown. The weight of the floor is transferred to the core as shear force. The geometry of the load path results in cantilever bending forces. Since floor F 30 is attached to the base of walls W 30 a & W 30 b , a force acts towards the core. This force is resolved through the floor F 30 in diaphragm action, and is balanced by similar forces acting towards and away from the core at the other wall positions of floor F 30 . The wall W 31 supports floor F 30 from below as shown. The geometry of the load path results in cantilever bending forces. Since the floor F 30 is attached to the base of wall W 31 , a force acts away from the core. This force is resolved through the floor F 30 in diaphragm action and is balanced by similar forces acting towards and away from the core at the other wall positions of floor F 30 . In some aspects, the walls W 30 a , W 31 , W 30 b may be as thin as 150 mm/6 inches in width.
[0042] As a result of the use of such a cantilever wall arrangement, columns within the floors are not required, thereby improving room space utilization, due to both the lack of columns, and the resulting consistent large room size and open layout of floor space. For example, each room may form an apartment that has a relatively large open space (e.g., 10 m×20 m) uninterrupted by columns, as compared to typical related art apartments in conventional residential buildings (typically having a column to be addressed at 8 m intervals or less). Among other advantages, the large open spaces uninterrupted by columns can greatly increase the value of the apartments and/or building as a whole. As such, aspects of the present invention may also be used in a straight (not twisted) structure. The novel aspects of the present invention permit construction of a structure with or without a twist, at little or no cost differential. The feature of space uninterrupted by columns remains an advantage in either case.
[0043] Further, and particular in the case of concrete-framed construction, because of the combined cantilever wall support and the spacing of the supports for each floor from both below and above, a floor structure of each floor can be quite thin, relative to the thickness of related art floor structures for a typical building application. With the addition of a perimeter beam, the floor structures may be a 2-way slab system rather than a flat plate system typically used for floor construction in conventional applications. The 2-way slab system requires less concrete material than the flat plate system for equivalent spans. Among other things, the reduced floor thickness, in conjunction with use of cantilever walls, reduces the overall building weight and the stress on the building support structure (e.g., the central core).
[0044] In addition to use of structural concrete cantilever walls, steel or other suitable material trusses may be used in the position of the cantilever walls. The truss structures would be cantilever trusses connecting the floor above, the floor below and the central core with sufficient stiffness and strength following standard structural principles.
[0045] FIG. 5A shows a view of the central core C 30 for the building B 3 of FIGS. 3 and 4 , with openings D 30 (e.g., doors) shown. As shown in FIG. 5A , the doors D 30 are not aligned vertically. Rather, the doors D 30 of alternating floors are generally aligned along an angled vertical offset (e.g., angled line A 1 ) which is equal to the desired twist of the building. Arranging the doors according to an even and odd floor staggered arrangement, the corresponding openings D 30 may be positioned on opposite sides for sequential floors. As such, the corresponding openings D 30 on an even floor may be offset as compared to the openings D 30 on an odd floor in similar fashion or degree to the offset of the cantilever walls between an even and an odd floor. For example, the open space (e.g., apartment) on any one floor may be offset by a length equal to nearly half of the open space of the floor above or below, including the offset due to a twist, by positioning of the cantilever walls. As such, the openings D 30 on successive floors may be generally offset to be nearly equal to half of the length of an open space, for example. Among other advantages, arrangement of the openings D 30 in this manner increases the stiffness and strength of the central core C 30 , relative to a related art core, in which each floor has an opening aligned in a vertical line or angled line for every floor. Such an arrangement in related art cores reduces the stiffness and strength of the core along such lines. In related art cores, the lintel beams created by aligned doorways on adjacent floors can often, dependent upon the exact situation, require a high density of material and reinforcement due to the forces the lintel beams attract as the building moves under lateral loads. In aspects of the present invention, the shallow lintel beams may be removed to alleviate the associated stress.
[0046] In the interior of the central core C 30 (e.g., in the area within the concave side of the wall of the central core C 30 , as shown in FIG. 4 ) may be located elevators, stairways, mechanical rooms, vertical risers, plumbing, electrical, and/or other features common to the interior of the building. Aspects of the central core C 30 of a building in accordance with aspects of the present invention may be similar to aspects of an equivalent building as is typical in the related art.
[0047] FIGS. 5B and 5C show renderings of the central core of FIG. 5A . FIG. 5D presents modeled results of stress for the core of FIG. 5A .
[0048] FIGS. 6A and 6B present overhead views of floors for a similar variation to that of FIGS. 3-5A , but with the floor profile being generally almond shaped, such that the slight twist between floors may be seen in the overlay of even and odd floors (e.g., see offset of even floors F 50 and F 52 and odd floors F 51 and F 53 , as shown in FIGS. 6A and 6B , respectively). The floorplans of each of the even floors, as shown in FIGS. 6A and 6B , may be identical, or nearly identical, and the floorplans of each of the odd floors may be likewise identical, or nearly identical, with the even floor plans being nearly opposite in orientation, allowing for twist angle, to the vertically adjacent odd floor plans. As shown in FIG. 6B , the nearly opposite orientation of the odd and even floor plans allows for alternating support of the floor F 53 , for example, by the walls W 53 from above and the walls W 52 from below.
[0049] FIGS. 7A-7C show features and views of a generally tear-drop shaped profile for floors and various aspects of implementation relating thereto, including cross-braced cantilever wall portions usable with twisting buildings, in accordance with an aspect of the present invention. As shown in FIG. 7A , an elevational view of the floors illustrates the twist angle A 1 , taken along an offset vertical line of alternating floors, where A 1 may range from 0° up to 100°, The offset cantilever walls E 10 and O 9 show an alternating support structure in which the cantilever walls E 10 , O 9 alternate support between the even floors and the odd floors by approximately one-half of an apartment length, for example. FIG. 7B shows that the same support walls E 10 , O 9 may be of varying lengths to permit construction of structures of varying shapes. As shown in FIG. 7C , a top view of a typical room space shows that the cantilever walls permit an open column-free space. Although shown in FIG. 7C as having a circumferential dimension of 20 meters and a radial dimensional range of 8-12 meters, the range of configurations for any individual open space is limited only by the principles of engineering design for the material being used, as is well known in the art.
[0050] FIG. 8 illustrates an aspect of the present invention in accordance to which the structure may comprise a limitless variation of cross-sectional shapes due to the ability to provide different length cantilever walls. As such, an individual space may include balconies or various other design features as suitable for the use and purpose of the structure.
[0051] FIGS. 9-11 present perspective and overhead views of a generally pentagon-shaped profile for floors usable in twisting buildings, in accordance with aspects of the present invention. As shown in FIGS. 9 and 11 , the cantilever walls E 110 may be configured to extend to the corners of the pentagon-shaped profile on every other floor, for example, while the cantilever walls O 110 may extend to a center portion of each exterior side of the profile on each of the other alternating floors. The cantilever walls E 110 and O 110 extend from and are supported by the central core C 110 . Doors D 110 may be provided as shown and described previously with respect to a vertically angle line, although the configuration for the doors D 110 may be varied substantially according to the desired layout of apartments, for example.
[0052] FIGS. 12A-12C show perspective views of an exemplary building designed in accordance with aspects of the present invention. As shown, the building has a generally tear-drop shaped cross-sectional profile.
[0053] FIG. 13 shows rendering of a 100° twist as applied to a building with a generally tear-drop shaped cross-sectional profile having doors aligned vertically as is standard in the prevailing art. For example, FIG. 13 shows a column T 1 of link beams that starts at a radial position of 0° as measured from the center of the central core at a point of column T 1 along the base of the structure and twists radially through a total of 100° as measured from the center of the central core to a point of column T 1 at the top of the structure. Parametric modeling of the structure shows that the torque effects of this design may be up unacceptable, up to ten times the wind effects.
[0054] FIG. 14 shows a rendering of a 60° twist as applied to a building with a generally tear-drop shaped cross-sectional profile having doors aligned vertically as is standard in the prevailing art, where the twist angle increases from base to top. A parametric analysis of the structure shows that the torque effects of this design are more equivalent to the wind forces.
[0055] FIG. 15 shows a rendering of a 600 twist as applied to a building with a generally tear-drop shaped cross-sectional profile having doors aligned vertically as is standard in the prevailing art, where only “tip” columns rotate. A parametric analysis of the structure shows that the torque effects of this design are less than the wind effects.
[0056] FIGS. 16A and 16B show a rendering of a central core 180 A and 180 B, respectively, in which the doors are staggered on alternating floors in the central core 180 B. By designing the building with the staggered doors on alternating floors and using the cantilevered walls supporting the floors from above and below, aspects of the present invention reduce the stress levels experienced by the forces described above so that a twisting building construction becomes feasible.
[0057] While this invention has been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the exemplary aspects of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. Therefore, the invention is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents. | A structure and method of construction for a building, includes a core wall structure, a plurality of support walls attached to the core wall structure and cantilevered from the core wall structure, a plurality of floor structures arranged vertically and attached to the core wall structure so that each floor structure of the plurality of floor structures is supported from below by a first set of the plurality of support walls and from above by a second set of the plurality of support walls, a position of the second set of the plurality of support walls radially offset from a position of the first set of the plurality of support walls, and a plurality of openings in the core wall, wherein at least one opening is provided between any two successive floor structures and alternating openings in a vertical direction are arranged to align along an angle of vertical offset. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for the handling of cargo pallets or containers in a cargo compartment such as in an aircraft, ship or train or in storage facilities for cargo containers and pallets. This invention further relates to apparatus installed in the floor of the cargo compartment for moving cargo pallets or containers into and out of a cargo compartment.
It is well-known to use cargo moving shuttle conveyors for moving articles fore and aft on a track in the floor in cargo compartments of aircraft and the like. U.S. Pat. No. 3,568,825 issued to Munger shows such a device in which a rotatable bar may be erected into a cargo engaging position by a tripping pin mechanism located in the track. In order to utilize this apparatus, it is necessary to have the shuttle conveyor moved to the location of the tripping mechanism in order to raise or lower the cargo engaging bar. While this system works suitably in many applications, it is frequently necessary to raise or lower the cargo engaging bar at a location other than the location of the tripping mechanism. In addition, the location and orientation of the tracks used in the Munger device permit ingestion of dirt and other abrasive material which occasionally clog and cause wear to the tracks.
It is therefore an object of this invention to provide a cargo shuttle for moving cargo into and out of a cargo space that solves the problems associated with the prior art described above.
An additional object of this invention is to provide a cargo transporting shuttle for an aircraft cargo deck which occupies a minimum of vertical space.
A further object of this invention is to provide a shuttle in an aircraft cargo deck which occupies a minimum amount of space between the floor of the cargo compartment and the rollers provided for movement of the cargo into and out of the cargo compartment.
SUMMARY OF THE INVENTION
An improved mechanism for transporting cargo on a roller-equipped, load bearing surface into and out of an elongated cargo storage compartment such as an aircraft cargo compartment includes a shuttle carriage which moves on a track means extending along the path of travel of the cargo in the cargo compartment. The shuttle carriage has wheels mounted rotatably thereon for movement along the track means and includes a frame upon which are mounted a first and a second cargo engaging pawl. The shuttle carriage assembly also includes a first and a second rocker arm, each of the rocker arms having a first and a second end. Means are provided for mounting the first and second pawls respectively to the first ends of the first and second rocker arms and means are provided for pivotally mounting the second ends of the rocker arms to the frame. The several means referred to above are pivotally mounted to each other so that each of the pawls can move between an extended position, in which the pawl extends from the frame and engages the cargo, and a nested position, in which the pawl is out of engagement with the cargo, A control means is associated with the first and second rocker arms for controlling the movement of the first and second pawls between the extended position and the nested position. A draw cable means associated with the carriage assembly is provided for moving the carriage along the track means.
In a preferred form of the invention means are included for rotatably mounting the first and second pawls on the first and second rocker arms respectively for movement between an erect position and a reclined position. A biasing means associated with each of the rocker arms and pawls is provided to bias the pawls into the erect position.
Also in a preferred form of the invention the control means includes a control means disposed within the track means and a scissors linkage means associated with the control mechanism and the first and second rocker arms. The scissors linkage means is operable by movement of the control means relative to the shuttle frame to move the first and second pawls between their respective extended and nested positions.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be derived by reading the ensuing specification in conjunction with the accompanying drawings, wherein:
FIG. 1 is a diagrammatic perspective view of a cargo moving shuttle constructed in accordance with this invention shown moving a cargo container over a load bearing surface.
FIG. 2 is a side elevational view of the apparatus shown in FIG. 1.
FIG. 3 is a diagrammatic perspective view of the apparatus shown in FIG. 1 with the shuttle means shown traversing beneath the cargo container.
FIG. 4 is a side elevational view of the apparatus shown in FIG. 3.
FIG. 5 is a diagrammatic perspective view of the apparatus of this invention shown moving a cargo container in a direction opposite to the direction shown in FIG. 1.
FIG. 6 is a side elevational view of the apparatus shown in FIG. 5.
FIG. 7 is a side elevational view, partly in section, of a cargo shuttle made in accordance with the principles of this invention and having a first pawl extended.
FIG. 8 is a side elevational view of the apparatus shown in FIG. 7 having the first pawl nested and the second pawl extended and traversing beneath the cargo container.
FIG. 9 is a plan view of the apparatus shown in FIG. 7.
FIG. 10 is a side elevational view corresponding to FIG. 7 with certain parts omitted for clarity.
FIG. 11 is a side elevational view corresponding to FIG. 8 with certain parts omitted and simplified for clarity.
DETAILED DESCRIPTION
Referring to FIGS. 1-6, a shuttle carriage 11 is shown moving cargo 31 over a cargo bed 33. A plurality of cargo rollers 35 are installed in the cargo bed 33 to reduce the friction between the cargo 31 and the cargo bed 33. The cargo 31 can be any container, pallet or other handling device well-known in the art. The shuttle carriage 11 has first and second cargo engaging pawls 13 and 13' respectively mounted thereon. Each of the pawls 13 or 13' is movable between an extended position in which the pawl is generally upright and contacts the cargo 31 and a nested position in which the pawl lies substantially within the frame of the shuttle carriage 11. As shown in FIGS. 1 and 2, the first pawl 13 is in the extended position and the carriage is positioned adjacent a first side 31a of the cargo so that the upright pawl 13 contacts the lower edge of the first side 31a . The second pawl 13' is in the nested position residing below the bottom surface of the cargo 31. A draw cable 21 is attached to the carriage 11 and driving forces are applied to the draw cable 21 in a first direction as shown by an arrow 15 in FIG. 2 to urge the shuttle carriage 11 in the first direction and thereby urge the cargo 31 in the same first direction as shown by an arrow A in FIGS. 1 and 2.
The extended and retracted positions of the pawls 13 and 13' can be reversed so that the shuttle can be used to move cargo in a second direction opposite the first direction. After the position of the pawls are reversed, the carriage is moved under the cargo 31 and when it reaches the opposite side, the second pawl 13' moves to an upright position so that it can then contact the lower edge of a second opposite side 31b of the cargo. Preferably, the pawls 13 and 13' are rotatably mounted on the shuttle carriage 11 for swinging movement between an erect position and a reclined position. The pawls 13 and 13' are arranged so that the first pawl 13 is used to push the cargo 31 in the first direction and the second pawl 13' is used to push the cargo 31 in the second direction. A stop is provided in the frame which prevents the first pawl 13 from being urged downwardly by cargo 31 when the shuttle is pulled in the first direction. Likewise, a stop is provided which prevents the second pawl 13' from being urged downwardly by the cargo 31 when the shuttle is pulled in the second direction. The stops will be described in greater detail below. FIGS. 3 and 4 illustrate the shuttle carriage 11 in transit from a position adjacent the first side 31a of the cargo to a position adjacent the second side 31b of the cargo. The first pawl 13 is placed in the nested position and the second pawl 13' is in the extended position. The position of the pawls is controlled preferably by the movement of an actuating mechanism which includes an elongated cable 24 associated with the pawls and disposed within the cargo bed 33 along the path of travel of the cargo 31. A preferred construction of the actuating mechanism will be described in detail later.
Referring now to FIG. 4, when the carriage is moved in a direction opposite to that in which it is to be used to move the cargo 31, the extended pawl 13 or 13' is urged by the cargo into a reclined position. When the second pawl 13' is in the extended position, a pulling force is applied to the draw cable 21 in the first direction as shown by the arrow 15 thereby urging the shuttle carriage 11 to move in the first direction. As the second pawl 13' engages the first side 31a of the cargo, the pawl is urged toward the second direction and downwardly, that is, toward the reclined position by the lower edge of the first side 31a of the cargo 31 as shown by the phantom line shuttle in FIG. 4. Contrary to the condition in which the second pawl 13' is extended and the shuttle is moving in the second direction, no stop is provided which prevents the second pawl 13' from being urged downwardly by the cargo when the second pawl 13' is extended and the shuttle is moved in the first direction. The second pawl 13' remains in the reclined position as it translates beneath the cargo. A biasing force is applied to the pawl to urge the pawl upwardly toward its erect position. However, the pawl is restrained from upward rotation by the lower surface of the cargo 31 until the shuttle 11 translates sufficiently to allow the second pawl 13' to clear the underside of the cargo 31, at which time the biasing force erects the second pawl 13'. The second pawl 13' is then in position to move the cargo 31 in the second direction as shown in FIGS. 5 and 6 and described above. When the first pawl 13 is in the nested position and the second pawl 13' is in the extended erect position engaging a second opposing side 31b of the cargo 31 a driving force is applied to the draw cable 21 in a second direction as shown by an arrow 16 in FIG. 6, thereby urging the shuttle carriage 11 and in turn the cargo 31 in the second direction as shown by an arrow B in FIGS. 5 and 6.
Referring now to FIGS. 7 and 9, a preferred embodiment of a shuttle carriage made in accordance with the principles of this invention comprises a generally rectangular frame 100 upon which four wheels 102 are rotatably mounted. The carriage 100 is supported by the wheels 102 for movement along the extension of a pair of tracks 104 and 104'. Each of the tracks 104 and 104' preferably comprises a U-shaped channel, the tracks 104 and 104' opening toward each other and being canted downwardly. The wheels 102 are mounted on the corners of the frame 100 and are oriented to engage and be guided by the tracks 104 and 104'. The tracks 104 and 104' could be any well-known track and could be oriented such that they open away from one another or could be canted in a direction other than downwardly. However, the downward cant of the tracks is preferred because it allows any dirt or other extraneous matter which may become lodged in the tracks to gravitate out of the tracks so that it will not increase the friction between the tracks and the wheels 102 or entirely block the movement of wheels 102 along the tracks 104 and 104'.
The frame 100 comprises first and second elongate side members 106 and 106' oriented in generally parallel spaced relation to one another. First and second elongate cross members 108 and 108' are disposed transversely to the side members 106 and 106' and join opposite ends of the side members 106 and 106' so that the side members 106 and 106' and the cross members 108 and 108' form a generally rectangular shape when viewed in plan. Preferably, the sidewalls 106 and 106' and cross members 108 and 108' are formed in a single unit.
First and second rocker arms 110 and 110' respectively are located within the frame 100. The first rocker arm is pivotally attached to the frame by a rocker pivot pin 112 which extends across the frame 100 intermediate and generally parallel to the cross members 108 and 108'. Mutually aligned pivot pin holes are provided in the respective side members 106 and 106'. The pivot pin 112 spans the width of the frame and has its ends extending into respective ones of the holes to centrally locate the pivot pin 112 in orthogonal relationship to the sides of the frame. The rocker pivot pin 112 passes through mounting holes formed in spaced arms 110a and 110b which extend from a first end of the rocker arm 110. A single arm 110a' extends from a first end of the second rocker arm 110' and is disposed between the spaced arms 110a and 110b. The rocker pivot pin 112 passes through a hole formed in the single arm 110a and extending therethrough. The rocker arms 110 and 110' are free to pivot upwardly and downwardly about a generally horizontal axis defined by the rocker pivot pin 112.
The nonadjacent second ends of the first and second rocker arms 110 and 110' are yoke shaped for receiving the lower ends of a first pawl 113 and a second pawl 113'. The first pawl 113 is pivotally mounted by means of a pawl pivot pin 120 which passes through aligned holes formed in the rocker arm 110 and the lower end of the pawl 113 respectively. The second pawl 113' is similarly pivotally mounted on the second rocker arm 110' by means of a second pawl pivot pin 120' which passes through aligned holes formed respectively through the second rocker arm 110' and the lower end of the second pawl 113'.
Each of the first and second pawls 113 and 113' is free to rotate about a generally horizontal axis defined by its associated pawl pivot pin 120 or 120' relative to the rocker arms 110 and 110'. The rotation of the first pawl 113 in a clockwise direction as shown in FIGS. 7 and 8 is restrained by a first pawl abutment 126 which is formed as a part of the first rocker arm 110. When the first pawl 113 is urged in the clockwise direction past a position in which the pawl is generally orthogonal to the rocker arm 110, the pawl contacts the first pawl abutment 126 and is restrained from further clockwise movement. Similarly, the rotation of the second pawl 113' in a counterclockwise direction, as shown in FIGS. 7 and 8, is restrained by a second pawl abutment 126' formed as a part of the second rocker arm 110'. The first pawl 113 is biased into an erect position against the first pawl abutment 126 by a first coil spring 128 and the second pawl 113' is biased into an erect position against the second pawl abutment 126' by a second coil spring 128'. The coils of the first coil spring 128 surround the first pawl pivot pin 120, and a first end 128a is hooked around the first pawl at a location above the pawl pivot pin 120. A second end 128b of the first spring extends from the coiled portion of the spring and abuts the upper surface of a ledge 130 formed as a part of the first rocker arm 110. The second spring 128' is similarly mounted on the second rocker arm 110', a first end 128a' being hooked around the second pawl 113' and a second end 128b' abutting a second ledge 130' formed as a part of the second rocker arm 110'.
Referring to FIG. 8, when the second pawl 113' is in the reclined position, the first end 128a' of the second spring 128' is urged downwardly by the second pawl 113' toward the ledge 130' and the second end 128b'. The downward movement of the first end 128a' causes the spring 128' to twist and compress. A torsional force is created within the spring 128' tending to oppose the twisting and thereby tending to urge the first end 128a' and in turn the second pawl 113' upwardly. The upward movement of the second pawl 113' is stopped by the under surface of a cargo container 131. However, when the shuttle has moved sufficiently to allow the upper end of the second pawl to clear the under surface of the cargo container 131, the second pawl 113' wll be urged upwardly by the second spring 128' to its erect position.
In FIG. 7 the first pawl 113 is shown extended from the frame 100 and in contact with the lower edges of a first side 131a of the cargo container 131. A first side 113a of the first pawl 113 abuts the cargo container 131. When a force is applied to a draw cable 121 in a first direction as shown by an arrow 115, the frame 100 is urged in the first direction. The first pawl 113 is prevented from rotating in a clockwise direction by the first pawl abutment 126 and therefore the first pawl 113 urges the cargo container 131 in the first direction as shown by the arrow A. In FIG. 7 the second pawl 113' is shown in the nested position. The upper end of the pawl 113' lies below the bottom surface 131c of the cargo container 131.
FIG. 8 shows the frame 100 positioned beneath the cargo container 131. In FIG. 8, the first pawl 113 is in the nested position while the second pawl 113' is in the extended but downwardly rotated (reclined) position. The second pawl 113' is reclined with respect to the rocker arm 110' and is being forced downwardly by the underside of the cargo container 131. After the frame 100 has moved sufficiently for the upper end of the second pawl 113' to clear the bottom of the cargo container 131, the second spring 128' will urge the second pawl 113' upwardly into its erect position against the second pawl abutment 126'. The erect position of the second pawl 113' is shown in phantom outline in FIG. 8. When a force is then applied on the draw cable 121 in a second direction as shown by an arrow 116, a first side 113a' of the second pawl 113' will abut the cargo 131 and urge the cargo container in the second direction as shown by the phantom outline arrow B in FIG. 8.
The linkage used to move the first and second rocker arms and the first and second pawls is located along both sides of the rocker arms and is interposed between the rocker arms and sidewalls 106 and 106' as seen in FIG. 9. The linkage adjacent sidewall 106 is the mirror image of the linkage located adjacent the sidewalls 106', and both sets of linkage operate identically and in unison with one another upon opposite sides of the rocker arms 110 and 110'. In the sectional view of FIGS. 7 and 8 only the linkage adjacent the sidewall 106 is visable. The orientation and mounting of the linkage will be described in reference to FIGS. 7 and 8. It will be understood that for each link described there is a mirror image link adjacent the sidewall 106' but not visible in FIGS. 7 and 8. Referring now to FIGS. 7 and 8, the control linkage comprises a first and second upper scissors link 136 and 136' respectively, each of the upper scissor links 136 and 136' having an upper end 136a and 136a' and a second lower end 136b and 136b' respectively. The upper end 136a of the first upper scissor link is pivotally attached to the first pawl 113 and first rocker arm 110 at the point of attachment of the first pawl 113 to the first rocker arm 110 by means of the pawl pivot pin 120 passing through a hole formed in the upper end of the upper scissor link. Similarly, the upper end 136a' of the second upper scissor link is pivotally attached to the second pawl 113' and second rocker arm 110' at the point of attachment of the second pawl 113' to the second rocker arm 110'. The lower end 136b of the first upper scissor link is pivotally attached to an upper end 138a of the first lower scissors link. A lower end 138b of the first lower scissor link is pivotally attached to the sidewall 106 by means of a linkage pivot pin 140 which extends from the sidewall 106 and passes through a hole formed in the lower end 138b of the first lower scissor link. The lower end 136b' of the second upper scissor link is pivotally attached to an upper end 138a' of a second lower scissor link 138. A lower end 138b' of the second lower scissor link 138' is pivotally attached to the sidewall 106 by means of a second linkage pivot pin 140' which extends from the sidewall 106 and passes through a hole formed in the lower end 138b' of the second lower scissor link. The first set of scissor links and the second set of scissor links are joined by a rigid connecting link 142 which has a left end 142a and a right end 142b (as viewed in FIGS. 7 and 8). The left end 142a is pivotally attached to the first upper and first lower scissor links 136 and 138 at their point of attachment to each other and the right end 142b is pivotally attached to the second upper scissor link 136' and second lower scissor link 138' at the point of attachment of the second upper and second lower scissor links to one another. The arrangement of the scissor links is such that when the upper and lower scissor links are generally aligned in an upright direction, the rocker arm and pawl associated with those scissor links is urged upwardly to place the pawl in its extended position, ready to move the cargo container 131 in either a first or a second direction depending on which of the pawls 113 or 113' is erected. When the upper and lower scissor links pivot about their common point of attachment the upper end of the upper scissor link approaches the lower end of the lower scissor link and the rocker arm and pawl associated with that pair of scissor links is urged downwardly, placing the pawl in the nested position.
The movement of the first and second pairs of scissor links and the first and second pawls is initiated by the relative movement of a control chain 144 which is attached to the respective sets of scissor links by means of control members 146 and 146'. One end of the chain 144 is attached to an outer end portion 146a of the control 146. The outer end portion 146a is elongate and lies generally parallel to the cross member 108, a first arm 146b extends orthogonally from a first end of the first portion 146a adjacent sidewall 106, the first arm is pivotally attached to the first upper and lower scissor links 136, 138 and the connecting link 142 at their common point of attachment. A second arm 146c extends orthogonally from a second end of the first portion 146a adjacent the sidewall 106'. The second arm 146c is pivotally attached to the scissor links 236, 238 and connecting link 242 at their common point of attachment as shown in FIG. 9. The other end of the chain 144 is attached to a first portion 146a' of a second control member 146' which is the mirror image of the first control member 146. The second control member 146' is pivotally attached to the scissor links associated with the second rocker arm 110' in a manner similar to that in which the first control member 146 is attached to the scissor links associated with the first rocker arm 110. The middle portion of the chain 144 passes beneath the frame 100 and lies along the path of travel of the cargo. At one or the other of the ends of the cargo compartment, the chain passes over a tensioning pulley (not shown). The pulley is controllable to place tension on the chain in either a forward or aft direction along the cargo compartment.
When the first pawl 113 is in its extended position, the first upper and lower scissor links 136 and 138 are in generally upright alignment and tension on the control chain 144 is in the first direction as shown by an arrow 115 in FIG. 7. To reverse the position of the pawls 113 and 113', the tension in the control chain 144 is shifted to the second direction as shown by an arrow 115' in FIG. 8. The shift in tension of the control chain moves the control members 146 and 146' to the right as shown in FIGS. 7 and 8 and in turn shifts the common point of attachment of the first and second pairs of scissor links to the right. The lower end of the first lower scissor link 138 is restrained from movement upwardly and downwardly by the first linkage pivot pin 140. Therefore, when the upper end 138a of the first lower scissor link is moved to the right, the lower scissor link rotates about the linkage pivot pin 140 in a clockwise direction. This movement pulls the lower end of the first upper scissor link 136 along with it and in turn moves the upper end of the first upper scissor link 136 toward the second end of the first lower scissor link 136. The first upper scissor link 136 urges the first rocker arm 110 to rotate downwardly about the rocker pivot pin 112. As the rocker arm 110 rotates downwardly, it urges the first pawl 113 downwardly into its nested position. At the same time, the upper end of the second lower scissor link 138' is rotated in a clockwise direction by the tension on the chain 144 and urges the second pair of scissor links 136', 138' into a generally upright alignment, thereby urging the second rocker arm 110' upwardly, placing the second pawl 113' into the extended position. The right/left movement (as viewed in FIG. 8) of the upper end of the first and second upper scissor links is restrained by the rocker pivot pin 112. It will be appreciated that the rigid nature of the connecting link 142 prevents both rocker arms and pawls to be in the extended position at the same time. When the first set of scissor linkage moves into its upright aligned position, the second set must necessarily move to its nonaligned position and vice versa because of the rigidity of the connecting link 142.
FIGS. 10 and 11 show the basic elements of the scissors linkage and control elements in a diagrammatic form. The pawls 113 and 113' are shown only partially and in phantom and the details of the linkage mountings is not shown. From FIGS. 10 and 11 the workings of the control linkages are readily apparent. The position of the rocker arms 110, 110' and pawls 113 and 113' in FIG. 10 corresponds to the position of those elements in FIG. 7. The first pawl 113 is in the extended position, that is, the pawl is generally upright and extends above the top of the sidewall 106. The first rocker arm 110 is generally orthogonal to the first pawl 113. The first upper and first lower scissor links 136 and 138 are aligned along their longitudinal axes and are generally parallel to the first pawl 113. The second pawl 113' is in the nested position in FIG. 10 and the second rocker arm 110' is canted downwardly from the rocker pivot pin 112. The second upper and second lower scissor links 136' and 138' are not aligned and the point of attachment of the scissor links 136', and 138' to one another is located to the left as viewed in FIG. 10 of the second pawl pivot pin 120'. The second scissor links are collapsed so that the upper end of the second upper scissor link 136' is adjacent the lower end of the second lower scissor link 138'.
In FIG. 11 (which corresponds to FIG. 8) the first pawl 113 is shown in the nested position and the second pawl 113' is in the extended position, generally upright. The second rocker arm 110' is orthogonal to the second pawl 113' and generally horizontal as viewed in FIG. 11. The first rocker arm 110 is canted downwardly from the rocker pivot pin 112. The change in position of the pawls and rocker arms is caused by the operation of the control element 148 upon the first and second sets of scissor links when a force is exerted on the control element 148 in a direction to the right as viewed in FIGS. 10 and 11. The point of attachment of the second upper and lower scissor links 136', 138' to one another is urged to the right, which in turn causes the second lower scissor link 138' to rotate clockwise about second linkage pivot pin 140' thereby urging the second upper scissor link 136' upwardly and causing the second rocker arm 110' to rotate counterclockwise about the rocker pivot pin 112. The second rocker arm 110' rotates until the second upper and lower scissor links 136', 138' are aligned upright at which time further rotation is restrained by the second linkage pivot pin 140'.
As the point of attachment of the second upper and lower scissor links 136', 138' moves to the right, the rigid connecting link 142 urges the point of attachment of the first upper and lower scissor links 136, 138 to one another to the right and downwardly. The first lower scissor link 138 thereby rotates in a clockwise direction about the first linkage pivot pin 140. As the first lower scissor link 138 rotates it urges the first upper scissor link 136 downwardly, thereby rotating the first rocker arm 110 counterclockwise about the rocker pivot pin 112. As the first rocker arm 110 rotates, the upper end of the first upper scissor link 136 approaches the lower end of the first lower scissor link 138, that is, the scissor links approach a collapsed condition. To reverse the positions shown in FIG. 11 to those shown in FIG. 10 the control element 148 is moved to the left relative to the sidewall 106 and the above-described linkage movement occurs in mirror image fashion to urge the first pawl upwardly and the second pawl downwardly.
As the shuttle passes beneath the cargo container 31 as shown in FIG. 8 the pawl 113' is in the reclined position and is constantly being urged against the bottom of the cargo container 131 by the pawl spring 128'. In order to reduce friction and ease the transit of the pawl 113' beneath the container, a pawl roller 150' is mounted on the upper end of the pawl 113'. Similarly, a pawl roller 150 is mounted on the first pawl 113. The pawl roller 150 extends beyond the second side 113b of the pawl 113 and the pawl roller 150' extends beyond the second side 113b' of the second pawl 113'. The pawl rollers 150 and 150' are mounted on pawl roller pins 152, 152' respectively.
Although a preferred embodiment of the cargo shuttle of this invention has been described and illustrated, it will be understood by those skilled in the art and others that several changes can be made while still remaining within the scope of the present invention. For example, the draw cable attached to the cargo shuttle could be a chain rather than a cable and the actuating means used to move the pawls from their nested to their extended position could be a cable as easily as it could be a chain. | A shuttle conveyor for moving articles fore and aft on a cargo support such as the baggage area in an aircraft cargo compartment comprises a shuttle carriage assembly travelling in tracks moved fore and aft by a cable. A control mechanism is provided to raise and lower selectively one of two cargo engaging pawls mounted on the shuttle carriage. The pawls are adapted to move cargo forward or aft in the compartment and are operated by a cable or chain operator. | 1 |
FIELD
This disclosure relates to a method of raising an existing slab which has settled.
BACKGROUND
Over time, portions of roadways, driveways, garage floors, sidewalks, patios, etc., often have a tendency to settle or sink. One area that is prone to settlement is a roadway slab adjacent to a bridge. This creates step-like structures or cracks to occur between sections of slabs or at joints.
There are several conventional ways to repair sunken slabs. One of these ways is to remove the damaged slab and then re-form the slab. Another method that is often used is mud jacking. In this repair method a hole is drilled through the sunken slab and wet mud is pumped under the slab until the slab is returned to its original position.
SUMMARY
A method of raising a slab is described that raises slabs needing to be raised. The described method is more efficient than conventional repairing methods such as slab re-forming and mud jacking.
In one specific application, the described method can be used to raise a sunken slab of a roadway to align to an adjacent slab without closing the roadway and breaking ongoing traffic. In contrast, slab re-reforming and mud jacking need to close at least portions of the roadway and interrupt ongoing traffic while implementing the repair.
In one disclosed example, a method of raising a slab resting on the ground includes introducing an inflatable hose underneath at least a portion of the slab needing to be raised. The inflatable hose is disposed between a bottom surface of the slab and the ground. The slab is lifted by inflating the hose with pressurized media so that the hose increases in volume to impose an upward force on the slab.
In another disclosed example, a method of slab jacking includes positioning an inflatable hose underneath at least a portion of a slab needing to be raised. The inflatable hose is positioned underneath the slab so as to be able to impose an upward lifting force on the slab when the hose is inflated. The hose is inflated with pressurized media so that the hose increases in volume to impose an upward force on the slab to lift the slab. Fill material is introduced into a space that is created underneath the slab when the slab is lifted. The inflated hose is then deflated and fill material is introduced into a void left by deflating the inflated hose.
DRAWINGS
FIG. 1 ( a ) is a schematic top view of two sections of sunken roadway approaches to a bridge that illustrates the inventive concepts described herein.
FIG. 1( b ) is a side elevation cross sectional view of FIG. 1( a ) taken along line A-A′.
FIG. 1( c ) is a side elevation cross sectional view of the roadway section of FIG. 1( b ) that has been raised by lifting the sunken slab and introducing fill material.
FIG. 1( d ) is a side elevation cross sectional view of the roadway section of FIG. 1( c ) with the hose deflated and a void left by the deflated hose filled with fill material.
FIG. 2( a ) is a side elevation cross sectional view of two adjacent sunken slabs needing to be raised.
FIG. 2( b ) is a side elevation cross sectional view of the two adjacent slabs of FIG. 2( a ) that have been raised by inflating the hoses and introducing fill material into a space that is created underneath the slabs.
FIG. 3( a ) is a side elevation cross sectional view of a sunken slab illustrating the use of a plurality of inflatable hoses to raise the slab.
FIG. 3( b ) is a side elevation cross sectional view of the slab of FIG. 3( a ) that has been raised by inflating the hoses and introducing fill material into a space that is created underneath the slab.
DETAILED DESCRIPTION
A method of raising a slab is described that raises slabs needing to be raised. For purposes of explaining the inventive concepts, the method will be described with respect to raising sunken slabs of roadways to align to their adjacent slabs without closing the roadway and breaking an ongoing traffic. However, the concepts described herein can be used to raise any slab needing to be raised, for example, slabs on driveways, garage floors, sidewalks, patios, etc. The slabs will generally be described as being formed from concrete. However, in appropriate circumstances, the concepts described herein may be used to raise slabs formed from asphalt.
With reference to FIGS. 1( a ), ( b ), ( c ) and ( d ), a first embodiment of raising a sunken slab is illustrated. In the illustrated embodiment, two concrete approach slabs 120 and 125 to a bridge 130 have settled and need to be raised. The slabs 120 , 125 are disposed on ground 160 which forms a roadbed underneath the slabs. The slabs 120 , 125 are lifted using two inflatable holes 140 and 145 , respectively, disposed underneath the slabs, and a space 170 that is created underneath each slab between the bottom of the slab and ground 160 when it is lifted is backfilled after the slabs are lifted.
The sunken slabs 120 and 125 need to be raised to align to the remaining roadway 110 and/or to the bridge 130 . Although FIGS. 1( a )-( d ) illustrate bridge approach slabs that have settled, the slabs can be any slabs needing to be raised, for example, slabs of sidewalks, driveways, patios, garage floors, etc.
The slab 120 has a bottom surface 122 and a top surface 124 . The top surface 124 was at an original level 116 before the slab 120 subsided. In the illustrated mode of slab settlement, a step-like structure 190 is formed between one end of the slab 120 and the bridge 130 , and a crack 195 is formed between the opposite end of the slab and the roadway 110 . Other settlement modes can occur including, but not limited to, settlement where the left end of the slab adjacent the roadway 110 drops down relative to the right end adjacent the bridge, or where the slab settles such that both the right and left ends drop down. The slab 125 is similar to the slab 120 and is not separately described in detail.
The inflatable hoses 140 and 145 are introduced underneath the approach slabs 120 and 125 . The hoses are positioned underneath the slabs so as to be able to impose an upward lifting force on the slabs when the hoses are inflated. In the illustrated embodiment, the hoses 140 and 145 are disposed between the bottom surface of the slabs and the ground 160 in direct contact with the bottom surface of the respective slabs and the ground. However, a thin layer of dirt may exist between the hoses and the bottom surfaces of the slabs. In addition, as illustrated in FIGS. 2( a ) and 2 ( b ), plates 252 , 254 may also be introduced between the bottom surface of the slab and the hose and/or between the hose and the ground to help to stabilize the hose relative to the slab and the ground.
Returning to FIG. 1( a ), the slabs 120 and 125 may be pre-existing slabs and the inflatable hoses 140 and 145 are introduced underneath the slabs in an appropriate way. For example, the inflatable hoses can be introduced by using directional drilling to drill holes underneath the slabs, with the hoses then being directed through the holes. Alternatively, the hoses can be introduced while the slabs are being formed, whereby the hoses are laid on the roadbed and thereafter the slabs are formed.
The roadway 110 has a first side edge 112 and a second side edge 114 . In the embodiment illustrated in FIG. 1( a ), the hose 140 is introduced so that the hose 140 extends across the entire roadway from the first side edge 112 to the second side edge 114 generally perpendicular to the first and second edges 112 and 114 . The hose 145 is illustrated as extending at an oblique angle from the second side edge 114 partially across the roadway to approximately the center of the roadway 110 . The hose(s) can extend any distance across the roadway, can be located at any position along the slab relative to the ends thereof, and can be disposed at any angle relative to the side edges, that one finds suitable as long as the hose(s) is able to lift the slab needing to be raised.
Turning to FIG. 1 ( c ), the sunken portion of the slab 120 is raised by inflating the hose 140 . The hose 140 is inflated with pressurized media so that the hose 140 increases in volume to impose an upward force on the slab 120 . Suitable pressurized media for inflating the hose includes, but is not limited to, pressurized gases such as air and pressurized liquids such as water. The pressurized media can be generated from a pressurized media source 180 and is injected through one end of the hose 140 into the hose 140 . The opposite end of the hose 140 can be closed to prevent escape of the pressurized media. Alternatively, the opposite end can be connected back to the media source 180 to form a closed loop circulation system.
The increase in size of the hose resulting from inflation creates an upward lifting force on the slab 120 that is sufficient to lift the slab. The size of the hose that is used should be sufficient to lift the slab upward a sufficient distance to raise the slab to the desired level. Further, the hose need not be fully inflated. The hose only need be inflated enough to raise the slab to the desired level. In addition, the size of the hose and pressure of the pressurized media should be sufficient to create enough upward lifting force to lift the weight of the slab. When it is desired to implement the method without closing the roadway and while there are objects such as cars or pedestrians on the slab 120 during lifting, the upward force should be sufficient to support both the slab 120 and the objects on the top surface of the slab 120 . In this manner, the slab 120 can be raised without breaking ongoing traffic on the roadway 110 .
Although the hose 140 is illustrated as having a cylindrical cross-sectional shape when fully inflated, hoses having other cross sectional shapes can be used, such as rectangle, polygon, oval or irregular shapes. For example, a hose 250 with an oval cross sectional shape when fully inflated is illustrated in FIG. 2 ( b ). The hose 140 can be made from any suitable material, such as rubber, canvas or nylon, so long as the hose 140 is inflatable to increase the volume from a collapsed or non-pressurized condition, and can hold the pressurized media when inflated.
Once the slab 120 is lifted by the inflated hose 140 , the open space 170 is created underneath the raised slab. Fill material is then introduced into the space 170 to fill the space and restore support to the slab. The fill material can be any material suitable for filling the space 170 . Examples of suitable fill material include, but are not limited to, dried fill material such as dried sand or wet fill material such as conventional mud used in mud-jacking. Dried fill materials are useful because they do not need time to dry. If wet fill material is used, drying time must be provided. An explanation of using dried sand to till voids underneath slabs is found in U.S. patent application Ser. No. 09/687,445 filed on Oct. 13, 2000, which is incorporated by reference in its entirety.
To introduce the fill material under the slab to fill the space 170 , one or more through-holes 150 (see FIG. 1( a )) can be drilled through the slab 120 so that the fill material can be injected into the space 170 via the through-hole 150 . Although one through-hole 150 is illustrated, any suitable number of through-holes can be drilled through the slab to achieve appropriate filling. The through-holes 150 can be disposed at any location on the slab 120 one finds suitable for backfilling the space 170 . In the illustrated embodiment the through-hole 150 is disposed close to the edges 114 of the roadway 110 so that a central region of the roadway 110 can remain open for traffic, e.g., vehicles and pedestrians. After filling, the through-holes 150 are filled in an appropriate way, such as by using concrete fill material.
Alternatively, the fill material can be injected into the space 170 from the side of the road. For example, as shown in FIG. 1( a ), an injection device 155 can be introduced into the space 170 from the side of the road to inject the fill material into the space 170 .
Turning to FIG. 1( d ), after the slab 120 is lifted and the space is filled with fill material, the hose 140 is deflated. Deflation of the hose 140 leaves a void resulting from the space occupied by the inflated hose. Additional fill material is then introduced again to fill the void. As shown in FIG. 1 ( d ), the sunken slab is thus returned to its original level 116 .
FIGS. 2( a ) and ( b ) illustrate another embodiment where two adjacent slabs 220 and 230 have settled and are raised using two inflatable hoses 240 and 250 and a space 270 underneath each slab is backfilled after the slabs 220 and 230 are lifted. Referring to FIG. 2( a ), the two sunken slabs 220 and 230 form part of a roadway supported on the ground 260 . The two slabs 220 and 230 have adjacent ends that have settled creating a step-like structure 285 and two cracks 290 and 295 . Each slab 220 and 230 has a bottom surface 222 and 232 and a top surface 224 and 234 , respectively. The top surfaces 224 and 234 were at an original level 216 before the slabs settled.
The two inflatable hoses 240 and 250 are positioned underneath the adjacent portions of the two slabs 220 and 230 needing to be raised. The hose 240 has a round cross section shape when fully inflated and the hose 250 has an oval cross section shape when fully inflated. The slabs 220 and 230 may be pre-existing slabs and the inflatable hoses 240 and 250 are introduced underneath them in an appropriate way. Alternatively, the inflatable hoses can be introduced while the slabs are being formed.
As discussed above, the two plates 252 and 254 can be used, if considered appropriate, between the slab 230 and the hose 250 and between the hose 250 and the ground 260 , respectively. The plates may be introduced at the same time as the hoses or they can be introduced after the hoses have been installed. The use of plates may be appropriate if there is concern about the stability of the ground or the slab as the hose reacts against it, if one wishes to spread the lifting force more evenly, or if there are concerns about creating punctures in the hose when pressurized media is introduced into the hose.
The lifting the slabs 220 , 230 can be performed while an automobile 205 is traveling on the slabs as shown in FIGS. 2( a ) and 2 ( b ).
Although one hose is illustrated in FIGS. 2( a ) and 2 ( b ) to raise each slab, two or more hoses can be used underneath each slab. In addition, the two slabs could also be raised using only one of the hoses by introducing the hose underneath both of the slabs at a position to provide a lifting force to each slab when inflated.
The hoses 240 and 250 are inflated with pressurized media so that each hose increases in volume to impose an upward lifting force on the respective slabs. The pressurized media can be introduced into the hoses and can be same type of media as discussed above for FIGS. 1( a ) to 1 ( d ). The upward force on the slab 220 is sufficient to support both the slab 2200 and the car 205 on the slab 220 . In this manner, ongoing traffic on the slabs need not be interrupted during raising the sunken slabs.
As shown in FIG. 2( b ) once the slabs are raised by inflating the hoses 240 , 250 , fill material is introduced into the created space 270 underneath the slabs 240 , 250 . The fill material can be any material suitable for filling the space 270 . Examples of suitable fill material include, but are not limited to, dried fill material such as dried sand or wet fill material such as conventional mud used in mud-jacking.
After the slabs 220 and 230 are lifted and the space backfilled to raise the slabs to the original level 216 , the hoses 240 and 250 would be deflated which leaves voids resulting from the space occupied by the inflated hose. Fill material is again introduced to fill the voids.
FIGS. 3( a ) and ( b ) illustrate a sunken slab 320 that forms part of a sidewalk 310 . The slab 320 is lifted using two hoses 340 and 350 , and a space 370 created under the lifted slab is back filled with fill material. The two hoses 340 , 350 are positioned underneath two portions of the slab 320 near opposite ends thereof. The slab 320 is raised by inflating the hoses 340 and 350 and then by introducing fill material into the space 370 underneath the slab 320 .
Both hoses 340 and 350 have a cylindrical structure when being fully inflated. However, FIG. 3( b ) shows the hose 340 as being partially inflated while the hose 350 is fully inflated. How much each hose is inflated depends on how high the slab needs to be lifted.
The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. | A method of raising a slab is described here that uses inflatable hoses to raise slabs needing to be raised, for example, to raise sunken slabs of a roadway to align to their adjacent slabs without closing the roadway and breaking ongoing traffic. The described method of raising a slab makes it more efficient to repair slabs needing to be raised while conventional repairing methods, for example, re-pouring, or mud jacking, which need to close the roadway and interrupt ongoing traffic, are more expensive, time consuming and less effective. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention pertains to the field of electronic circuits. More particularly, this invention relates to switching circuits.
[0003] 2. Art Background
[0004] A wide variety of systems commonly include switching circuits that employ field effect transistors (FETs) as switching devices. A typical switching circuit based on an FET provides an “on” state in which electrical current flows in the channel of the FET between the source and the drain of the FET and an “off” state in which electrical current is pinched off from flowing through the channel of the FET. The on/off state of a switching circuit based on an FET is usually controlled by bias voltages applied to the FET.
[0005] In many systems, the FETs in switching circuits are commonly subjected to relatively large voltages when in the off state. For example, a mobile telephone usually includes a switching circuit that connects its antenna to its receiver. Typically, the FET in the switching circuit when in its off state is subjected to a relatively large voltage drop from a transmit signal generated in the mobile telephone.
[0006] A relatively large voltage applied across the channel of an FET when it is in its off state may cause the FET to inadvertently switch to its on state. The maximum voltage that can be applied across the channel of an FET while maintaining its off state may be referred to as the withstanding voltage of the FET.
[0007] Unfortunately, an FET that inadvertently switches on when its withstanding voltage is exceeded may cause a variety of undesirable effects. In a mobile telephone, for example, a switching circuit that connects an antenna to a receiver may inadvertently switch on if the withstanding voltage of the FET in the switching circuit is exceeded, thereby severely distorting its transmit signal.
SUMMARY OF THE INVENTION
[0008] A switching circuit is disclosed that employs equity voltage division among a series of transistors to reduce the likelihood that the withstanding voltages of individual transistors will be exceeded. A switching circuit according to the present teachings includes a series of transistors and circuitry for biasing the transistors such that a voltage input to the switching circuit divides substantially equally among the transistors when the transistors are in an off state.
[0009] Other features and advantages of the present invention will be apparent from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is described with respect to particular exemplary embodiments thereof and reference is accordingly made to the drawings in which:
[0011] [0011]FIG. 1 shows a switching circuit with equity voltage division according to the present teachings;
[0012] [0012]FIG. 2 shows one embodiment of a switching circuit according to the present teachings including the components in its bias circuit;
[0013] [0013]FIGS. 3-5 show embodiments of a switching circuit according to the present teachings including the components in its bias circuit.
DETAILED DESCRIPTION
[0014] [0014]FIG. 1 shows a switching circuit 10 with equity voltage division according to the present teachings. The switching circuit 10 includes a set of FETs (transistors Q 1 through Qn) that are arranged in series from a node 20 of the switching circuit 10 through a series of nodes 22 - 26 to a node 28 of the switching circuit 10 . The switching circuit 10 includes a bias circuit 14 that biases the transistors Q 1 -Qn. An AC source 12 is shown coupled to the node 20 and a load 16 is shown connected to the node 28 .
[0015] The transistors Q 1 -Qn and the components in the bias circuit 14 are selected and arranged such that the voltage generated by the AC source 12 is substantially equally divided among the transistors Q 1 -Qn when the transistors Q 1 -Qn are biased in the off state. For example, the AC voltage drop across the transistor Q 1 between the nodes 20 and 22 is substantially equal to the voltage drop across the transistor Q 2 between the nodes 22 and 24 which is substantially equal to the AC voltage drop across the transistor Qn between the nodes 26 and 28 when the transistors Q 1 -Qn are in an off state. As a consequence, each of the transistors Q 1 -Qn in its off state is subjected to 1/n of the total magnitude of the voltage from the AC source 12 , thereby decreasing the likelihood that the withstanding voltages of the transistors Q 1 -Qn will be exceeded. The number and the sizes of the transistors Q 1 -Qn may be pre-selected such that the voltage drop across each transistor Q 1 -Qn does not exceed its withstanding voltage given the magnitude of the AC source 12 .
[0016] The bias circuit 14 applies bias voltages to the transistors Q 1 -Qn to switch each transistor Q 1 -Qn between its on and off states as needed to open and close the switching circuit 10 . The components in the bias circuit 14 are selected and arranged so that the substantially equal voltage division among the transistors Q 1 -Qn is maintained. For example, the selection and arrangement of components in the bias circuit 14 avoids the creation of AC paths to ground that might otherwise destroy the symmetry of the switching circuit 10 and defeat its equity voltage division.
[0017] [0017]FIG. 2 shows one embodiment of the switching circuit 10 including the components in its bias circuit 14 . This embodiment provides equity voltage division using two series connected transistors—the transistors Q 1 and Q 2 , i.e. n=2. The transistors Q 1 and Q 2 are the switching FETs and are operated in series to maximize the overall withstanding voltage of the switching circuit 10 .
[0018] The bias circuit 14 in this embodiment includes a DC supply 30 , a set of resistors R 1 -R 8 , and a set of capacitors C 1 -C 3 . In this embodiment, the AC source 12 is AC coupled to the node 20 via a capacitor C 4 . The bias circuit 14 in the embodiment shown turns off the transistors Q 1 and Q 2 by applying −3 volts to the gates of the transistors Q 1 and Q 2 . The resistors R 1 -R 6 are selected such that R 1 =R 2 , R 3 =R 5 , and R 4 =R 6 . Thus, in the absence of resistors R 7 , R 8 and the DC supply 30 the voltage drop across the transistor Q 1 between the nodes 20 and 22 is substantially equal to the voltage drop across the transistor Q 2 between the nodes 22 and 28 .
[0019] The resistors R 7 , R 8 and the DC supply 30 are arranged so as to not upset the symmetry of voltage division across the transistors Q 1 and Q 2 . The DC supply 30 is tied in through the resistors R 7 and R 8 . The capacitors C 1 -C 3 AC couple the resistor divider of R 3 -R 6 to the transistors Q 1 -Q 2 .
[0020] The terminals of the resistors R 7 and R 8 that are opposite of ground have the same AC potential. The DC supply 30 appears as a circuit that is in parallel with the AC source 12 from an AC perspective. There are no additional paths through which current can escape from the nodes 22 , 28 to ground and all of the AC current that enters the node 20 and proceeds into the first transistor Q 1 flows through to the node 28 . Thus, the AC current in the transistor Q 1 equals the AC current in the transistor Q 2 . Given that the transistors Q 1 and Q 2 are surrounded by substantially identical components and provided that the size of the transistors Q 1 and Q 2 are substantially similar, the AC voltage drop is substantially equally divided among the transistors Q 1 and Q 2 .
[0021] The resistors R 1 , R 2 , and R 7 provide a DC reference for the channels of the transistors Q 1 and Q 2 to ground. The capacitors C 4 and C 5 provide the channels of the transistors Q 1 and Q 2 with DC isolation from the AC source 12 and the load R 9 . The resistors R 3 -R 6 connect the gates of the transistors Q 1 and Q 2 to the DC supply- 30 .
[0022] The entire ladder structure defined by the resistors R 1 -R 6 , the capacitors C 1 -C 3 , and the transistors Q 1 -Q 2 may be viewed as a periodic ladder structure in which each stage of the ladder structure is substantially similar to the last including substantially similar arrangements of components with substantially similar component values. As a consequence, an input voltage at the node 20 drops equally across the transistors Q 1 and Q 2 because each ladder stage has the same impedance as the previous stage.
[0023] When the DC supply 30 voltage is below the threshold voltage of the transistors Q 1 and Q 2 , the switching circuit 10 is off, and the voltage at the node 28 is close to zero. When the DC supply 30 voltage is above the threshold voltage of the transistors Q 1 and Q 2 , the switching circuit 10 is on and signal energy from the AC source 12 is effectively coupled to the load R 9 .
[0024] In embodiments in which enhancement mode FETs are used as the transistors Q 1 and Q 2 , a finite amount of gate current should be supplied in the on state. The appropriate amount of gate current may be supplied through the gate bias resistors. Other methods may be employed to apply the appropriate gate bias voltages to the FETs. In addition, either pole of the DC supply 30 may be referenced to ground.
[0025] If an even number of transistors is used to form the switching circuit 10 , its ladder structure is preferably composed of substantially identical pairs of ladder sections, i.e. R 3 =R 5 , R 4 =R 6 , R 1 =R 2 . In addition, the widths W of the transistors Q 1 and Q 2 are substantially equal, i.e. W(Q 1 )=W(Q 2 ). Alternatively, if an even number of transistors is used to form the switching circuit 10 , its ladder structure is preferably composed of mirror image ladder sections, i.e. R 3 =R 6 , R 4 =R 5 , R 1 =R 2 , and W(Q 1 )=W(Q 2 ).
[0026] If an odd number of transistors is used to form the switching circuit 10 , the ladder structure is preferably composed of substantially similar sections, i.e. R 3 =R 5 , R 4 =R 6 , R 1 =R 2 , and W(Q 1 )=W(Q 2 ).
[0027] In one embodiment, the resistors connecting each gate to the corresponding FET source and drain may be identical, i.e. R 3 =R 4 , and R 5 =R 6 .
[0028] The nodes 40 - 43 have paths to ground through the resistor R 8 . The electrical current paths to ground from each node 40 - 43 includes the node 20 or nodes that are the AC equivalent to the node 20 . Thus, the AC signal in the switch 10 that flows past the node 20 and proceeds into the first transistor Q 1 has no escape from the switch structure until it emerges from the node 28 . This maintains substantial equity voltage division in the switch 10 .
[0029] [0029]FIG. 3 shows another embodiment of the switching circuit 10 including the components in its bias circuit 14 . In this embodiment, the connection to node 22 is eliminated and the capacitor C 2 is eliminated and the resistors R 4 and R 5 are merged into R 11 where preferably R 11 = 2 R 3 = 2 R 6 .
[0030] [0030]FIG. 4 shows yet another embodiment of the switching circuit 10 . In this embodiment, the opposite side of the DC supply 30 is referenced to ground in comparison to the embodiments shown above.
[0031] [0031]FIG. 5 shows still another embodiment of the switching circuit 10 . In this embodiment, two separate DC supplies 30 - 31 are employed.
[0032] Each transistor in a ladder structure of a switching circuit according to the present teachings operates beneficially from having. the magnitude of AC gate to source voltage being equal to the AC gate to drain voltage. This is in addition to the benefit derived from having substantially equal AC voltage drops across each transistor. It is also preferable that the transistors used in the ladder structure be formed symmetrically, so that no physical distinction exists between the source and drain terminals.
[0033] A switching circuit according to the present teachings provide a high power switch that creates a relatively low on state insertion loss as well as a relatively high off state isolation and withstanding voltage. The present teachings enable the use of a relatively low overall transistor size in comparison to prior art schemes. The present techniques yield an off state withstanding voltage that is proportional to the number of transistors that are arranged in series. This lowers the number series transistors required to achieve a particular off state withstanding voltage and consequently lowers the insertion loss and final die size.
[0034] The foregoing detailed description of the present invention is provided for the purposes of illustration and is not intended to be exhaustive or to limit the invention to the precise embodiment disclosed. Accordingly, the scope of the present invention is defined by the appended claims. | A switching circuit that employs equity voltage division among a series of transistors to reduce the likelihood that the withstanding voltages of individual transistors will be exceeded. A switching circuit according to the present teachings include a series of transistors and circuitry for biasing the transistors such that a voltage input to the switching circuit divides substantially equally among the transistors when the transistors are in an off state. | 7 |
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/438,230, entitled “Optimizing the Acquisition of Goods”, which was filed on Jan. 31, 2011, the contents of which are expressly incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to electronic commerce, and more particularly, to systems and methods for optimizing acquisition of goods in e-commerce applications.
BACKGROUND
[0003] Individual shoppers or consumers (users) face a challenge both in person and virtually when they are making purchasing decisions. Goods, such as apparel, movies, food, and books pose a significant problem. Consumers can acquire many more goods than they are able to accurately or efficiently keep track of or organize while making a purchasing decision. When the goods are individual apparel items, ones that are mixed together and used at the same time to form a look or style, the challenge becomes even more complex. In order to make the best acquisition decisions, consumers must keep track of what they own and how the things that they own can be combined with the new items they acquire. When faced with this complex task, consumers can either pre-organize and commit to memory what they own or pursue trial and error by acquiring the goods, matching them and then returning them until they make satisfactory matches.
[0004] The inefficient and ineffective systems that users employ to avoid the process being merely that of a system of trial and error are numerous. Consumers attempt to take photos of the goods, they create lists of the goods, they copy goods arrangements submitted by professionals, and they use the equally fallible opinions or memories of their friends. These supplements to the trial and error process lead to continued dissatisfaction of items acquired leading to returns, disposal, or even worse additional confusion and frustration.
[0005] The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent upon a reading of the specification and a study of the drawings.
SUMMARY
[0006] A facility is provided for adding, identifying, comparing, organizing, annotating, sharing and discovering goods to acquire. This facility provides users with the information and the ability to make informed goods acquisition decisions at the point of sale where they could not have done so previously. Through the system of goods organization, the user will be able to benefit from the identifiable information about the goods that they currently own when presented with new acquirable goods. Knowing the relations between the existing goods owned allows users to benefit from objective measurements of the likelihood of success or satisfaction when presented with a new acquisition target.
[0007] Because the facility organizes the goods that the consumer owns, the facility can also help the consumer with the process of goods discovery. Previously unknown preferences that the user has can be identified and users will not have to rely on their interest being peaked to find goods that present ideal acquisition candidates.
[0008] In one embodiment, a computer implemented method for recommending a target item is provided. The method comprises steps of: receiving an identification information for the target item; locating the target item in an item database using the identification information, the item database containing metadata of the target item; comparing the metadata of the target item to metadata of a profile, the profile comprising metadata of a plurality of items located in the item database; calculating a confidence measurement, the confidence measurement quantizing an overlap between the metadata of the target item and the metadata of the profile; and contacting a user associated with the profile about the target item if the confidence measurement exceeds a pre-determined value.
[0009] In another embodiment, a computer implemented method for finding items similar to a target item is provided. The method comprises steps of: receiving an identification information for the target item; locating the target item in an item database using the identification information, the item database containing metadata of the target item; comparing the metadata of the target item to metadata of a plurality of items in the item database; calculating a similarity measurement for each of the plurality of items, each similarity measurement quantizing an overlap between the metadata of the target item and the metadata of the corresponding item of the plurality of items; and recommending to a user one or more items that have similarity measurements exceeding a pre-determined value.
[0010] In yet another embodiment, a computer implemented method for finding items pair with a target item is provided. The method comprises steps of: receiving an identification information for the target item; locating the target item in an item database using the identification information, the item database containing metadata of the target item; comparing the metadata of the target item to metadata of a plurality of items in the item database; calculating a pairing measurement for each of the plurality of items, each pairing measurement quantizing how well the target item pairs with the corresponding item of the plurality of items, based on the metadata of the target item and the corresponding item; and recommending to a user one or more items that have pairing measurements exceeding a pre-determined value.
[0011] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, not is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] One or more embodiments of the present invention are illustrated by way of example and are not limited by the figures of the accompanying drawings, in which like references indicate similar elements.
[0013] FIG. 1 is a diagram illustrating an example of a suitable computing environment in which the facility may operate.
[0014] FIG. 2 is a flow diagram illustrating the profiling routine invoked by the facility in some embodiments.
[0015] FIG. 3 is a flow diagram illustrating the cataloging routine invoked by the facility in some embodiments.
[0016] FIG. 4 is a flow diagram illustrating the discovery routine invoked by the facility in some embodiments.
[0017] FIG. 5 is a flow diagram illustrating the targeting routine invoked by the facility in some embodiments.
[0018] FIG. 6 is a flow diagram illustrating the pairing routine invoked by the facility in some embodiments.
[0019] FIG. 7 is a block diagram of a processing system that can be used to implement an facility implementing the techniques described herein.
DETAILED DESCRIPTION
[0020] Various aspects of the invention will now be described. The following description provides specific details for a thorough understanding and enabling description of these examples. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail, so as to avoid unnecessarily obscuring the relevant description. Although the diagrams depict components as functionally separate, such depiction is merely for illustrative purposes. It will be apparent to those skilled in the art that the components portrayed in this figure may be arbitrarily combined or divided into separate components.
[0021] The terminology used in the description presented below is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section.
[0022] References in this specification to “an embodiment,” “one embodiment,” or the like mean that the particular feature, structure, or characteristic being described is included in at least one embodiment of the present invention. Occurrences of such phrases in this specification do not necessarily all refer to the same embodiment.
[0023] A facility is provided for adding, identifying, comparing, organizing, annotating, sharing and discovering goods to acquire. The facility is based upon dynamic collections of item metadata stored in databases accessible through multiple internet access points including but not limited to mobile. This item metadata is accessed by the user through an efficient item lookup procedure. For example this look up is completed through a number of options including the process of obtaining a near field communication (NFC) tag, a RFID, an audio message, a product's Universal Product Code, QR code or other barcode through a mobile bar code scanner or near field communications scanner. In one embodiment, the scanner may have a visual sensor such as a camera to read the code or tag. The product's model number, name or image can be also used to locate the item. Once the item is either located in the database or a generic metadata item representation is selected by the user, the user has many options including creating, using or sharing a profile which is a collection of items metadata, or engaging in other metadata comparison procedures that aid the user with informed decision making tasks at the point of sale. Tasks include but are not limited to size comparison, promotions, ratings, sharing and consistency with a profile. Because item data is stored in the cloud and accessible through mobile or other web based access methods, the user can access their information in multiple shopping mediums including in physical and online stores, shops or websites.
[0024] The facility also allows users to keep track of the items that they own or would like to purchase in the future through the use of lists. The lists may be sorted and manipulated. These lists allow users to avoid purchasing duplicate items and they allow other users to identify users they know to be interested in purchasing specific items with targeted promotions to facilitate acquisition.
[0025] Thus the facility is enabling users to optimize their acquisition of items through the use of profiles which facilitate metadata comparison that would otherwise be subject to inadequate or inaccurate completion. Doing so removes the difficulty users have in identifying items that they will be satisfied with purchasing.
[0026] Turning now to the figures, FIG. 1 is a diagram illustrating an example of a suitable computing environment in which the facility may be implemented. A system for implementing the facility includes a general purpose or special purpose computing systems or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the facility include, but are not limited to, personal computers, server computers, handheld or laptop devices, cellular/mobile telephones, tablet devices, multiprocessor systems, microprocessor-based systems, set-top boxes, network capable television, game console, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0027] FIG. 2 is a flow diagram illustrating the profiling routine invoked by the facility in some embodiments. The facility allows a user to find an item of interest in a database in an efficient manner by either scanning, entering or looking up the item using a variety of methods. If this item is located in the database then the item will have metadata, which is structured information that describes or explains the item, pre-populated and associated with the item. If the item is not located in the database, the user can find a generic representation of the item of interest with a similar set of subsequent metadata to represent the item entered. The user can then take that item and its associated metadata, and perform a number of higher level assignments, associations or comparisons to profiles. A profile is a collection of database items, where the metadata of all the items in the profile are used to define the profile. The user can then associate a friendly name with the profile to facilitate more natural interaction with the system making it more efficient and effective. Users can then publish or share their profiles and use profiles to do metadata comparisons. These metadata comparisons in the context of looking up apparel item would enable sizing recommendations, and the opportunity for price or promotional information to be shared with the user. By comparing profile metadata across many profiles created by multiple users, insights into item attributes that may otherwise not be apparent to a user will become apparent. As an example if apparel items were to be compared between multiple manufactures, a size medium could be identified through the use of metadata comparison to translate to a size large in another manufacturer's item. This in turn builds user confidence in using the system as the facility is enabling the user to make purchasing decisions with confidence. As another example, if an apparel item were selected to be compared against a profile representing a certain fashion style or look, then the profile's respective metadata from the items associated with that profile would enable a user to determine if the item of interest has metadata that produces a good match to that fashion style profile or not. In one embodiment, the metadata of a target item may include, but not limited to, size information, manufacture information, customer rating information, fashion style information, color information, fit information such as regular fit or slim fit, and/or season information.
[0028] FIG. 3 is a flow diagram illustrating the cataloging routine invoked by the facility in some embodiments. The facility, in various embodiments, can allow a user to save the item associated with a profile as in FIG. 2 to multiple lists associated with various states associated with item ownership. For example, after an item is compared with a profile, it can be saved to a list indicating ownership. This then would allow a scan of an item in the future to indicate if the item is already owned by comparison with this list, or it would allow a metadata comparison with a future item of interest to indicate to the user that the item is highly similar to an item already owned. In this way duplicate item acquisition could be prevented or encouraged through the use of this list. As a further example of lists, a user could also after comparison, save the item to a wishlist to aide them in remembering the item of interest for the future after comparison against a profile. This improves the user's ability to shop by keeping a list of items to acquire for the user in a centralized location in the routine associated with item comparison with profiles.
[0029] FIG. 4 is a flow diagram illustrating the discovery routine invoked by the facility in some embodiments. The facility, in various embodiments, can allow a user to request items that are similar to the one that they have scanned known to the system. After the item's metadata is retrieved by the system, the user can request similar items to be returned for the user to review. This helps the user's ability to discover similar items of interest that may otherwise require extensive effort to compare. For example, a user may scan one apparel item at a store and like it, but would also like to know what other items are available from other manufacturers or retailers. By using the facility, the other manufacturer's items in the system's database can be pulled up by the facility based on their metadata comparison with the item of interest and presented to the user. These items can then be compared against profiles in the way any item can be with this system. In one embodiment, a similarity measurement is calculated, the similarity measurement quantizing an overlap between the metadata of the target item and the metadata of the candidate item.
[0030] FIG. 5 is a flow diagram illustrating the targeting routine invoked by the facility in some embodiments. The facility, in various embodiments, can allow users to identify items on a user's lists and then target the user with promotions or other communications or confidence information based on profile comparisons. For example, a user's wishlist could be scanned by the facility to identify items that are on sale. These items could be compared against a profile, a confidence measurement could be calculated based upon the item's metadata overlap with the profile's metadata definition. An email could then be generated presenting the user with a promotion for the item with an associated confidence measurement. This provides the user of the targeting mechanism the ability to know the item that the individual is interested in, how well if fits with their profile and offer them a promotion.
[0031] FIG. 6 is a flow diagram illustrating the pairing routine invoked by the facility in some embodiments. The facility, in various embodiments, can allow users to request items that pair with the one that they have scanned that are known to the system. Pairing information may be added into the facility by the user, or automatically by the facility. After the item's metadata is retrieved by the system, the user can request items that match or pair well with the user to review. This helps the user's ability to pair items of interest that may otherwise require extensive effort to pair. For example, a user may scan one apparel item at a store and like it, but want to know what other items they own, or are for sale from other manufacturer's that pair well with their item of interest. By using the facility, the other items known to the system can be pulled up by the facility based on their metadata comparison with the item of interests and presented to the user. These items can then be compared against profiles in the way any item can be with this system. In one embodiment, a pairing measurement is calculated for each of the plurality of items, each pairing measurement quantizing how well the target item pairs with the corresponding item of the plurality of items, based on the metadata of the target item and the corresponding item. One or more items that have pairing measurements exceeding a pre-determined value is recommended to a user.
[0032] FIG. 7 is a block diagram of a processing system that can be used to implement any of the techniques described above, such as the facility. Note that in certain embodiments, at least some of the components illustrated in FIG. 7 may be distributed between two or more physically separate but connected computing platforms or boxes. The processing can represent a conventional server-class computer, PC, mobile communication device (e.g., smartphone), or any other known or conventional processing/communication device.
[0033] The processing system 701 shown in FIG. 7 includes one or more processors 710 , i.e. a central processing unit (CPU), memory 720 , at least one communication device 740 such as an Ethernet adapter and/or wireless communication subsystem (e.g., cellular, WiFi, Bluetooth or the like), and one or more I/O devices 770 , 780 , all coupled to each other through an interconnect 790 .
[0034] The processor(s) 710 control(s) the operation of the computer system 701 and may be or include one or more programmable general-purpose or special-purpose microprocessors, microcontrollers, application specific integrated circuits (ASICs), programmable logic devices (PLDs), or a combination of such devices. The interconnect 790 can include one or more buses, direct connections and/or other types of physical connections, and may include various bridges, controllers and/or adapters such as are well-known in the art. The interconnect 790 further may include a “system bus”, which may be connected through one or more adapters to one or more expansion buses, such as a form of Peripheral Component Interconnect (PCI) bus, HyperTransport or industry standard architecture (ISA) bus, small computer system interface (SCSI) bus, universal serial bus (USB), or Institute of Electrical and Electronics Engineers (IEEE) standard 1394 bus (sometimes referred to as “Firewire”).
[0035] The memory 720 may be or include one or more memory devices of one or more types, such as read-only memory (ROM), random access memory (RAM), flash memory, disk drives, etc. The network adapter 740 is a device suitable for enabling the processing system 701 to communicate data with a remote processing system over a communication link, and may be, for example, a conventional telephone modem, a wireless modem, a Digital Subscriber Line (DSL) modem, a cable modem, a radio transceiver, a satellite transceiver, an Ethernet adapter, or the like. The I/O devices 770 , 780 may include, for example, one or more devices such as: a pointing device such as a mouse, trackball, joystick, touchpad, or the like; a keyboard; a microphone with speech recognition interface; audio speakers; a display device; etc. Note, however, that such I/O devices may be unnecessary in a system that operates exclusively as a server and provides no direct user interface, as is the case with the server in at least some embodiments. Other variations upon the illustrated set of components can be implemented in a manner consistent with the invention.
[0036] Software and/or firmware 730 to program the processor(s) 710 to carry out actions described above may be stored in memory 720 . In certain embodiments, such software or firmware may be initially provided to the computer system 701 by downloading it from a remote system through the computer system 701 (e.g., via network adapter 740 ).
[0037] The techniques introduced above can be implemented by, for example, programmable circuitry (e.g., one or more microprocessors) programmed with software and/or firmware, or entirely in special-purpose hardwired circuitry, or in a combination of such forms. Special-purpose hardwired circuitry may be in the form of, for example, one or more application-specific integrated circuits (ASICs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), etc.
[0038] Software or firmware for use in implementing the techniques introduced here may be stored on a machine-readable storage medium and may be executed by one or more general-purpose or special-purpose programmable microprocessors. A “machine-readable storage medium”, as the term is used herein, includes any mechanism that can store information in a form accessible by a machine (a machine may be, for example, a computer, network device, cellular phone, personal digital assistant (PDA), manufacturing tool, any device with one or more processors, etc.). For example, a machine-accessible storage medium includes recordable/non-recordable media (e.g., read-only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; etc.), etc.
[0039] The term “logic”, as used herein, can include, for example, programmable circuitry programmed with specific software and/or firmware, special-purpose hardwired circuitry, or a combination thereof.
[0040] The foregoing description of various embodiments of the claimed subject matter has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the claimed subject matter to the precise forms disclosed. Many modifications and variations will be apparent to the practitioner skilled in the art. Embodiments were chosen and described in order to best describe the principles of the invention and its practical application, thereby enabling others skilled in the relevant art to understand the claimed subject matter, the various embodiments and with various modifications that are suited to the particular use contemplated.
[0041] The teachings of the invention provided herein can be applied to other systems, not necessarily the system described above. The elements and acts of the various embodiments described above can be combined to provide further embodiments.
[0042] While the above description describes certain embodiments of the invention, and describes the best mode contemplated, no matter how detailed the above appears in text, the invention can be practiced in many ways. Details of the system may vary considerably in its implementation details, while still being encompassed by the invention disclosed herein. As noted above, particular terminology used when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to any specific characteristics, features, or aspects of the invention with which that terminology is associated. In general, the terms used in the following claims should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above Detailed Description section explicitly defines such terms. Accordingly, the actual scope of the invention encompasses not only the disclosed embodiments, but also all equivalent ways of practicing or implementing the invention under the claims. | A facility is provided for adding, identifying, comparing, organizing, annotating, sharing and discovering goods to acquire. This facility provides users with the information and the ability to make informed goods acquisition decisions at the point of sale where they could not have done so previously. Through the system of goods organization, the user will be able to benefit from the identifiable information about the goods that they currently own when presented with new acquirable goods. Knowing the relations between the existing goods owned allows users to benefit from objective measurements of the likelihood of success or satisfaction when presented with a new acquisition target. | 6 |
RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD OF THE INVENTION
[0003] The present invention relates to a process for the preparation of synthesis gas (“syngas”), i.e., a mixture of carbon monoxide and hydrogen, from natural gas. More particularly, the present invention relates to controlling the exit stream composition of a syngas reactor by controlling the feed hydrocarbon composition.
BACKGROUND
[0004] Large quantities of methane, the main component of natural gas, are available in many areas of the world. However, a significant portion of that natural gas is situated in areas that are geographically remote from population and industrial centers (“stranded gas”). The costs of compression, transportation, and storage often makes the use of stranded gas economically unattractive. Consequently, the stranded natural gas is often flared. Flaring not only wastes the energy content and any possible economic value the natural gas may have but may also create environmental concerns.
[0005] To improve the economics of natural gas transportation and utilization, much research has focused on using the methane component of natural gas as a starting material for the production of higher hydrocarbons and hydrocarbon liquids. The conversion of methane to higher hydrocarbons is typically carried out in two steps. In the first step, methane is reacted to produce carbon monoxide and hydrogen (i.e., synthesis gas or “syngas”). In a second step, the syngas is converted to higher hydrocarbon products by processes such as Fischer-Tropsch synthesis. For example, fuels with boiling points in the middle distillate range, such as kerosene and diesel fuel, and hydrocarbon waxes may be produced from the syngas. In addition, syngas may be used for the manufacture of ammonia, hydrogen, methanol, and other chemicals. Less traditional uses of syngas continue to be developed and have increased in importance in recent years, such as in the production of acetic acid and acetic anhydride manufacture. Among the promising new developments in syngas chemistry are routes to ethylene.
[0006] There are currently three primary methods for converting methane to syngas. Those methods include: steam reforming (the most widespread), dry reforming (also called CO 2 reforming), and partial oxidation. Steam reforming, dry reforming, and partial oxidation ideally proceed according to the following reactions respectively:
CH 4 +H 2 O+heat→CO+3H 2 (1)
CH 4 +CO 2 +heat→2CO+2H 2 (2)
CH 4 +½O 2 →CO+2H 2 +heat (3)
[0007] For a general discussion of steam reforming, dry (or CO 2 ) reforming, and partial oxidation, please refer to HAROLD GUNARDSON, Industrial Gases in Petrochemical Processing 41-80 (1998), the contents of which are incorporated herein by reference.
[0008] Although a theoretical H 2 :CO ratio can be calculated for any given reaction, relative amounts of hydrogen and carbon in a syngas product stream depend on many factors including the type of reaction, the process technology, the feedstock composition, and the reactor operating conditions. The theoretical ratio of hydrogen to carbon monoxide in the reactant stream of reactions 1, 2, and 3 can easily be calculated as 3:1, 2:2 (i.e., 1:1), and 2:1. The actual ratio of hydrogen to carbon monoxide in syngas product streams can range as low as 0.6 with CO 2 reforming of natural gas or partial oxidation of petroleum coke to as high as 6.5 with steam methane reforming. In addition, it has been noticed in GUNARDSON on pages 68-71 the actual molar ratio of H 2 :CO in the product stream can vary depending upon the feedstock used.
[0009] There are many processes, such as the production of methanol, in which an H 2 :CO molar ratio of about 2:1 is desired. There are also processes in which a molar ratio of hydrogen and carbon monoxide of less than 2:1 is preferable. One such process is hydroformylation, which is the addition of one molecule of carbon monoxide and one molecule of hydrogen to an olefin to make an aldehyde. The following reaction illustrates one of the simplest examples of hydroformylation:
C 2 H 4 +CO+H 2 →CH 3 CH 2 CHO (4)
[0010] Hydroformylation is, inter alia, an intermediate step in both methyl methacrylate synthesis and the oxo process to produce alcohols. Additionally, there may be other processes in which an H 2 :CO ratio of between 2:1 and about 1:1 is desirable.
[0011] As noted above, one method of producing syngas with a molar ratio of hydrogen to carbon monoxide of between about 2:1 and about 1:1 is by the partial oxidation of methane followed by the CO 2 reforming of methane. Unfortunately, CO 2 reforming is endothermic and requires external heating to drive the reaction, which increases the capital cost of CO 2 reforming. In addition, this scheme of partial oxidation followed by CO 2 reforming requires two reactors thereby also increasing the capital cost. Thus, in many situations, partial oxidation followed by CO 2 reforming may be economically or physically (or both) unfeasible or undesirable.
[0012] There is, therefore, a need for a less capital intensive process in which the H 2 :CO molar ratio in the product stream can be varied and controlled between about 2:1 and about 1:1
SUMMARY OF THE PREFERRED EMBODIMENTS
[0013] The present invention provides a method for controlling the H 2 :CO molar ratio between about 2:1 and about 1:1 in a syngas product stream by controlling the feed hydrocarbon composition.
[0014] An embodiment of the present method generally includes predetermining a desired syngas product stream H 2 :CO molar ratio, selecting a hydrocarbon with an actual natural H 2 :CO molar ratio greater than the desired molar ratio, selecting a hydrocarbon with an actual natural H 2 :CO molar ratio less than the desired molar ratio, mixing the two hydrocarbons on-line such that the actual natural H 2 :CO molar ratio of the mixture is equal to the desired molar ratio, and net catalytically partially oxidizing the mixture to produce syngas with the desired H 2 :CO molar ratio.
[0015] It is also possible to control and vary the product stream composition by controlling and varying the feed stream composition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a more detailed understanding of the present invention, reference is made to the accompanying FIGURE, which is a schematic cross sectional view of a first preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The preferred reactor is a standard catalytic partial oxidation (“CPOX”) reactor 90 comprising a refractory lining 20 and a CPOX catalyst system 10 . The reactants for reactor 90 comprise oxygen-containing stream 40 and hydrocarbon feedstreams 70 and 80 which are combined to become feedstream 30 . Streams 30 and 40 are mixed to become stream 50 which is introduced to catalyst system 10 . After reacting in catalyst system 10 , the stream exits reactor 90 as product stream 60 . Definitions of terms of art used in this Detailed Description (e.g., “ideal natural H 2 :CO ratio”) are defined at the end of this Detailed Description.
[0018] Referring now to the catalyst system 10 , any of a variety of well known catalysts containing various metals such as, by way of example only, Group VIII metals, iron, cobalt, nickel, ruthenium, rhodium, palladium, iridium, platinum, cerium, samarium, or combinations thereof may be used. These catalysts may be supported on a variety of supports such as, by way of example only, alumina, silica, magnesia, zirconia, yttria, calcium oxide, zinc ozide, perovskites, lanthanide oxides, partially stabilized zirconia, or combinations thereof. The catalyst supports may be configured in several ways as are known in the art such as, by way of example only, monoliths, pellets, pills, spheres, granules, gauze, particulates, beads, rings, or ceramic honeycomb structures or any other support as is known in the art. Preferably, gas hourly space velocity of the feed stream is great enough and the catalyst bed length is short enough such that the contact time of the feed stream with the catalyst is no more than about 200 ms or optionally, no more than about 10 ms. The bed length is preferably at least about ⅛ inch long and the gas hourly space velocity of feed gas across the bed is preferably about 1,000-10,000,000 NL/kg/hr, and more preferably about 20,000-6,000,000 NL/kg/hr.
[0019] In operation, the desired H 2 :CO molar ratio for product stream 60 is predetermined for maximization of a downstream process (not shown). For purposes of this example only, the predetermined ratio will be 1.75:1. This desired ratio is achieved by controlling the composition of the feed stream 50 which in turn is achieved by controlling the composition and relative flow of hydrocarbon feed streams 70 and 80 .
[0020] For purposes of this example and for simplicity's sake, ideal (rather than actual) natural H 2 :CO ratios will be used for the hydrocarbon feed streams. It should be understood that in actual operation, the actual natural H 2 :CO ratios for the actual reactor conditions should be used. It should also be understood that although the following calculations are done with pure feed streams, diluted feed streams may be used. If diluted feed streams are used, one of ordinary skill in the art can easily modify the flow rate of the diluted streams so that the amounts of the reactant hydrocarbons in the feed streams create the proper relative reactant gas proportions in the mixed feed stream.
[0021] In accordance with one embodiment of the present invention, hydrocarbon feed stream 70 is chosen to be methane CH 4 because its ideal natural H 2 :CO ratio for CPOX is 2:1 (greater than the predetermined desired ratio). Hydrocarbon feed stream 80 is chosen to be ethane because its ideal natural H 2 :CO ratio for CPOX is 1.5:1 (less than the predetermined desired ratio). Determining the proper relative flows of hydrocarbon feed streams 70 and 80 is done by adjusting the relative flows such that the weighted average of the ideal natural H 2 :CO ratios is equal to the desired ratio. For a binary mixture such as this one (of methane and ethane), the proper ratio can be calculated by solving the following set of equations for x and y where C equals the desired H 2 :CO ratio, A equals the natural H 2 :CO ratio of stream 70 (e.g., 2), B equals the natural H 2 :CO ratio of stream 80 (e.g., 1.5), x equals the percentage of the total combined molar flow of streams 70 and 80 of the component of stream 70 , and y equals the percentage of the total combined molar flow of streams 70 and 80 of the component of stream 80 :
Ax+By=C (5)
x+y= 1 (6)
[0022] Solving Equations 5 and 6 for x and y for the current example, x=0.5 and y=0.5. Thus, in this example stream 70 and stream 80 should each have 50% of the combined molar flow of the two streams ( 70 plus 80 ). (i.e., both streams 70 and 80 should have equal molar flow rates of methane and ethane respectively).
[0023] The two feed streams 70 and 80 are then fed, along with oxygen containing stream 40 , into a syngas reactor 90 . The oxygen containing stream 40 is preferably substantially pure oxygen, but it may also comprise air or oxygen-enriched air.
[0024] In situations where there are greater than two hydrocarbon feed streams, the relative molar flow rates of the plurality of streams needed to achieve the desired product stream H 2 :CO molar ratio can be calculated by solving the following set of equations for x 1 , x 2 , . . . x n .
A 1 x 1 +A 2 x 2 + . . . A n x n =C (7)
x 1 +x 2 + . . . x n =1 (8)
[0025] In Equations 6 and 7, n is the number of hydrocarbon feed streams, A 1 , A 2 , . . . A n are the natural H 2 :CO ratios of the corresponding hydrocarbon feed streams, x 1 , x 2 . . . x n are the percentages of each respective hydrocarbon flow, and C is the desired product stream H 2 :CO molar ratio. Unless there are other constraints, there will be multiple solutions to these equations. However, one of ordinary skill in the art can easily determine an acceptable ratio of hydrocarbon feeds based on factors such as, for example, feed cost, feed availability, and environmental concerns.
[0026] It was found that with a propane-oxygen feedstream, syngas was generated in high selectivity, with a small amount of CO 2 . The operation was stable and H 2 :CO ratio was about 1.3:1. With a methane-oxygen feed stream, these catalysts yield syngas with low CO 2 selectivity and H 2 :CO ratio of about 1.8-2:1. From these observations, it is proposed that by varying and controlling the hydrocarbon composition in the feed, the H 2 :CO ratio in the syngas product can be modified based on the desired use of the syngas. By using a selective and stable catalyst for syngas generation from a variety of hydrocarbons, a single-stage process can be designed for obtaining syngas with a H 2 :CO ratio less than 2:1.
[0027] It is contemplated that in some instances it may happen that the actual natural H 2 :CO ratio of a mixture may not equal the molar weighted average of the actual natural H 2 :CO ratios of the components of the mixture due to differences in the chemical behavior of the mixture from the individual components. In this instance, the flow of the feed components can be adjusted to reach the desired H 2 :CO ratio in the product stream. For example, if the actual H 2 :CO ratio in the product stream is greater than desired, increasing the relative amount of the feed components with lower actual natural H 2 :CO ratio should decrease the observed product stream H 2 :CO ratio. The opposite should also be true (i.e., to raise the product stream H 2 :CO ratio, increase the relative proportion of the higher actual natural H 2 :CO ratio feed components).
EXAMPLES
Example 1
CPOX with Rh/Yb Catalyst
[0028] Procedure for Preparation of Rh/Yb/ZrO 2 Catalysts
[0029] The Rh-Yb catalyst supported on Zirconia granules can be prepared according to the following procedure, given here for laboratory-scale batches:
[0030] 1. Dissolve 0.5476 grams of Yb(NO 3 ) 3 .5H 2 O in 3 grams of distilled and de-ionized (DDI) water at about 70° C. on the hotplate. Add this solution to ZrO 2 granules (35-50 mesh, 10.20 grams, 1100° C.-calcined).
[0031] 2. Dry the material at about 70° C. for 1 hour and calcine in air according to the following schedule: 5° C./min ramp up to 125° C.; hold at 125° C. for 1 hour; 5° C./min ramp up to 400° C.; hold at 400° C. for 1 hour; 5° C./min ramp up to 800° C.; hold at 800° C. for 1 hour; 5° C./min ramp up to 1000° C.; hold at 1000° C. for 3 hours; 10° C./min ramp down to room temperature.
[0032] 3. The above procedure should result in 2 wt % Yb based on the weight of ZrO 2 granules.
[0033] 4. Dissolve 0.9947 grams of RhCl 3 .xH 2 O in 3 grams of DDI water at about 60° C. and add to the Yb 2 O 3 -coated ZrO 2 granules at about 70° C.
[0034] 5. Dry the material at about 70° C. for 1 hour and calcine in air according to the following schedule: 5° C./min ramp up to 125° C.; hold at 125° C. for 1 hour; 5° C./min ramp up to 400° C.; hold at 400° C. for 1 hour; 5° C./min ramp up to 800° C.; hold at 800° C. for 1 hour; 5° C./min ramp up to 1000° C.; hold at 1000° C. for 3 hours; 10° C./min ramp down to room temperature.
[0035] 6. The above procedure should result in 4 wt % Rh based on the weight of ZrO 2 granules.
[0036] 7. Reduce the catalyst with H 2 using 1:1 by volume flow of N 2 :H 2 mixture at 0.3 standard liter per minute (SLPM) measured at 0° C. and 1 atm pressure, using the following schedule: 3° C./min ramp up to 125° C.; hold at 125° C. for 0.5 hour; 3° C./min ramp up to 500° C.; hold at 500° C. for 3 hours; 5° C./min ramp down to room temperature.
[0037] Test Procedure
[0038] The partial oxidation reactions are carried out in a conventional flow apparatus using a 44 mm O.D.×38 mm I.D. quartz insert embedded inside a refractory-lined steel vessel. The quartz insert contains a catalyst bed containing the Rh/Yb/ZrO 2 catalyst as prepared above. Preheating the hydrocarbon feed that flows through the catalyst bed provides the heat needed to initiate the reaction. Oxygen is mixed with the hydrocarbon feed stream immediately before the mixture enters the catalyst bed. Once the reaction is initiated, it proceeded autothermally. Two thermocouples with ceramic sheaths are used to measure catalyst inlet and outlet temperatures. The molar ratio of feed hydrocarbon to O 2 is generally about 2:1, however the relative amounts of the gases, the catalyst inlet temperature and the reactant gas pressure can be varied by the operator according to the parameters being evaluated (see the following Tables). The product gas mixture is analyzed for the feed hydrocarbons, O 2 , CO, H 2 , CO 2 and N 2 using a gas chromatograph equipped with a thermal conductivity detector. A gas chromatograph equipped with a flame ionization detector analyzes the gas mixture for CH 4 , C 2 H 6 , C 2 H 4 and C 2 H 2 . The feed hydrocarbon conversion levels and the CO and H 2 product selectivities obtained are considered predictive of the conversion and selectivities that will be obtained when the same catalyst is employed in a commercial scale reactor under similar conditions of reactant concentrations, temperature, reactant gas pressure and space velocity.
[0039] The following test data were obtained at a total feed flowrate of 3.5 SLPM at a preheat temperature of 3000° C. and hydrocarbon:oxygen molar ratio of 2:1.
Feed Hydrocarbons Feed molar ratio H2:CO molar ratio CH 4 CH 4 :O 2 = 2:1 2.04 CH 4 ,C 2 H 6 CH 4 :C 2 H 6 :O 2 = 1:1:1 1.74 C 2 H 6 C 2 H 6 :O 2 = 2:1 1.67 C 2 H 6 , C 3 H 8 C 2 H 6 :C 3 H 8 :O 2 = 1:1:1 1.56 CH 4 , C 3 H 8 CH 4 :C 3 H 8 :O 2 = 1:1:1 1.50 C 3 H 8 C 3 H 8 :O 2 = 2:1 1.46
[0040] The results shown above clearly indicate the effect of feed hydrocarbon composition on the product hydrocarbon:carbon monoxide ratio (referred to as ‘syngas ratio’). By mixing hydrocarbons with different carbon numbers, a wide range of syngas ratios can be obtained, without modifying the process conditions. All of the above reactions occur under the same preheat temperature range, flow rates and heat transfer rates, so there is no need for design changes.
[0041] For purposes of this specification, the following definitions shall apply.
[0042] The term “catalyst system” as used herein means any acceptable system for catalyzing the desired reaction in the reaction zone. By way of example only, the catalyst system of a syngas steam reforming reaction usually includes a support and a catalyst. Acceptable supports include, for example, particulates, pills, beads, granules, pellets, monoliths, ceramic honeycomb structures, wire gauze, or any other suitable supports such as those listed herein. Likewise, The catalyst may be selected from the group consisting of nickel, samarium, rhodium, cobalt, platinum, rhodium-samarium, platinum-rhodium Ni—MgO, combinations thereof, or any other catalysts as is well known in the art such as those cited herein. The above-exemplified examples of supports and catalysts are only examples. There are a plethora of catalysts systems known in the art which would be acceptable and are contemplated to fall within the scope, such as those disclosed in STRUCTURED CATALYSTS AND REACTORS 179-208, 599-615 (Andrzej Cybulski and Jacob A. Moulijn eds. 1998) incorporated herein by reference for all purposes.
[0043] The term “natural H 2 :CO ratio” shall mean the H 2 :CO ratio expected to be present in the product stream of the net partial oxidation of a feed stream.
[0044] The “ideal natural H 2 :CO ratio” is the H 2 :CO ratio predicted by the basic partial oxidation reaction. For example, the basic partial oxidation reaction for methane (CH 4 ) is:
CH 4 +½O 2 →CO+2H 2 (3)
[0045] The H 2 :CO ratio in the product of that reaction is 2:1. The generalized partial oxidation reaction for alkanes is:
C n H (2n+2) +(n/2)O 2 →n CO+(n+1)H 2 (9)
[0046] Thus, the ideal natural H 2 :CO ratio of an alkane is [(n+1)/n]:1. The reaction for the partial oxidation of any hydrocarbon consisting of only carbon and hydrogen (e.g., isobutane) can easily be determined by one of ordinary skill in the art by balancing the equation:
a HC+ b O 2 →c CO+ d H 2 (10)
[0047] where HC is the molecular formula of the hydrocarbon and a, b, c, and d are the stoichiometric coefficients that balance the equation. In Equation 10, the ideal natural H 2 :CO ratio for HC is (d/c): 1.
[0048] The “actual natural H 2 :CO ratio” of a feed stream is the H 2 :CO ratio observed in the product stream of the net partial oxidation of a given feed stream under given reactor conditions. It may differ from the ideal natural H 2 :CO ratio because of side reactions or adverse reactor conditions. For example, the actual natural H 2 :CO ratio of a methane feed is often measured to be approximately 1.8:1 due to the existence of secondary reactions and may vary with variations in reactor conditions and catalyst systems. While the example discussed above uses the ideal natural H 2 :CO ratios for methane and ethane for the calculation, the calculations are performed exactly the same using the actual natural H 2 :CO ratio (i.e., the H 2 :CO ratio of the product stream is controlled by controlling the weighted average of the actual natural H 2 :CO ratios of the hydrocarbon feed streams).
[0049] For the purposes of this disclosure, the term “net partial oxidation reaction” means that the partial oxidation reaction shown in Equation (3), above, predominates. However, other reactions such as steam reforming (Equation 1), dry reforming (Equation (2)) and/or water-gas shift (Equation (11)) may also occur to a lesser extent.
CH 4 +CO 2 ⇄2CO+2H 2 (2)
CO+H 2 O⇄CO 2 +H 2 (11)
[0050] The actual natural H 2 :CO ratio resulting from the catalytic net partial oxidation of the methane, or natural gas, and oxygen feed mixture is about 2:1, similar to the ideal natural H 2 :CO ratio of Equation (3).
[0051] Without further elaboration, it is believed that one skilled in the art can, using the description herein, utilize the present invention to its fullest extent. The embodiments herein are to be construed as illustrative, and not as constraining the remainder of the disclosure in any way whatsoever. | A method for generating syngas having a H 2 :CO ratio of less than 2:1 including selecting a predetermined desired syngas H 2 :CO molar ratio, selecting a hydrocarbon with a natural H 2 :CO molar ratio less than the desired ratio, selecting a hydrocarbon with a natural H 2 :CO molar ratio greater than the desired ratio, mixing the two hydrocarbons such that the natural H 2 :CO molar ratio of the mixture is the desired ratio, and catalytically partially oxidizing the mixture to produce syngas with the desired ratio. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to clarification of beverages such as beer and wine, and, more particularly, to a premix composition and process for effecting such clarification in an efficient and advantageous single-step process.
[0003] 2. Description of the Prior Art
[0004] Non-biological haze in unstabilized beer arises from complexation of haze-sensitive proteins and haze-producing polyphenols and tannoids. Accordingly, silica gels such as hydrogel or xerogel have been used for effecting clarification of beer by adsorbing haze-sensitive proteins. However, silica hydrogel contains greater than 30% water and is therefore prone to microbial growth on storage. Silica xerogel contains only 5% water but becomes compacted upon hydration. Crosslinked polyvinylpyrrolidone (PVPP) also has been effective for treating unstabilized beer by specific adsorption of condensed and polymeric polyphenols and tannoids present in beer. Sequential treatments with silica gels and PVPP have been used with some measure of success. Combinations of silica hydrogel and PVPP for a single treatment process have been considered but when hydrated such an admixture becomes voluminous and clumpy making it difficult to pump homogeneously. Similarly, the industry has warned that xerogel and PVP should never be present simultaneously, as they may neutralize each other's effects.
[0005] The prior art is represented by the following U.S. patents: U.S. Pat. Nos. 2,316,241; 3,117,004; 3,163,538; 3,413,120; 3,512,987; 3,554,759; 3,617,301; 3,818,111; 3,903,316; 4,166,141; 4,820,420; 4,910,182; and by the following, foreign patents and technical publications:
[0006] (1) Gorinstein, S et al, J of Food Biochemistry 14, 161-172 (1990).
[0007] (2) Boschet, G. Brauindustrie 70 (16) 1441-4 (1985).
[0008] (3) McMurrough, I. et al J. Am. Soc. Brewing Chemists 50 (2) 67-76 (1992).
[0009] (4) GB 1,151,476 ('69) Deutsche Gold (silica+PVP).
[0010] (5) Weyh, H. Inst. Chem. Tech. Anal. Chem. 8050 (1987).
[0011] (6) Boschet, G. Bios (Nancy) 17 (8-9) 49-52 (1986).
[0012] (7) Birkner, F. EPA 183162 A2 Jun. 4, 1986 EP 85114640 (Nov. 18, 1985).
[0013] (8) Hums, N. DE 3509892A1 Sep. 25, 1986.
[0014] (9) Buchvarov, V. Monatsschr. Brauwiss 39 (5) 188-92 (1986)
[0015] (10) Wackerbauer, K. Monatsschr. Brauwiss 37 (5) 201-7 (1984).
[0016] (11) Chi, C. W. DE 3302258A1 Jan. 25, 1983.
[0017] (12) Jaeger, P. Mitt. Versuchsstn Gaerungsgewerke Wien 34 (9-10) 83-9 (1980).
[0018] (13) Sfat, M. R. Tech. Q, Master Brew Assn Am 12 (4) 243-8 (1975)
[0019] (14) Silbereisen, K. Monatsschr. Brauwiss 21 (8) 221-35 (1968).
[0020] (15) Schafft, H. Brauwelt 117 (36) 3-7 (1977).
[0021] (16) Blecher, L. Brew. Dig, 51 (7) 33-5, 44 (1976).
[0022] (17) Grace, DE 3302258A1 (1983).
[0023] (18) Chi, C. W. Can. Pat. 1,178,222.
[0024] (19) Suhner, Ger. Pat. Publicn. 1907610, C.A. 75, October 1972 (p. 2/6) QD 1A5.
[0025] However, none of these references disclose a composition for clarifying beer or wine in an efficient and advantageous manner with a premix composition of a silica xerogel having defined characteristics present in a predetermined amount with a crosslinked polyvinyl lactam polymer.
[0026] Accordingly, it is an object of the present invention to provide a new and improved premix composition of a siliceous material and crosslinked polyvinylpyrrolidone for use in clarification of beer or wine.
[0027] Another object herein is to provide a stable premix composition for clarification of beer or wine which has a long shelf life and is not prone to microbiological contamination.
[0028] Still another object of the invention is to provide a stable premix composition of a siliceous material and a crosslinked polyvinyl lactam which is effective for colloidal stabilization of beer.
[0029] Among the other objects herein is to provide such a premix composition which can efficiently remove sensitive proteins, polyphenols, flavanoids and tannoids from beer, and to effect a substantially complete reduction in chill haze in the beer.
[0030] Yet another object herein is to provide a process for colloidal stabilization of beer in a single dosing and a single filtration operation.
[0031] A specific object herein is to provide a stable premix composition which is selective to removal of high molecular weight proteins while leaving the desirable low molecular weight proteins remaining in the clarified beer.
[0032] A feature of the present invention is the provision of a stable premix of predetermined composition which is a siliceous xerogel material having less than about 10% by weight of water therein, and a particle size as defined by its mean volume average diamter, Mv, of less than 50μ, both in the dry state and as a 10% aqueous slurry, and a crosslinked polyvinyl lactam, preferably crosslinked polyvinylpyrrolidone (PVPP), in a weight ratio of about 40 to 90% of the xerogel to about 10 to 60% of PVPP, for effective clarification of beer.
[0033] These and other objects and features of the invention will be made apparent from the following description of the invention.
SUMMARY OF THE INVENTION
[0034] What is described herein is a premix composition for clarifying beer in an effective manner which comprises, by weight, (a) 40 to 90% silica xerogel having less than 10% water therein, preferably 5% or less, and (b) 10 to 60% by weight of crosslinked polyvinylpyrrolidone (PVPP). Preferably, (a) is 60 to 85% and (b) is 15 to 40%; most preferably, (a) is 70 to 80% and (b) is 20 to 30%.
[0035] In this invention, (a) has a particle size as defined by its mean volume average diamter, Mv, in both the dry state and as a 10% aqueous slurry, of less than 50μ, preferably about 5-30μ, component (b) has a defined particle size in the dry state of about 20 to 50μ, and, in a 10% aqueous slurry, of about 30 to 90μ.
[0036] A premix composition wherein prior to admixture, the ratio between particle sizes of (a) in a 10% aqueous slurry to its dry state is about 0.6 to about 2.0.
[0037] A premix composition wherein prior to admixture, the ratio between the particle sizes of (b) in a 10% aqueous slurry to the dry state is about 1.0 to about 2.0.
[0038] A premix composition wherein the particle size, as defined by its mean volume average diameter, Mv, of (a) is less than the correspondingly defined particle size of (b).
[0039] A feature of the invention is the provision of a flocculated aqueous slurry of the defined premix composition, preferably including about 5 to about 20% by wt. of the premix composition and about 80 to about 95% water, for example, which is prepared by admixing silica xerogel and PVPP in defined proportions, and slowly adding water thereto with agitation.
[0040] Another feature of the invention is the provision of a process for clarifying beer which includes treating beer with such an agitated flocculated aqueous slurry of the defined premix, and filtering the thus-treated beer, wherein both proteins and polyphenols are removed in one step from the treated beer in a contact time of about 3 hours or less. Such a process requires only a dose of about 10 lbs. of the premix composition for each 100 barrels of beer. The process also features a step of conveniently pumping both the clarified beer and the spent premix composition out of the treatment tank into a filter tank after carrying out the clarification step.
[0041] The clarified beer or wine is obtained herein in a process which is conducted at an advantageous filter flow rate, with undetectable residual soluble polyvinylpyrrolidone therein, and no biological growth in the premix, with effective haze stability after time, and easy redispersibility of the used premix.
IN THE DRAWING
[0042] The FIGURE is a graphical representation of dispersibility of premix compositions of silica xerogel and PVPP as a function of composition.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Silica gel is produced by reacting sodium silicate with sulfuric acid. The gel then is broken up, washed and sized. This product is known as silica “hydrogel”. Sodium sulfate is a by-product of the process of formation of silica hydrogel. When sodium sulfate is removed from silica hydrogel and the residue is dried to less than 10% water therein, a silica product known as “xerogel” is obtained.
[0044] In this invention, a stable premix composition is provided which includes a predetermined composition of xerogel having less than 10% water therein, preferably 5% or less. Suitable xerogels for use herein include SIL-Proof® BG-5 and BG-6 (SCM Chemicals); Britesorb® D-300 (PQ Corp.), and Lucilite XLC (Crossfield Corp.).
[0045] The other component of the premix composition is crosslinked polyvinylpyrrolidone (PVPP), such as Polyclar® PC-10, which is available from International Specialty Products, Inc. (ISP).
[0046] In accordance with the present invention, the premix composition for colloidal stabilization of beer is prepared by admixing xerogel and crosslinked polyvinylpyrrolidone (PVPP) solids.
[0047] Suitable premix compositions in accordance with the invention contain about 40 to 90% by weight of xerogel, preferably 60 to 85%, and most preferably about 70-80%; and about 10 to 60% of PVPP, preferably about 15 to 40%, and most preferably about 20 to 30%.
[0048] In the premix composition, the xerogel component provides the larger surface area to receive the PVPP component in a predetermined ratio without causing compactation of the resultant admixture. Accordingly, suitable xerogel: PVPP wt. ratios in the premix composition generally will depend upon the particle size of the xerogel used therein. Suitable specific premix compositions herein include, for example, 83% xerogel and 17% PVPP (a 15:3 wt. ratio); 70% xerogel and 30% PVPP (a 7:3 wt. ratio); and 63% xerogel with 37% PVPP (a 1:7 wt. ratio). In the preferred forms of the invention, the xerogel component of the premix should have a smaller particle size than the PVPP so that it can be complexed between the PVPP particles.
[0049] The premixed composition can be stored in a stable condition for prolonged periods of time with minimal chance of microbial contamination. Before use, the premix composition must be hydrated with water with agitation to form an aqueous dispersion or slurry having a premix concentration of about 5-20 wt. %. In this aqueous dispersion, PVPP stabilizes the xerogel by flocculating the xerogel without affecting the requisite adsorbing characteristics of each material. This flocculated, aqueous dispersion then is used in a single-step treatment of unstabilized beer. During this treatment, the flocculated premix in the dispersion remains in the slurry state without any significant compaction.
[0050] This stable, flocculated aqueous premix slurry is achieved herein because its PVPP component quickly hydrates upon addition of water thereto to form a swelled system. The swelled PVPP system then immediately complexes the xerogel component to prevent premature compaction of the system while the xerogel becomes fully hydrated. Then, in this complexed condition, the xerogel can become fully hydrated by addition of water to the premix over a long period of time without causing compaction of the system.
[0051] Suitably, the solid premix composition of the invention usually is hydrated with water for about 3 hours to form a thick, flocculated aqueous slurry containing about 5-20 wt. % of the premix. This flocculated composition can be kept in a holding tank for long periods without affecting the clarifying properties of either component, and with advantageous microbiological stability.
[0052] The flocculated hydrated premix slurry thus-prepared then is pumped into the beer treatment tank where it can perform its clarifying and chill haze stability functions. After treatment, the clarified beer is pumped into a filter tank then the stabilized beer is passed through a cake of diatomaceous earth to remove any traces of the premix remaining in the beer. Alternate filtration systems like ceramic candles, membrane filtration or centrifugation can be used in the place of diatomaceous earth filtration.
[0053] In a typical run, 18 lbs. of the premix composition of the invention at a 15:3 wt. ratio of xerogel to PVPP is used for each 100 barrels of unstabilized beer. This single step treatment produced stabilized beer with a prolonged shelf life showing an efficacy removal of sensitive proteins and haze-making polyphenols.
[0054] While the mechanism of action of the xerogel and PVPP components of the premix upon each other is not completely understood at present, it is believed that the water-insoluble polymeric PVPP component is a microcrystalline system which can hydrogen bond or complex to the xerogel via water bridges without penetration to prevent the xerogel from settling out. The PVPP also provides the matrix for simultaneous adsorption of polyphenols and high molecular weight proteins onto the xerogel by a process of diffusion, attachment and penetration.
[0055] The advantageous clarification results are achieved herein in a single dosing step with about a 2-30 minute contact time with the two component premix composition of the invention and a single filtration step, operating with an efficient Filter Index, i.e. less pressure build-up across the filter, less diatomaceous earth in the filtration step and a greater beer volume throughput through the filter. The stabilized and filtered beer obtained herein had a shelf-life of greater than 3 months, which was over 3 times that of beer treated with either single component of the premix, and equal to sequential single treatments with each component.
[0056] The FIGURE shows the effective dispersibility of xerogel and PVPP premix systems as a function of its composition. The degree of dispersibility in an aqueous premix at a 10-20 wt. % concentration is inversely related to the number of inversions required to redisperse a slurry of given composition which has stood for 24 hours. Suitable premix compositions require less than 1000 inversions, preferably less than 500 inversions, and, most preferably less than 100 inversions. As is seen therein, these properties are achieved in premix compositions which contain about 10-60% by weight PVPP (Polyclar 10), preferably 15-40%, and, most preferably, about 20-30%, the rest being the defined silica xerogel component.
EXAMPLES
Methods of Analysis
Tannoid Content (Tannometer)
[0057] Tannoids are defined as those fractions of the polyphenolic compounds that can be precipitated by the addition of PVP K90 to the beer sample. They include the low and medium molecular weight polyphenols. The haze in beer is fundamentally a complex between the condensed polyphenols, referred to as TANNOIDS (T), and the SENSITIVE PROTEINS (P), in an equilibrium governed by the law of mass action as shown in equation (1) and equation (2):
P+T PT (1)
[0058] so that
[P]×[T]=k[PT] (2)
[0059] where [P] is the concentration of polypeptides and proteins (Sensitive Proteins defined as substances giving haze when tannin is added) and [T] is the concentration of tannoids that form precipitate with PVP K 90 (molecular weight 350,000).
[0060] For the analysis of Tannoids, a solution of PVP K90 was injected into a beer sample. The Tannoids in the beer form a precipitate with PVP K90 through hydrogen bonding. The addition of PVP K90 is plotted against the formation of haze and the maxima of the peak gives the Tannoid Content expressed as mg PVP/L beer.
[0061] A lower value of tannoids in the treated beer indicates a reduction in haze.
Sensitive Proteins (Tannometer)
[0062] The sensitive protein test via the Tannometer provides insight to the levels of haze forming proteins present in beer. In this test, a solution of tannic acid was dosed into a beer sample. Proteins in the beer complex with tannin to form an insoluble PT complex giving rise to haze. The result is expressed in EBC units of haze corresponding to the addition of 10 mg of tannin per liter of beer.
[0063] A lower value of sensitive proteins in the treated beer indicates a reduction in haze.
Flavanoids and Polyphenols
[0064] The flavanoid content in beer samples was analyzed by Analytica EBC, method 9.9.2. Total polyphenols in beer is analyzed using Methods of Analysis of ASBC, method BEER-35. Both methods give an absorbance value measured by a spectrometer and the results are expressed in ppm. HPLC with dual-electrode offers a precise qualitative and quantitative method for the determination of haze producing flavanols in beer.
[0065] The flavanoid/polyphenols in beer are of two-fold interest, owing to their proven involvement in haze formation and their potential impact on flavor. Malt and hops provide beer with its share of the polyphenols.
[0066] The absence of protective groups on the hydroxylated flavanoid matrix is the reason why these polyphenols can react with proteins thereby causing colloidal instability in beer. Also, associated with polyphenols is the characteristic astringent flavors in beer. The anthocyanogens which are part of the polyphenols can easily be hydrolyzed to anthocyanidin. These anthocyanidins give beer harsh and astringent flavors. Polyclar adsorbs these anthocyanogens thereby reducing the formation of astringency in beer.
Total Haze and Aging Test
[0067] The total haze is read directly from the bottle, using an Lg automatic haze meter. The haze meter is calibrated with certified haze standards obtained from Advanced Polymer Systems. All readings are taken with distilled water in the measuring chamber to prevent the formation of condensation on the outside surface of cold samples.
[0068] Haze readings are taken on fresh beer samples at 22° C. and at 0° C. Aging tests are performed by incubating samples in a dry oven at 37° C. for one week and then transferring to storage at 0° C. for one day before taking total haze readings on the cold samples. Samples are put through this cycle for several weeks or until an excessive value for haze is obtained. The end of useful shelf life is generally taken to be 2.0 EBC haze units and one week storage at 37° C. is taken as being equal to one-month storage at ambient temperature.
RUNS 1-8
Examples 1-8
[0069] Runs 1-8 are Lab Runs.
[0070] Runs 1, 2, 3, 4 are Comparative Runs.
[0071] Runs 5 and 6 are Invention Runs.
[0072] Runs 7 and 8 are Control Runs.
Double Filtration—Filtration After Sequential Addition of Each Component
Run No. 1
[0073] A sample of unstabilized beer was obtained from a commercial source (Anheuser-Busch, Newark, N.J.) and used for Examples 1 through 7. This beer sample was not treated with any form of stabilizer and was centrifuged to decrease yeast cell count to approximately 1 million cells per ml by the brewery. In a 1500-ml glass jar equipped with a lid was added 1000-ml of unstabilized beer, 0.571 g (equivalent to a dosing rate of 15-lbs/100 bbl) of Xerogel (Britesorb D-300, PQ Corporation) and a magnetic stir bar. This mixture was placed on a magnetic stir plate within a refrigerator, set at 0° C. After 3 hours of stirring, 1.90 g of diatomaceous earth (DE) was added (equivalent to 50-lbs/100 bbl) and mixed into the solution by swirling the jar. This mixture was then vacuum filtered through a 2.5-μm glass fiber filter using a Buchner funnel and vacuum flask. To the filtrate was added 0.114 g of Polyclar®10 (equivalent to 3-lbs/100 bbl) and mechanically stirred at 0° C. for 15 minutes. 1.90 g of DE was again added and mixed into solution and filtered as previously described.
[0074] The clear filtered beer was analyzed for tannoid content, sensitive proteins, total polyphenols, flavanoids, and also subjected to heat forcing tests to determine colloidal stability, described under “Methods of Analysis”. Results can be found in Tables 1, 2 and 3.
Run No. 2
[0075] Run 1 was repeated except that 0.267 g of Polyclar®10 (equivalent to 7-lbs/100 bbl) was added in place of 0.114 g of Polyclar®10 after the first filtration process. Results can be found in Tables 1, 2 and 3.
Single Filtration—Sequential Addition of Components
Run No. 3
[0076] In an experiment similar to that performed in Example 1, a 1000-ml sample of unstabilized beer was dosed with 0.571 g of Xerogel (Britesorb D-300, equivalent to 15-lbs/100 bbl) and mechanically stirred for 2¾ hours. Then, 0.114 g of Polyclar®10 (equivalent to 3-lbs/100 bbl) was added to the mixture and stirred for an additional 15 minutes. DE was dosed into the sample and the mixture was filtered as described in Example 1. Results can be found in Tables 1, 2 and 3.
Run No. 4
[0077] Example 3 was repeated except that 0.267 g Polyclar 10 (equivalent to 7-lbs/100 bbl) was used in the place of 0.114 g of Polyclar®10. Results can be found in Tables 1, 2 and 3.
Premix of Components—Single Filtration
Run No. 5
[0078] In an experiment similar to that performed in Example 1, Xerogel (Britesorb D-300) and Polyclar®10 were premixed in the ratio of 15:3 by weight. A 1000-ml sample of unstabilized beer was dosed with 0.685 g of the 15:3 ratio premix (equivalent to 18-lbs/100 bbl). The sample was placed on a magnetic stir plate within a refrigerator, set at 0° C. After 3 hours of stirring, 1.90 g of diatomaceous earth (DE, equivalent to 50-lbs/100 bbl) was added and mixed into the solution by swirling the jar. This mixture was then vacuum filtered through a 2.5-μm glass fiber filter using a Buchner funnel and vacuum flask. The filtered beer was then analyzed as described in Example 1. Results can be found in Tables 1, 2 and 3.
Run No. 6
[0079] Example 5 was repeated except that Xerogel (Britesorb D-300) and Polyclar®10 were premixed in the ratio of 15:7 by weight. A 1000-ml sample of beer was dosed with 0.838 g of the 15:7 ratio premix (equivalent to 22-lbs/100 bbl) and processed as described in Example 5. Results can be found in Tables 1, 2 and 3.
Control Sample (Treated with Xerogel Alone or Untreated) for Examples 1 Through 6
Run No. 7
[0080] A control experiment was performed by dosing 1000-ml of unstabilized beer with 0.157 g of Xerogel (Britesorb D-300, equivalent to 15-lbs/100 bbl). The mixture was mechanically stirred for 3 hours in a refrigerator, set at 0° C. 1.90 g of diatomaceous earth (DE) was added to the mixture (equivalent to 50-lbs/100 bbl) and mixed into the solution by swirling the jar. This mixture was then vacuum filtered through a 2.5-μm glass fiber filter using a Buchner funnel and vacuum flask. The filtered beer was then analyzed as described in Example 1. Results can be found in Tables 1, 2 and 3.
Run No. 8
[0081] A second control experiment was performed using 1000-ml of unstabilized beer with no form of beer stabilizer added. The beer was mechanically stirred for 3 hours in a refrigerator, set at 0° C. 1.90 g of diatomaceous earth (DE) added to the beer (equivalent to 50-lbs/100 bbl) and into solution by swirling the jar. This mixture was vacuum filtered through a 2.5-μm glass fiber filter a Buchner funnel and vacuum flask. The filtered beer then analyzed as described in Example 1. Results can be in Tables 1, 2 and 3.
TABLES 1-3 Dosing Rates Quantity Xerogel Amount of Xerogel (Britesorb D-300) Polyclar ® 10 DE Beer (Britesorb D-300) Polyclar ® 10 DE Run (lbs/100 bbl) (lbs/100 bbl) (lbs/100 bbl) (ml) (g) (g) (g) 1 15 3 50 1000 0.571 0.114 1.904 2 15 7 50 1000 0.571 0.267 1.904 3 15 3 50 1000 0.571 0.114 1.904 4 15 7 50 1000 0.571 0.267 1.904 5 15 3 50 1000 0.571 0.114 1.904 6 15 7 50 1000 0.571 0.267 1.904 7 15 0 50 1000 0.571 0 1.904 8 0 0 50 1000 0 0 1.904
[0082] [0082] TABLE 2 Sensitive Proteins Total Tannoids (EBC at Polyphenols Flavanoids Run (mg/L) 10 mg/L beer) (mg/L) (mg/L) 1 15.9 0.4 168.1 34.8 2 0.0 0.4 135.3 28.5 3 13.0 0.6 177.1 34.8 4 0.0 0.8 150.1 28.8 5 15.5 0.6 169.7 32.5 6 0.0 1.1 143.5 28.8 7 32.6 0.7 206.6 37.5 8 37.5 4.3 214.8 38.9
[0083] [0083] TABLE 3* Initial Week 1 Week 2 Week 3 Week 4 Run (EBC) (EBC) (EBC) (EBC) (EBC) 1 0.83 5.82 8.26 12.56 17.56 2 0.82 2.61 4.68 6.32 10.28 3 1.45 4.93 7.26 11.46 17.82 4 1.42 2.81 4.52 6.18 11.25 5 1.43 5.68 7.10 12.86 17.10 6 1.22 2.86 4.73 6.08 11.23 7 1.65 10.58 15.60 16.58 >18.00 8 4.57 >18.00 >18.00 >18.00 >18.00
Example 9
Large Scale Trial
Runs 9a, 9b and 9c
[0084] In separate experiments, 36,000 gallons of unstabilized beer was treated at 20-lbs/100 bbl with Xerogel (Britesorb D-300, Control Example 9a), 15-lbs/100 bbl with Xerogel (Millennium BG6, Example 9b), and 10 lbs/100 bbl with a 7:3 ratio by weight of Xerogel (Millennium BG6) and Polyclar 10 (Example 9c). The treatments were followed by dosing of DE at 50-lbs/100 bbl (as body feed) and filtered. Results of analysis can be found in Tables 4, 5 and 6.
[0085] Example 9c was more homogeneous and easier to dose into the beer than Examples 9a and 9b. Example 9c also emptied quite easily from the slurry tank in comparison to Examples 9a and 9b, which compacted solidly at the bottom of the tank.
[0086] Filter index for Example 9c was found to be four times better than Example 9b and 2 times better than Example 9a. Filter index is an operational parameter that measures the efficiency of large-scale beer filtration. The value is based on filter pressure, amount of DE used, and the rate of filtration.
TABLE 4 Run Treatment 9a Britesorb D-300 at 20-lbs/100 bbl 9b Millennium BG6 at 15-lbs/100 bbl 9c 7:3 ratio by weight of a Premix of Xerogel (Millennium BG6) and Polyclar 10 at 10-lbs/100 bbl
[0087] [0087] TABLE 5 Sensitive Proteins Total Tannoids (EBC at Polyphenols Flavanoids Run (mg/L) 10 mg/L beer) (mg/L) (mg/L) 9a 33.0 0.3 141.0 31.5 9b 28.6 0.6 143.5 31.5 9c 18.9 0.5 126.3 25.5
[0088] [0088] TABLE 6 Initial Week 1 Week 2 Week 3 Week 4 Total Total Total Total Total Run (EBC) (EBC) (EBC) (EBC) (EBC) 9a 0.54 1.04 1.35 3.10 4.50 9b 0.86 1.50 2.36 3.96 6.46 9c 0.62 0.80 1.52 2.01 3.60
[0089] The advantages of the combined treatment at 10-lbs/100 bbl, Invention Run 9c, over treatment with xerogel alone at 15-lbs/100 bbl and 20 lbs/100 bbl, Runs 9a and 9b, respectively, is clearly evident by the low value of total haze in EBC units.
Example 10
Premix of Components
[0090] Xerogel (Millennium BG5) and Polyclar®10 were premixed in the ratio of 7:3 by weight. A 1000-ml sample of a new unstabilized beer was dosed with 0.381 g of the 7:3 ratio premix (equivalent to 10-lbs/100 bbl). The sample was mechanically stirred using a magnetic stir plate within a refrigerator, set at 0° C. After 3 hours of stirring, 1.90 g of diatomaceous earth (DE, equivalent to 50-lbs/100 bbl) was added and mixed into the solution by swirling the jar. This mixture was then vacuum filtered through a 2.5-μm glass fiber filter using a Buchner funnel and vacuum flask. The filtered beer was then analyzed as described in Example 1. Results can be found in Tables 7 and 8 below.
Example 11
Premix of Components
[0091] Example 10 was repeated except that the 7:3 premix was dosed at 0.571 g (equivalent to 15-lbs/100 bbl). Results can be found in Tables 7 and 8.
Example 12
Polyclar®10 Treatment
[0092] In an experiment similar to Example 11, a 1000-ml sample of unstabilized beer was dosed with 0.114 g of Polyclar®10 (equivalent to 3-lbs/100 bbl) in place of the premix. Results can be found in Tables 7 and 8.
Example 13
Xerogel Treatment
[0093] Example 12 was repeated except that 0.762 g of Xerogel (Millennium BG5, equivalent to 20-lbs/100 bbl) was used in place of Polyclar®10. Results can be found in Tables 7 and 8.
Example 14
Xerogel Treatment—Control for Examples 10 Through 13
[0094] Example 12 was repeated except that 0.571 g of Xerogel (Millennium BG5, equivalent to 15-lbs/100 bbl) was used in of Polyclar®10. Results can be found in Tables 7 and 8.
TABLE 7 Sensitive Proteins Total Tannoids (EBC at Polyphenols Flavanoids Example (mg/L) 10 mg/L beer) (mg/L) (mg/L) 10 15.5 0.4 151.7 27.9 11 15.2 0.4 130.4 23.6 12 14.5 1.8 151.7 27.5 13 32.2 0.2 190.2 37.2 14 32.0 0.2 189.4 36.2
[0095] [0095] TABLE 8 Initial Week 1 Week 2 Week 3 Total Total Total Total Example (EBC) (EBC) (EBC) (EBC) 10 0.64 1.39 3.75 6.24 11 0.65 1.17 2.68 4.65 12 0.68 4.79 6.44 8.60 13 0.92 3.15 8.60 14.40 14 0.65 4.00 10.19 16.42
[0096] Invention Example 11 produced distinctly superior haze stability.
Example 15
Premix of Components
[0097] Example 10 was repeated except that xerogel, Lucilite XLC (Crossfield Corp.) was used in place of Xerogel, Millennium BG5. Results can be found in Tables 9 and 10.
Example 16
Premix of Components
[0098] Example 11 was repeated except that Xerogel, Lucilite XLC (Crossfield Corp.) was used in place of Xerogel, Millennium BG5. Results can be found in Tables 9 and 10.
Example 17
Polyclar®10 Treatment
[0099] Example 12 was repeated. Results can be found in Tables 9 and 10.
Example 18
Xerogel Treatment
[0100] Example 13 was repeated except that Xerogel, Lucilite XLC (Crossfield Corp.) was used in place of Xerogel, Millennium BG5. Results can be found in Tables 9 and 10.
Example 19
Xerogel Treatment—Control for Examples 15 Through 18
[0101] Example 14 was repeated except that Xerogel, Lucilite XLC (Crossfield Corp.) was used in place of Xerogel, Millennium BG5. Results can be found in Tables 9 and 10.
TABLE 9 Sensitive Proteins Total Tannoids (EBC at Polyphenols Flavanoids Example (mg/L) 10 mg/L beer) (mg/L) (mg/L) 15 13.1 0.3 148.4 25.8 16 12.1 0.2 134.5 23.5 17 13.0 2.9 149.2 26.1 18 31.1 0.2 188.6 36.5 19 31.2 0.2 189.4 37.5
[0102] [0102] TABLE 10 Initial Week 1 Week 2 Week 3 Total Total Total Total Example (EBC) (EBC) (EBC) (EBC) 15 0.44 2.01 6.69 10.63 16 0.43 1.12 3.82 6.39 17 0.51 6.87 10.20 12.34 18 0.56 3.32 10.30 15.32 19 0.45 4.91 14.61 16.42
[0103] Example 16 produced far superior stabilization (lower otal EBC value) than Comparative Runs 17-19.
Example 20
Sedimentation Properties of Polyclar®10
[0104] To a 100 ml stoppered graduated cylinder was added log of Polyclar®10 and a quantity of distilled water to bring the total volume of the mixture to 100 ml. The sample was thoroughly mixed to disperse the solids and allowed to stand overnight to fully hydrate. The mixture was then re-mixed by vigorous inversion of the cylinder to fully disperse the solids. The volume of settled solids was noted after 15 min., 30 min., 1 hour, 3 hours, 6 hours, and 24 hours of settling time. Results are found in Table 11.
Example 21
Sedimentation Properties of Xerogel (Millennium BG6)
[0105] Example 20 was repeated except that 10 g of Xerogel (Millennium BG6) was used in place of Polyclar®10. Results are tabulated in Table 11.
Example 22
Sedimentation Properties of Xerogel (Millennium BG5)
[0106] Example 20 was repeated except that 10 g of Xerogel (Millennium BG5) was used in place of Polyclar®10. Results are tabulated in Table 11.
Example 23
Sedimentation Properties of Xerogel (Crossfield. Lucilite XLC)
[0107] Example 20 was repeated except that log of Xerogel (Crossfield, Lucilite XLC) was used in place of Polyclar®10. Results are tabulated in Table 11.
Example 24
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG6) Mixture
[0108] Example 20 was repeated except that 10 g of Polyclar®10 was replaced with a solid premix containing 7 g of Xerogel (Millennium BG6) and 3 g Polyclar®10. Results are tabulated in Table 11.
Example 25
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG5) Mixture
[0109] Example 20 was repeated except that 10 g of Polyclar®10 was replaced with a solid premix containing 7 g of Xerogel (Millennium BG5) and 3 g Polyclar®10. Results are tabulated in Table 11.
Example 26
Sedimentation Properties of Polyclar®10/Xerogel (Crossfield, Lucilite XLC) Mixture
[0110] Example 20 was repeated except that 10 g of Polyclar®10 was replaced with a solid premix containing 7 g of Xerogel (Crossfield, Lucilite XLC) and 3 g Polyclar®10. Results are tabulated in Table 11.
Example 27
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG6) Mixture
[0111] Example 20 was repeated except that 8 g of Xerogel (Millennium BG6) and 2 g of Polyclar 10 were used. Results are tabulated in Table 11.
Example 28
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG5) Mixture
[0112] Example 20 was repeated except that 8 g of Xerogel (Millennium BG5) and 2 g of Polyclar 10 were used. Results are tabulated in Table 11.
Example 29
Sedimentation Properties of Polyclar®10/Xerogel (Crossfield, Lucilite XLC) Mixture
[0113] Example 20 was repeated except that 8 g of Xerogel (Crossfield, Lucilite XLC) and 2 g of Polyclar®10 were used. Results are tabulated in Table 11.
TABLE 11 Quantity of Components Level of Solids at Indicated Time (ml) Xerogel Polyclar 15 30 1 3 6 24 Example (g) (g) (min) (min) (hr) (hr) (hr) (hr) 20 0 10 99 98 97 97 95 55 21 10 (Millennium BG6) 0 0.5 1 2 3 20 26 22 10 (Millennium BG5) 0 16 20 23 29 30 31 23 10 (Lucilite XLC) 0 95 92 88 35 36 36 24 7 (Millennium BG6) 3 83 75 62 59 58 57 25 7 (Millennium BG5) 3 86 78 76 73 72 71 26 7 (Lucilite XLC) 3 96 95 95 95 93 93 27 8 (Millennium BG6) 2 20 28 43 44 44 44 28 8 (Millennium BG5) 2 28 40 50 49 49 47 29 8 (Lucilite XLC) 2 88 81 81 80 75 74
[0114] The results established a reduced level of compacted solids for invention runs.
Example 30
Dispersion Properties of Polyclar®10
[0115] The sample from Example 20, after settling for 24 hours, was inverted up and down at the rate of about 60 inversions per minute. The number of inversions to re-disperse the solids was noted (each 180 degree rotation constitutes one inversion). Results are tabulated in Table 12.
Example 31
Sedimentation Properties of Xerogel (Millennium BG6)
[0116] The sample from Example 21, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 32
Sedimentation Properties of Xerogel (Millennium BG5)
[0117] The sample from Example 22, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 33
Sedimentation Properties of Xerogel (Crossfield, Lucilite XLC)
[0118] The sample from Example 23, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 34
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG6) Mixture
[0119] The sample from Example 24, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 35
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG5) Mixture
[0120] The sample from Example 25, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 36
Sedimentation Properties of Polyclar®10/Xerogel (Crossfield, Lucilite XLC) Mixture
[0121] The sample from Example 26, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 37
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG6) Mixture
[0122] The sample from Example 27, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 38
Sedimentation Properties of Polyclar®10/Xerogel (Millennium BG5) Mixture
[0123] The sample from Example 28, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
Example 39
Sedimentation Properties of Polyclar®10/Xerogel (Crossfield, Lucilite XLC) Mixture
[0124] The sample from Example 29, after settling for 24 hours, was inverted up and down and the number of inversions to re-disperse the solids is noted. Results are tabulated in Table 12.
TABLE 12 Quantity Xerogel Polyclar Example (g) (g) # of Inversions 30 0 10 57 31 10 (Millennium BG6) 0 >2000 32 10 (Millennium BG5) 0 1700 33 10 (Lucilite XLC) 0 250 34 7 (Millennium BG6) 3 160 35 7 (Millennium BG5) 3 44 36 7 (Lucilite XLC) 3 <40* 37 8 (Millennium BG6) 2 450 38 8 (Millennium BG5) 2 80 39 8 (Lucilite XLC) 2 150
[0125] The above data shows that the premix considerably reduced the number of inversions necessary to flocculate the sample, as compared to a single component.
Example 40
Filter Flow Rate Properties of Polyclar® 10/Xerogel
[0126] The following twelve admixtures were prepared by blending xerogel (Britesorb D-300) and increasing quantities of Polyclar 10 containing the following weight % of Polyclar 10. 0%, 8%, 16%, 25%, 30%, 32%, 42%, 50%, 65%, 75%, 85% and 100%. This was carried out by mixing the components in a V-blender for a period of 60 minutes. The filter flow rates for the flow of water over a filter bed prepared from the above admixtures were determined as follows.
[0127] 4.00 g of different admixtures (premix in samples) were separately mixed (hydrated) in 200 ml of distilled water for 24 hours and then the Filter Flow Rate Index determined using Schenk pressure filter apparatus. Filter bed was established with the experimental premix in test, and then the time required for 100 ml of water to pass through the bed was measured with the a stop watch in seconds. (at 20° C., pressure of 0.2 bar, filter diameter 60 mm, type of filter Schenk D filter Mat). The Filter Flow Rate Index (FFR I) is then calculated as
[0128] Filter Flow Rate Index=1000/t where t is time in seconds for 100 ml of filtrate to be collected. The results are shown in Table 13.
TABLE 13 Filter Flow Rate Index as function of Polyclar 10 concentration in Premix of Polyclar 10 and Britesorb D-300 (Xerogel from PQ Corporation) Wt. % Polyclar 10 in the 0 8 16 25 30 32 42 50 65 75 85 100 admixture Filter Flow Rate Index 25 46 122 156 181 156 123 68 41 16 7
Example 41
Filter Flow Rate Properties of Polyclar® 10/Xerogel
[0129] The experiment in Example 40 was repeated replacing Britesorb D-300 with BG6. The following weight % Polyclar 10 were used in this case, 0%, 17%, 25%, 30%, 32%, 41%, 50%, 65%, 75%, 85%, 90% and 100%. The results are tabulated in Table 14.
TABLE 14 Filter Flow Rate Index as function of Polyclar 10 concentration in Premix of Polyclar 10 and BG 6 (Xerogel from Millenium) Wt. % Polyclar 10 0 17 25 30 32 41 50 65 75 85 90 100 in the admixture Filler Flow Rate Index 6.5 15.5 19.5 13.5 19.5 92 162 111 88 68 46 7
[0130] In this case, Filter Flow Rate maximizes at Polyclar 10 concentration of between 41% and 65% (premix with BG6.)
Example 42
Effect of Complete Hydration on the Particle Size Distribution of Xerogel, Polyclar 10 and the Premix of Xerogel and Polyclar 10
[0131] The descriptions for various sample preparation are shown below and the results are summarized in Table 15.
Example 42-A1
[0132] Particle size distribution was determined on DRY powder of BG6 by Microtrac SRA 9200 (see results under DRY in Table 15). Later, 10 g of BG6 was added to a stoppered graduated cylinder. Distilled water was added to bring the volume to the 100 ml mark and mixed with the powder to disperse the solids. It was then allowed to stand overnight to fully hydrate the contents in the cylinder. The sample was then re-mixed by vigorous inversions of the cylinder to fully disperse the solid. The sample was then tested for particle size distribution, similar to the DRY sample, results are shown under Column IV in Table 15.
Example 42-A2
[0133] Particle size distribution was determined on DRY powder of Polyclar 10 by Microtrac 9200 (see results under DRY in Table 1). Later, 10 g of Polyclar 10 was added to a stoppered graduated cylinder. Distilled water was added to bring the volume to the 100 ml mark and mixed with the powder to disperse the solids. It was then allowed to stand overnight to fully hydrate the contents in the cylinder. The sample was then re-mixed by vigorous inversions of the cylinder to fully disperse the solid. The sample was then tested for particle size distribution, similar to the DRY sample, results are shown under Column IV in Table 15.
Example 42-A3
[0134] Polyclar 10/Xerogel (BG6) premix was prepared by mixing 70 g of BG6 and 30 g of Polyclar 10 in a V-blender for a period of 60 minutes. Particle size distribution of the premix was determined and recorded under Column III in Table 15. Later, log of this premix was added to a stoppered graduated cylinder. Distilled water was added to bring the volume to the 100 ml mark and mixed with the powder to disperse the solids. It was then allowed to stand overnight to fully hydrate the contents in the cylinder. The samples was then re-mixed by vigorous inversions of the cylinder to fully disperse the solids. The samples was then tested for paticle size distribution, similar to the DRY sample, by Microtarc-SRA 9200, results are shown under HYDRATED in Table 15.
Example 42-B1
[0135] Example A1 was repeated, except in this case the Xerogel BG5 was used instead of Xerogel BG6.
Example 42-B2
[0136] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Xerogel BG5 and Polyclar 10.
Example 42-C1
[0137] Example 42-A1 was repeated, except in this case the Xerogel Britesorb D-300 was used instead of Xerogel BG6.
Example 42-C2
[0138] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Xerogel Britesorb D-300 and Polyclar 10.
Example 42-D1
[0139] Example 42-A1 was repeated, except in this case the Xerogel Lucilite XLC was used instead of Xerogel BG6.
Example 42-D2
[0140] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Xerogel Lucilite XLC and Polyclar 10.
Example 42-E1
[0141] Example 42-A1 was repeated, except in this case the Xerogel Stabifix was used instead of Xerogel BG6.
Example 42-E2
[0142] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Xerogel Stabifix and Polyclar 10.
Example 42-F1
[0143] Example 42-A1 was repeated, except in this case the Hydrogel Chillgarde was used instead of Xerogel BG6.
Example 42-F2
[0144] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Hydrogel Chillgarde and Polyclar 10.
Example 42-G1
[0145] Example 42-A1 was repeated, except in this case the Hydrogel Britesorb A-100 was used instead of Xerogel BG6.
Example 42-G2
[0146] Example 42-A3 was repeated, except in this case the 7:3 premix was made with Hydrogel Britesorb A-100 and Polyclar 10.
TABLE 15 IV-Hydrated 10% slurry in water, after 24 hours III-Dry Mv, Mv, microns microns V-Ratio of Range of particle (mean Range of particle (mean Mv (Hydrated) I II size, microns volume dia) size, microns volume dia) MV (Dry) A1 Xerogel (BG6) 0.7-60.0 10.09 1.2-70.0 17.09 1.69 A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 A3 Premix, 7:3 ratio 0.7-100.0 13.65 1.3-200.0 49.78 3.65 B1 Xerogel (BG5) 0.75-161.4 28.42 2.121-161.4 25.80 0.91 A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 B2 Premix, 7:3 ratio 0.810-161.4 28.97 4.241-248.9 64.55 2.20 C1 Xerogel (Britesorb D-300) 0.75-88.0 18.47 2.121-62.23 16.43 0.89 A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 C2 Premix, 7:3 ratio 1.06-88.0 21.21 3.27-176 50.37 2.40 D1 Xerogel (Lucilite XLC) 0.75-62.23 15.03 2.121-44.0 13.40 0.89 A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 D2 Premix, 7:3 ratio 0.75-74.0 16.93 4.241-248.9 80.02 4.70 E1 Xerogel (Stabifix) 0.75-114.1 22.42 2.121-88.0 21.12 0.94 A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 E2 Premix, 7:3 ratio 0.75-88.0 23.95 3.27-209.3 62.53 2.60 F1 Hydrogel (Chillgarde) Clumping Clumping 3.0-80.70 19.35 — A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 F2 Premix, 7:3 ratio Clumping Clumping 6.0-248.9 76.08 — G1 Hydrogel (Britesorb A-100) Clumping Clumping 3.0-62.23 17.90 — A2 Polyclar 10 1.3-100.0 33.34 1.5-200.0 45.76 1.37 G2 Premix, 7:3 ratio Clumping Clumping 4.63-248.9 80.18 —
[0147] The mean volume diameter of the hydrated premix of Xerogel and Polyclar 10 shows a marked increase compared to the individual components. This increase in the particle size under wet conditions is indicative of the flocculent effect of Polyclar 10.
Example 43
Effect of Different Modes of Filtration on the Residual PVP (Polyvinylpyrrolidone) in Beer
[0148] Unstabilized beer samples were treated with different doses of Polyclar 10 and Xerogel (Britesorb D-300) and the premix of Britesorb D-300 and Polyclar 10, and then subjected to different modes of filtration as per procedure outlined in earlier examples and listed below. Residual PVP in beer was analyzed (by the method described in “Confirmation by Pyrolysis-Gas Chromatography of the Absence of Polyvinylpyrrolidone in Beer Treated with Cross-linked Polyvinylpyrrolidone” by T. M. H. Cheng and E. G. Malawer published in J. Am.Soc.Brew.Chem. 54(2):85-90,1990). Results are shown in Table 16.
[0149] Procedure for Preparation of Beer Samples
[0150] Double Filtration—Filtration After Addition of each Component, 15:3 ratio Britesorb D-300: Polyclar 10
[0151] This was carried out as per procedure in Run No. 1 as shown in A in Table 16.
[0152] Double Filtration—Filtration After Addition of each Component, 15:7 ratio Britesorb D-300: Polyclar 10
[0153] This was carried out as per procedure in Run No. 2 as shown in B in Table 16.
[0154] Premix of Components—Single Filtration, 15:3 ratio Britesorb D-300: Polyclar 10
[0155] This was carried out as per procedure in Run No. 5 as shown in C in Table 16.
[0156] Premix of Components—Single Filtration, 15:7 ratio Britesorb D-300: Polyclar 10
[0157] This was carried out as per procedure in Run No. 6 as shown in D in Table 16.
TABLE 16 Dose levels of Xerogel Residual soluble PVP Type of Treatment (Britesorb D-300): Polyclar used PVP ppm A Double Filtration- Filtration after addition of each component, 15:3 15 lb/100 bbl of Xerogel added first. Filtered. Then <0.5 ratio, Britesorb D-300: Polyclar 10 3 lb/100 bbl Polyclar 10 added. Then filtered. B Double Filtration- Filtration after addition of each component, 15:7 15 lb/100 bbl of Xerogel added first. Filtered. Then 1.1 ratio, Britesorb D-300: Polyclar 10 7 lb/100 bbl Polyclar 10 added. Then filtered. C Premix of Components - Single filtration, 15:3 ratio, Xerogel and Polyclar 10 premixed at 15:3 ratio. Then below detection Britesorb D-300: Polyclar 10 dosed at 15 lb/100 bbl level D Premix of Components - Single filtration, 15:7 ratio, Xerogel and Polyclar 10 premixed at 15:7 ratio. Then below detection Britesorb D-300: Polyclar 10 dosed at 22 lb/100 bbl level
[0158] It can be seen from the results in Table 16 that the presence of silicagel when mixed with crosslinked PVP facilitates the adsorption of any trace residual soluble PVP.
Example 44
Microbiological Stability of Premix of Xerogel/Polyclar 10 System and Comparison with Other Premix and Single Components
[0159] Polyclar 10/Xerogel (Britesorb D-300) premix was prepared by mixing 150 g of Xerogel (Britesorb D-300) and 30 g of Polyclar 10 in a V blender for a period of 60 minutes. Similarly, a premix of 150 g of Xerogel (Chillgarde) and 30 g of Polyclar 10 was prepared by mixing in a V blender for a period of 60 minutes. These two premixes together with single components of Polyclar 10, Chillgarde and Britesorb D-300 were also, used in the experiment. All the samples were assessed for microbilogical stability using the test “Adequacy of Preservation (Challenge) Test” from Sutton Laboratories, Method MLM 100-9. The challenge test protocol is designed to assess effective antimicrobial activity over storage time, thus simulating shelf life of the product.
TABLE 17 Mold count, cfu/g (colony forming units/g) Comments Polyclar 10 <10 cfu/g acceptable Chillgarde (hydrogel) 40,000 cfu/g Not acceptable, very high Britesorb D-300 (xerogel) <10 cfu/g acceptable Premix, 15:3, <5,600 cfu/g Not acceptable, Chillgarde (hydrogel):Polyclar 10 high. Premix, 15:3, <10 cfu/g acceptable xerogel (Britesorb D-300):Polyclar 10
[0160] The results in Table 17 above demonstrate that the premix of xerogel (Britesorb D-300) and Polyclar 10 gave a higher microbiological stability than the premix of Hydrogel (Chillgarde) and Polyclar 10. The premix of Xerogel (Britesorb D-300) and Polyclar 10 also has an acceptable microbiological stability. On the other hand, the premix of Hydrogel (Chillgarde) and Polyclar 10 had a “not acceptable” result with considerably higher mold growth.
[0161] While the invention has been described with particular reference to certain embodiments thereof, it will be understood that changes and modifications may be made which are within the skill of the art. Accordingly, it is intended to be bound only by the following claims. | A premix composition for clarifying beverages like beer includes, by weight, (a) about 40 to 90%, preferably 60-85%, of silica xerogel having less than 10% water therein, preferably 5% or less, and a particle size, as defined by its mean volume average diameter MV, in both the dry state and as a 10% aqueous slurry, of less than 50μ, preferably about 5-30μ, and (b) about 10 to 60%, preferably 15-40%, of crosslinked polyvinylpyrrolidone having a particle size as defined, in the dry state, of about 10 to 50μ, and about 30-60μin a 10% aqueous slurry, and a process of obtaining, chill-haze stabilized beer with substantial reduction in high molecular weight proteins, as well as polyphenols, flavanoids and tannins, in an efficient and effective single-step process at a rapid filter-flow rate, with undetectable residual soluble plyvinylpyrrolidone thereafter, and no microbiological growth in the premix, effective haze stability after time, and advantageous redispersibility of the premix used in the process. | 1 |
FIELD OF THE INVENTION
The instant invention relates to volumetric infusion pumps for parenteral delivery of fluids in a medical environment.
BACKGROUND OF THE INVENTION
Previous medical infusion pumps have comprehended a wide variety of methods for pumping fluids into a patient. The most common of these methods has been a peristaltic pump. In a peristaltic pump, a plurality of actuators or fingers serve to massage a parenteral fluid delivery tube in a substantially linear progression. The primary problem associated with peristaltic pumping technology is that the tube is repeatedly deformed in an identical manner, thereby over the course of time destroying the elastic recovery properties of the tube so that the tube maintains a compressed aspect. This destruction of the elastic recovery properties of the tube results in the volumetric output of the pump changing markedly over time. Another common type of pump used in the volumetric delivery of medical fluids is commonly known as a cassette pump. Although cassette pumps do not display the fairly rapid degradation of performance as evidenced in a peristaltic pump, they require a fairly elaborate pump cassette to be integrated with the IV tube. This added expense of having to change a cassette along with an IV set every time an operator wishes to change the medicament delivered to the patient, significantly raises the cost of patient care. Additionally, as both peristaltic and cassette pumps, as well as other infusion devices present in the market, require a fairly elaborate knowledge of the specific pumping device to ensure that the IV set is loaded appropriately, generally medical infusion pumps were purely the purview of the nursing or medical staff in a hospital environment.
The necessity of manually loading a set into an IV pump is universal in the art. Generally when a standard IV set is used, in addition to the rapid degradation of accuracy mentioned above, great difficulty is encountered in correctly loading the set into those pumps presently in the art. The state of the art of loading technology as it relates to medical infusion pumps has progressed only to the state of enclosing the IV tube between a pumping device and a door or cover and adding progressively more elaborate sensors and alarms to assure that the tube is correctly loaded into the pump. Even so, loading errors occur with regularity requiring great efforts on the part of hospital staffs to ensure that critical errors are minimized.
The state of the art in infusion pumps also includes the requirement of manually assuring that a free-flow condition of medicament does not occur when an IV set is installed or removed from a pump. Although hospital staffs exercise great care and diligence in their attempts to assure that free-flow conditions do not occur, a demonstrable need for additional precautions directed to the prevention of a free-flow condition has been a continuous concern of healthcare workers.
U.S. Pat No. 5,199,852 to Danby discloses a pumping arrangement including a squeezing device for deforming a length of pliant tubing first in one direction locally to reduce its volume, and in another direction tending to restore its original cross-section and on either side of the squeezing device, inlet and outlet valves which operate by occluding the tubing. The control of the valves is by a plurality of motors controlled by a microprocessor.
U.S. Pat No. 5,151,091 to Danby et al. discloses a pumping device which alternately compresses and reforms a section of tubing.
U.S. Pat No. 5,055,001 to Natwick et al. discloses an infusion pump with spring controlled valves designed to open at a specific predetermined pressure.
U.S. Pat No. 3,489,097 to Gemeinhardt discloses a flexible tube pump having a unitary fixture operative to act as an inlet and outlet valve and a pumping body located therebetween, driven off an eccentric.
U.S. Pat No. 2,922,379 to Schultz discloses a multi-line pump having an inlet and an outlet valve mechanism and a pumping body located therebetween wherein both the inlet valve mechanism and the outlet valve mechanism are driven from a single cam.
U.S. Pat No. 3,359,910 to Latham discloses a cam driven pump having inlet and outlet valves driven from a single cam and a pump body driven by an eccentric co-rotating with the single cam.
U.S. Pat No. 4,239,464 to Hein discloses a blood pump having an inlet and outlet plunger serving as valves and a displacement plunger located therebetween.
U.S. Pat No. 5,364,242 to Olson describes a drug pump having at least one rotatable cam and a reciprocally mounted follower engaged with the cam in a tube which is compressed by the follower during rotation of the cam. In the embodiment disclosed there are three cams.
U.S. Pat No. 5,131,816 to Brown et al. discloses a infusion pump containing a plurality of linear peristaltic pumps and includes a position encoder mounted on the pump motor shaft to determine when the shaft has reached the stop position in the pump cycle.
U.S. Pat No. 4,950,245 to Brown et al. discloses a multiple pump which is individually controlled by a programmable controller within the pump.
U.S. Pat No. 4,273,121 to Jassawalla discloses a medical infusion system including a cassette and a deformable diaphragm and inlet and outlet windows which are occludable to pump the fluid contained in the cassette.
U.S. Pat No. 4,936,760 to Williams discloses a infusion pump adapted to use a special tube wherein the tube has diametrically opposed handles extending longitudinally thereon and wherein the handles are adapted to be gripped by pump actuators so as to deform the tube transversely by pulling or pushing on the handles.
U.S. Pat No. 5,092,749 to Meijer discloses a drive mechanism for actuating the fingers of a peristaltic pump having a jointed arm pivotally attached at one end to a drive member and at the other end to a fixed point on the base of the pump and a rotary cam actuator mounted on the base to urge against the arm and reciprocate the drive member.
U.S. Pat No. 4,850,817 to Nason et al. discloses a mechanical drive system for a medication infusion system comprising a cassette pump wherein inside the cassette a single cam drives the inlet and outlet valves as well as the pump mechanism.
U.S. Pat No. 5,252,044 to Raines discloses a cassette pump.
U.S. Pat No. 3,606,596 to Edwards discloses a drug dispensing pump.
U.S. Pat No. 3,518,033 to Anderson discloses an extracorporeal heart.
SUMMARY AND OBJECTS OF THE INVENTION
The instant invention provides for an infusion pump wherein the pump has a pumping body which consists of a v-shaped groove extending longitudinally along a pump assembly and has associated therewith a fixed, and a moveable jaw and a plurality of valves located at either end of the v-shaped groove or shuttle.
In operation, an operator such as a nurse or patient would commence infusion of a medicament by inserting a standard IV set tube into a tube loading orifice located on the front of the pump. Additionally, the operator would simultaneously insert a slide clamp which is associated with the tube into a appropriate slide clamp orifice located upstream, i.e. more toward the fluid source, of the tube loading orifice. The operator would then actuate a tube loading sequence in which a series of pawls and a moveable upper jaw would serve to seize the tube and draw it into a tubeway, part of which is comprised of the v-shaped groove and valves. As the loading cycle progresses the jaws and pawls close about the tube capturing the tube within the tubeway. Sequentially as the valves close to occlude the tube, the slide clamp would be moved to a position such that the slide clamp would no longer occlude the tube. Upon receipt of appropriate signals from associated electronics which would determine the pumping speed, allowable volume of air, temperature and pressure, the pump is actuated wherein fluid is drawn from the fluid source and expelled from the pump in a constant and metered amount.
Should the tube be misloaded into the tubeway or the tubeloading orifice, appropriate sensors would determine the existence of such a state and effect an alarm directed thereto.
At the end of the infusion, actuation by an operator would serve to automatically close the slide clamp and realease the tube from the pump.
The pump comprehends a variety of sensors directed to improve the safety of the infusion of medicament in addition to the sensors recited previously which provide information on the state of the fluid passing through the pump, the pump comprehends a variety of sensors operative to provide information regarding the state of various mechanical subassemblies within the pump itself. Among the sensors are devices directed to providing positional location of the shuttle or v-shaped slot aforementioned, valve operation, slide clamp location, misload detection, and manual operation of the tubeloading assembly.
The sensors relating to the state of the fluid being passed through the pump have themselves been improved with regard to accuracy. This has been accomplished by the development of the method of making contact between the sensor and the tube such that the contact is normal to the tube and the tube is placed in contact with the various sensors in such a way that there is neither a volumetric nor a stress gradient across the tube.
Therefore, it is a primary object of the invention to provide for an infusion pump capable to delivering an accurate volume of medicament using a standard infusion set.
It is another object of the invention to provide an infusion pump having a pumping shuttle and valves associated therewith, wherein the pumping shuttle and valves are mechanically synchronized.
It is a further object of the invention to provide an infusion pump having greatly improved accuracy whereby the output of the pumping member is linearized over the course of a pumping cycle.
It is another object of the invention to provide for a plurality of valves in an infusion pump such that the valves are adapted to occlude an infusion set tube while having a shape adapted to promote the elastic recovery of the tube when the valve is released therefrom.
It is an additional object of the invention to provide an infusion pump having enhanced resistance to medication errors by providing for an automatically loaded slide clamp associated with the infusion set.
It is a further object of the invention to provide, in the aforementioned infusion pump having a resistance to medication errors, a slide clamp sensor operative to sense whether the slide clamp aforementioned is opened or closed.
It is an additional object of the invention to provide for a synchronized, automatic closure of the slide clamp at all times when a free flow of medicament is possible.
It is an additional primary object of the invention to provide for an infusion pump capable of automatically loading a standard IV set therein.
It is a further object of the invention to provide for an infusion pump capable of sensing an incorrectly automatically loaded IV set and further capable of realeasing the set from the pump in a state operative to prevent free flow of medicament through the set.
It is another object of the invention to provide an autotubeloader assembly operative to automatically load and unload a standard IV set from an associated infusion pump.
It is an additional object of the invention to provide for a synchronization of the slide clamp state and the valve state such that when one of the valves is in an open state, the second of the valves is in a closed state and when both valves are in an open state, the slide clamp is in a closed state.
It is an additional object of the invention to provide for a partial cycle of the pumping member immediately subsequent to the tubeloading cycle, so as to ensure that the tube is properly seated in the pumping member aforementioned.
It is another object of the invention to provide a cam associated with the pumping member wherein the cam is operative to linearize the output of the pump.
It is a further object of the invention to provide for a variability of pumping speed over the course of a pumping cycle.
It is another object of the invention to provide a further linearization of pump output by varying the speed of the pumping member.
It is an additional object of the invention to provide a variability in pumping output over the course of an infusion by varying the speed of the pumping member.
It is a further object of the invention to provide for a hydrodynamic assistance in the elastic recovery of the tube during the fill portion of a pumping cycle.
It is another object of the invention to provide a pumping body having an aspect adapted to be assembled with other pumping bodies into a multiple channel pump having a single controller.
It is a further object of the invention to provide for a tubeloading assembly having pawls adapted to capture and restrain an IV tube within the pump.
It is another primary object of the invention to provide for a sensor housing and an actuation assembly associated with the housing adapted to place a sensor in substantially normal contact with the tube.
It is an additional object of the invention to provide for a sensor housing and an actuation assembly operative to place a sensor in contact with a tube such that the volumetric gradient across the tube beneath the sensor is essentially zero.
It is a further object of the invention to provide for a sensor housing and an actuation assembly operative to place a sensor in contact with a tube such that the stress gradient of the tube beneath the sensor is essentially zero.
It is another object of the invention to provide for a single datum body operative to fix the relative location of the various elements within the pump.
It is a further object of the invention to provide for a plurality of shafts associated with the single datum body and cooperative therewith to fix the relative location of the various elements of the pump.
It is an additional object of the invention to provide a compact means for pumping a medicament.
It is a further object of the invention to provide for a fluid seal barrier operative to prevent fluid ingress to various electrical components of the pump.
It is another object of the invention to provide for a case having a geometry operative to enforce a downward orientation of the tube in those areas exterior to the pump.
It is a further object of the invention to provide for manual means for actuating the automatic tube loading feature.
These and other objects of the instant invention will become apparent in the detailed description of the preferred embodiment, claims and drawings appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the complete pump assembly.
FIG. 2 is an exploded view of the pump sub-assembly.
FIG. 2A is an exploded view of the motor mounts and pump drive motor.
FIG. 3 is an isometric view of the chassis or datum body with the associated datum shafts.
FIG. 4 is an isometric view of the index wheel and the associated sensor.
FIG. 5 is a face-on plan view of the pump drive cam.
FIG. 6 is an isometric view of the valve cam lands on the main drive cam.
FIG. 7 is a graph showing the relation between linear displacement of the shuttle and volumetric displacement of the tube when there is no linearization of the fluid output.
FIG. 8 is an isometric view of the downstream platen.
FIG. 9 is a graph of displaced volume of the tube versus cam angle when the cam provides a linearizing correction to the pump displacement.
FIG. 10 is a cross-sectional view substantially along line A--A of FIG. 1.
FIG. 11 is an isometric view of the rear of the shuttle platen and shuttle.
FIG. 12 is an exploded view of the pump motor encoder.
FIG. 13 is an isometric view of the valve sub-assembly.
FIG. 14 is an exploded view of the valve sub-assembly as shown in FIG. 13.
FIG. 15A is an isometric view of substantially the rear and side of one of the valves.
FIG. 15B is an isometric view showing substantially the bottom or tube-facing side of one of the valves.
FIG. 16 is an exploded view of the tubeloader sub-assembly.
FIG. 17 is an isometric view of the upstream platen showing the tube-present sensor in contact with a tube.
FIG. 18 is an assembled view of the tubeloader sub-assembly.
FIG. 18A is a plan view of the downstream platen showing a pawl in engagement with a tube.
FIG. 18B is a plan view of a tubeloading pawl.
FIG. 19 is an exploded view of the tubeloader camshaft.
FIG. 19A is an assembled view of the tubeloader camshaft and tubeloader motor.
FIG. 20 is an exploded view of the tubeloader motor and encoder.
FIG. 21 is a plan view of the sensor housings wherein shadow-views of the open and closed positions thereof are included.
FIG. 22 is an exploded view of the downstream sensor housings.
FIG. 23 is an exploded view of the upstream pressure sensor housing.
FIG. 24 is an isometric view of the air detector housing as connected to the pressure sensor housing.
FIG. 25 is an isometric view of the slide clamp loader sub-assembly.
FIG. 26 is an exploded view of the slide clamp loader sub-assembly.
FIG. 27 is an isometric view of the slide clamp.
FIG. 28 is an isometric view of the slide clamp sensor and the associated upstream platen.
FIG. 29 is an isometric view of the downstream platen with the temperature sensors in an exploded view therebeneath.
FIG. 30 is an isometric view of the pump housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment of the instant invention, pump assembly 10 consists of a plurality of sub-assemblies as shown in FIG. 1, which perform various associated functions in concert with the pump sub-assembly 12.
THE PUMP SUB-ASSEMBLY
The pump sub-assembly, as seen in FIG. 2, comprises a housing 14 to which various associated elements are affixed. Housing or chassis 14 is preferably made of a molded plastic so as to speed assembly and fabrication thereof. Chassis 14 further comprises an aft plate 16 formed integral with chassis 14, wherein aft plate 16 has defined therein a plurality of apertures.
Motor shaft aperture 18 is substantially centrally located in aft plate 16 and is operative to allow pump motor shaft 20 to pass therethrough. Aft plate 16 further has defined therein pump motor mounting holes 22 which are spaced radially outwardly from pump motor shaft aperture 18. These holes serve to locate accurately pump motor 24 with respect to the chassis 14. Abaft of the aft chassis plate 16 are a plurality of mounting wings 26 which are operative to securely fix the chassis to the downstream platen 500 located on the downstream side of the chassis 14 and the upstream platen located on the upstream side of the chassis 14; wherein upstream denotes the side of the assembly 10 which is located closer to the fluid inlet thereto and downstream denotes that side of the assembly 10 which is located closer to the fluid outlet therefrom.
As seen in FIGS. 2 and 3, chassis 14 further defines a plurality of apertures substantially transverse to the pump motor axis 32 which is defined as being coaxial with pump motor shaft 20.
Set before wings 26 is an upstream fluid barrier tab 27A and a downstream fluid barrier tab 27B which are cooperative with the slide clamp actuator support and downstream platen aft plate 580 to provide a fluid shield between the fluid source (IV tube or set) and the associated electrical apparatus located abaft of the combined fluid stop assembly composed of the three elements aforementioned.
These transverse ports or apertures serve to allow access to various mechanisms interior to the chassis as shall be subsequently described and also provide a single datum point to fix the relative locations of the various sub-assemblies which depend from the various parts associated with these apertures. This style of manufacture provides an accurate and robust means of fabricating the pump assembly 10 whilst providing an economy of measured points requiring adjustment to ensure correct operation of the device. These apertures are reproduced on both the upstream sidewall 32 and downstream sidewall 34 of the chassis 14.
The first such aperture set is the valve pivot shaft ports 36, 38 which serve to support and locate the valve pivot shaft 410 relative to the chassis 14.
The second such aperture set supports the tubeloader camshaft 510 and is denoted as the tubeloader camshaft ports 40, 42.
The third such aperture serves to support and locate, relative to the chassis 14, the tubeloader layshaft 512 and is denoted the tubeloader layshaft apertures 44, 48.
The fourth such aperture set serves to allow access of the pump valve cam actuators 422, to the interior of the chassis 14, and is denoted valve actuator ports 46, 50.
The chassis defines a cavity 52 therein which serves to house the pump drive sub-assembly as shown in FIG. 2.
The pump motor 24 is the aftmost element of this sub-assembly. This motor is preferably a variable speed d.c. motor having an internal speed reduction gearbox 54 which in the preferred embodiment provides a 64 to 1 reduction of motor speed.
The output of the pump motor gearbox 54 is pump shaft 20. Pump shaft 20, as aforedescribed, extends axially into cavity 52 via pump shaft aperture 18.
Interior to cavity 52 and in circumferential engagement with pump shaft 20 is drive collet 56. Drive collet 56 has a further mechanical engagement with pump shaft 20 via a combination of a plurality of collet flats 58 which are impressed on shaft 20 so as to provide a polygonal surface operative to engage grubscrews 60 which thread through collet 56 via threaded grubscrew holes 62 which are situated radially and transversely to shaft axis 32 though drive collet 56. Drive collet 56 further has defined therein a drive pin aperture 61 which is longitudinally parallel and radially outwardly from pump shaft axis 32 and is operative to support and drive fixing pin 63 in concert with movement of collet 56 and motor shaft 20.
Surmounting drive collet 56 and coaxial therewith, is the pump index wheel 64, as shown in FIG. 4.
Index wheel 64 is operative, with associated sensors, to determine the location of the pump elements. The index wheel has defined therein a first radial slot 66 and a second radial slot 68, which are about the periphery of index wheel 64. These two slots are located 180 degrees away from each other.
The index wheel 64 is comprised of a wheel disc portion 70 and a hub portion 72 wherein the hub portion 72 is radially interior to and substantially forward of the wheel disc portion 70. The hub portion 72 of the index wheel 64 is connected to the wheel disc 70 by a plurality of webs 74 extensive from the hub 72 to the disc 70. The hub portion further comprehends a cylindrical longitudinally extensive portion 76 and a transverse annular portion 80, wherein the cylindrical portion 76 extends forward of disc plate 70 and the annular portion 80 extends radially inwardly from the cylindrical portion 76 to the motor shaft 20.
Annular portion 80 further defines a motor shaft port 82 which is coextensive with the motor shaft 20 and a fixing pin port 84 located outward from the motor shaft port 82 and parallel therewith. The motor shaft port 82 allows the motor shaft 20 to pass through the index wheel 64 while the fixing pin port 84 enforces co-rotation of the motor shaft 20 and the index wheel 64 when fixing pin 63 is inserted therethrough.
Hub portion 72 has defined therein two access ports 86, 88 which allow access to the collet grub screws 60. These hub access ports 86, 88 are accessible from the exterior of the chassis 14 via set screw access port 90.
Surmounting the index wheel 64 and forward of the annular portion 80 thereof, resides the pump drive cam 100 shown in FIGS. 5 and 6. Pump cam 100 consists of a front face area 102 and a rear face area 104.
The front face area 102 further comprises an exterior cam land 106 and an interior cam land 108. The exterior and interior cam lands 106, 108 are cooperatively formed so as to provide positive actuation of pump cam follower 110. The shape and aspect of the two lands 106, 108 are non-linear with respect to the variation of distance of various parts of the lands 106, 108 from the pump shaft axis 32.
The rotary to linear motion conversion, as realized by cam 100, introduces a non-linear error as shown in FIG. 7, in the volumetric output of the pump with respect to time (as measured in shaft encoder counts). The aspect of the interior land 108 and the exterior land 106 act cooperatively to achieve a first order correction of this error so as to linearize the output of the pump with respect to volume. This is achieved by an alteration of the change in radial displacement of the cam lands 106, 108 with respect to the motor shaft axis 32 as aforedescribed so as to minimize the effects of angular error on the accuracy of the pump.
Specifically, to a first approximation the cam executes an inverse sine function as determined by the radial distance of the lands 106, 108 from the shaft axis 32.
As can be seen in FIG. 7, the characteristic volumetric output of a tube between two v-grooves executing a relative motion is a non-linear function of displacement of the grooves. This shuttle 200 structure is recited in the Patent to Danby et al, U.S. Pat. No. 5,150,019 corresponding to U. K. Pat. No. 2,225,065 as aforerecited.
As seen in FIG. 5, the alteration of the cam profile, as herein described, provides a markedly more linear output by increasing the shuttle speed during the middle of the stroke (between 30 degrees and 60 degrees of cam angle) and decreasing the speed of the shuttle 200 at the beginning and end of the stroke.
As seen in FIG. 9, this variable linear velocity provides a significantly more linearised volumetric output wherein output is essentially linear between 30 degrees and 70 degrees of cam angle. The variation between upward and downward strokes being due to use of simple radii within the cam.
Referring now to FIG. 5, which depicts cam lands 106, 108 in face on aspect, shows the various cam positions clearly. As shown, there are two primary pumping portions 110, 112 corresponding to downward and upward movements of the shuttle 200. Also seen are dwell portions 114, 116 which allow the inlet and outlet valves to be actuated as shall be subsequently described.
Further linearization of output is controlled electronically via a position sensitive speed control which shall be subsequently described.
Referring now to FIG. 6, the reverse side 118 of cam 100 is shown. As can be seen, there are two concentric valve cam lands 120, 122. In this embodiment, the inner valve cam land 120 drives the upstream (inlet) valve and the outer valve cam land 122 drives the downstream (outlet) valve. As can be seen, at no time are the inlet and outlet valves simultaneously operated, thereby positively preventing a free flow condition of medicament. The duration and dwell of the valve cam lands 120, 122 are arranged to provide for proper valve synchronization although the inner valve cam race 120 and the outer valve cam race 122 are at differing radii as measured from the pump shaft axis 32.
The rear hub 118 of the drive cam 100 also defines a cam fixing in port 124 which serves to lock the relative location of the drive cam 100 to that of the drive collet 56, via fixing pin 63 and, therefore, to that of motor shaft 20.
Motor shaft 20 is capped by nosebearing 126 which is located immediately afore cam 100. The motor shaft 20 passes through cam 100 via cam motor shaft port 127 defined centrally in the cam 100. Surrounding cam motor shaft port 127 is the forward cam annulus 128 which serves as a lash adjustment for cam 100 float along motor shaft 20 between collet 56 and nosebearing 126.
In the preferred embodiment of the instant invention, nosebearing 126 is a roller type bearing. Nosebearing 126 fits into the nosebearing race 132 in the rear side of the shuttle platen 130.
Shuttle platen 130 is affixed to the forward chassis surface 53 by a plurality of fasteners which connect shuttle platen 130 to forward chassis surface 53 via a plurality of fastener ports 134 defined in the shuttle platen 130 and a second plurality of fastener ports 136 defined in the forward surface 53 of chassis 14. The relative location of the shuttle platen 130 with respect to the chassis 14 is defined by register pins 138 in the forward chassis surface 53 for which corresponding shuttle platen register ports 140 are defined in the back surface of shuttle platen 130.
Shuttle platen 130 additionally has defined therethrough a shuttle drive cam follower throughport 142 which is defined to allow the shuttle actuating cam follower 144 access to the shuttle drive cam 100. The front surface of the shuttle platen 146 defines a plurality of channels 148 in which the shuttle 200 resides. These shuttle platen channels 148 are of a low friction finish so as to allow free movement of the shuttle 200 thereacross. The front shuttle platen surface 146 further defines side rails 150, 152 which are operative to limit torsional movement of the shuttle 200 as the shuttle 200 performs its motion.
Throughport 142, as aforementioned, allows passage therethrough of cam follower 144. Cam follower 144 is an annular roller bearing of such dimension as to allow motion thereof between the pump drive cam lands 106, 108. The shuttle drive cam follower 144 rides on the shuttle drive pin 154 which resides in the shuttle drive pin recess 156 so as to be flush with the front surface 201 of the shuttle 200. The drive pin 154 further comprises a head 158 which is operative to spread drive forces evenly to the shuttle 200 and furthermore, provides an adequate peripheral area for effective press-fit connection thereof to the shuttle 200.
The shaft portion 160 of the shuttle drive pin 154 extends through the shuttle 200 via drive pin port 202 defined therein, and is sufficiently extensive to pass through the shuttle platen 130 and engage shuttle drive cam follower 144.
The shuttle platen 130 completes the datum or register point set based on measuring locations throughout the pump 10 from the chassis 14 and associated components.
The shuttle platen side rails 150, 152 have forward surfaces 162, 164 upon which are located a plurality of datum surfaces 168, 170. These datum pads 168, 170 are operative to fix the distance from shuttle 200 to that of the upper jaw 220 of the pump assembly. This distance, experiment has found, must be maintained at 0.2 mm. This distance is critical due to the pump geometry wherein, as shown in FIG. 10, the initial deformation of the tube section acted upon by the pump is dependent upon the lateral distance between the moving shuttle indent 204 and the fixed, or non-moving, indent 206 so as to provide a deformation of the initially circular tube cross-section to an equiangular quadrilateral cross-section. This initial deformation bears on the amount of closure of the pump tube lumen 6 as the pump cycles through its stroke; as the stroke throw is fixed by the lift of the drive cam lands 106, 108. The amount of deformation of the pump tube lumen fixes the volumetric output of the pump, per stroke or cycle thereof.
The lower portion of the side rails 150, 152 are laterally extensive beyond the shuttle 200. The forward surfaces of the lower lateral extension 172, 174 have associated therewith a second set of datum pads 176, 178 which are operative to fix the distance of the lower fixed jaw 222 from the shuttle 200. The function of these lower jaw datum pads 176, 178 are similar to the function of the upper datum pads 168, 170 as aforedescribed.
Shuttle 200 further comprises, as shown in FIG. 11, a rear side 207 of the shuttle 200. The rear shuttle side 207 further has defined therein a plurality of slide rails 206. The slide rails 206 are operative to provide for a minimization of friction betwixt the shuttle 200 and the shuttle platen 130. The slide rails 206 are in substantially full face engagement with the channels 146A of the shuttle platen 130, and provide a fixation of both longitudinal and lateral lash between the shuttle 200 and the shuttle platen 130.
The front surfaces 201 of the shuttle 200 defines a pump groove aperture 204. This aperture, or indent 204, is of a substantially v-shaped cross-section and has a rounded interior corner 211 so as to provide for a conformation of the tube 5 and the groove aperture 204 when the tube 5 is loaded therein.
The rear surface 207 of the shuttle 200 further has defined therein a plurality of pockets 203 arranged in a substantially vertical array. These pockets 203 are adapted to contain a plurality of magnets which are cooperative with a magnetic sensor 322 to sense the linear position of the shuttle 200.
SENSORS ASSOCIATED WITH THE PUMP SUB-ASSEMBLY
The pump sub-assembly, as previously described, has associated therewith a plurality of sensors which are operative to provide information as to the function and location of the various elements thereof.
The aftmost of the sensors is the drive motor shaft encoder 300. This sensor comprises an encoder flag wheel 302 which is attached to the armature shaft 303 of motor 24. The pump motor flag wheel 302 has, in the preferred embodiment of the instant invention, twelve flags 304 extending radially outwardly from the hub 306 thereof.
These flags 304 act in concert with two optical switches 308, 310 to fix the location of the armature shaft 303 of the pump drive motor 24. The switches 308, 310 further consist of a light emitting diode and a photocell as shown in FIG. 12. The arrangement of the optical switches 308, 310 allows for a first switch 308 to sense the edge 311E of flag 304, and the second switch 310 to sense the middle 311M of a subsequent flag 304. This arrangement allows for greater resolution of motor shaft position and direction as read by the encoder 300.
In this presently preferred embodiment, the resolution of encoder 300 is 1/3072 of a rotation of motor shaft 20. The encoder assembly 300 resides in a pump motor encoder support collar 312 which is a sliding fit over motor housing 24 and is affixed thereto by pinch clamp 313.
The motor encoder 300 senses armature shaft 303 rotation directly. However, as there are mechanisms resident between the armature shaft 303 and the shuttle 200, further sensors are desired.
Moving forward along motor shaft axis 32, one returns to index wheel 64. As aforementioned, index wheel 64 has a plurality of circumferentially coextensive radially disposed slots 66, 68. Associated with these slots is an index wheel optical sensor 314. This sensor comprises a light emitting diode 315 and an optical sensor or switch 316.
The index wheel sensor 314 is cooperative with the index wheel 64 and the slots 66, 68 therein to provide positional information of the rotational location of the pump motor shaft 20.
In operation, the index wheel sensor 314 acts in concert with the pump encoder 300 to provide this positional information as well as directional information of the motor shaft 20. The index wheel sensor times the passage of each of the slots 66, 68 past the index wheel switch 314. The two slots 66, 68 are of differing widths so as to provide information as to whether the shuttle 200 is beginning the upstroke thereof or the downstroke thereof, where a first width indexes the upstroke and a second width indexes the downstroke.
Associated with the shuttle 200 itself is a linear gross position sensor 320. This sensor comprises a linear position Hall effect sensor 322 and a plurality of magnets 324, 326. Shuttle position sensor magnets 324, 326 present opposite poles to the shuttle Hall switch 322, so as to provide a field gradient operative to provide an indicium of the linear position of the shuttle 200.
The combination of the encoder 300 and the other associated sensors aforementioned, provide inputs to a control mechanism, which may operate more than one pump so as to accurately control the speed of variable speed motor 24, the primary feature provided by such speed control is a temporal variability of the output of the pump 10. Additionally, such speed control allows for an electronically controlled linearization of the pump output per individual stroke as well as improving the time integrated output of the pump 10. In the preferred embodiment the per stroke linearization of output is realized in combination with the drive cam 100 as aforementioned. The time integrated output of the pump is made more accurate by the pump speed being markedly increased at such points as would provide for a discontinuity in the output profile as measured with respect to time so as to minimize the effects of such discontinuities in output.
As a manufacturing convenience, both the shuttle linear position sensor 320 and the index wheel sensor 314 are electrically connected to the associated signal processing electronics by a shared printed circuit strip denoted as the pump sensor circuit strip.
THE VALVE SUB-ASSEMBLY
The valve sub-assembly is shown, removed from the associated pump sub-assembly, in FIGS. 13 and 14. The valve sub-assembly consists of a valve pivot shaft 410 which is carried by chassis 14 by being supported thereby in pivot shaft ports 36, 38. Valves 412, 414 pivot about this shaft 410 and are supported thereon by valve pivot bearings 416, 418 which are clearance therefor fit onto pivot shaft 410 and into valves 412, 414.
The two valves 412, 414 are denoted individually as the upstream valve 412 and the downstream valve 414. The upstream valve 412 comprises a pivot bearing aperture 420 adapted to accept thereinto the upstream valve pivot bearing 416 and thereby pivot about valve pivot shaft 410. The upstream valve 412 further comprises an upstream valveshaft aperture 422 which is located axially parallel to the pivot shaft 410 and substantially vertically displaced therefrom. The upstream valveshaft aperture 422 is adapted to slidingly receive the upstream valveshaft 424 therein. The upstream valveshaft 424 extends laterally from the upstream valve 412 and is disposed to enter into the chassis 14 via upstream valveshaft aperture 48. The upstream valve actuator shaft 424 is substantially cylindrical and has defined therein an outer cam race cutout 426. The outer cam race cutout 426 is operative to allow the upstream valve actuator 424 to clear the outer or downstream valve race 122 defined on cam 100. The upstream valve actuator 424 terminates in a cam follower nub 428, which is adapted to support the upstream valve roller cam follower 430. The upstream cam follower 430 is, in the preferred embodiment, a roller bearing so as to provide rolling contact between the valve cam land 120 and the upstream valve actuator 424.
Returning to valve 412 or 414, the valve further comprises a valve blade 432, as shown in FIG. 15B, which is of a substantially v-shaped cross-section wherein the first side of the valve blade 434 and the second side of the valve blade 436 subtend an angle of approximately 90 degrees therebetween and also define a 0.5 millimeter rounded vertex 438. The combination of the included angle and the rounded vertex 438 provide for an optimal arrangement between the conflicting necessities of ensuring that the tube 5 is sealed during the appropriate part of the pump cycle while simultaneously ensuring that the tube will reform into an accurate approximation of its initial shape when the valve blade 432 is lifted from the tube 5.
The rounded vertex 438 of the valve blade 434 defines a 0.5 mm curvature. This curvature, in combination with the 0.7 mm distance between the valve blade 434 and the valve anvil 570, to be discussed subsequently, provide for an optimization of the two necessities of ensuring sealing while providing for elastic recovery of the tube during the appropriate part of the pump cycle.
Additionally, the tube 5, due to its deformation by the shuttle 200 in combination with the upper and lower jaws 220, 222, comprehends a partial vacuum within that portion of the tube lumen 6 located adjacent to shuttle 200, and the opening of the inlet valve 412 with the positioning of the shuttle 200 providing conditions conducive to assist hydrodynamically the elastic recovery of the tube section below the inlet valve 412.
The upstream valve body 412 further comprises a valve lifting tang 440 which is cooperative with a valve loading cam to raise the valve during the tube loading operation. The valve body 412 comprehends a valve spring seat tang 442 which extends upwardly from the distal end 444 of the valve blade arm 435. The valve spring tang 442 defines a valve spring retainer port 446 which is operative to provide support for the distal end 448 of the valve spring retainer 450. The valve spring retainer 450, in combination with valve spring tang 442, serves to completely capture the valve spring 452 therebetween. The valve spring retainer 450 comprises a substantially c-shaped base 454 which is operative to slidingly fit about the tubeloader layshaft 512, to be described subsequently. The valve spring retainer base 454 is designed to permit oscillatory motion of the retainer 450 about the aforementioned tubeloader layshaft so as to accommodate the motion of the valve 412, 414.
The downstream valve 414 is resident on the valve pivot shaft 410 adjacent to the shuttle 200. The downstream valve 414 is essentially a mirror image of the upstream valve 412 about a plane transverse to the pivot shaft 410 and displays all of the associated elements of the upstream valve 412 in a reversed orientation as seen in FIG. 14. The downstream valve actuator arm 456 is shortened to align the downstream valve cam follower 458 with the outer valve cam land 122.
The action of the two valves 412, 414 is such that at no time during the pump cycle are both valves open at the same time. Furthermore, as both the valves 412, 414 and the shuttle 200 are driven by a single motor 24 and off of a single drive cam body 100, exact synchronization of the valves 412, 414 and the pump shuttle 200 is positively achieved by wholly mechanical.
SENSORS ASSOCIATED WITH THE VALVE SUB-ASSEMBLY
Associated with each of the valves 412, 414 is a valve motion sensor 328, 330. Each of these valve motion sensors 328, 330 is actuated by a magnet 332, 334 which is inserted into a valve sensor magnet port 332A, 334A in the outboard end 444 of the valve blade tang 435. Located therebelow, in the associated valve anvil and outwardly located therefrom is the valve motion sensor Hall switch 328, 330 which, with associated software, linked to the output of the valve sensor switches 328, 330 to that of the drive motor encoder 300, serves to stop the pump 10 and activate an alarm if a valve 412, 414 is not operating correctly. This is essentially accomplished by comparing the expected output of the appropriate valve sensor 328, 330 with the expected signal therefrom at a specific motor 24 and drive cam location.
Residing outwardly from each valve 412, 414 and separated therefrom on valve pivot shaft 410 by tube present arm spacers 460 is the tube present sensor arm 340. The upstream tube present sensor, in conjunction with the downstream tube present sensor, serves to determine the actual physical presence or absence of the IV tube in the pump 10. Each of the tube present sensors 332, 334 comprises an annular bearing or tube sensor pivot 336 which surrounds and rides on the valve pivot shaft 410. The tube sensor arm web 338 extends outwardly from the tube sensor pivot 336 and serves to support the tube sensing blade 340 which extends forwardly from the sensor arm web 338 and the tube sensor flag 342 which extends substantially rearwardly from the sensor arm web 338. The sensor blade 340 comprises a downward extension thereof so, when installed, the sensor blade tip 344 resides on the appropriate valve anvil. The insertion of a tube 5 between the blade tip 344 and the valve anvil will, therefore, serve to raise the blade 340 away from the anvil 570 and cause the sensor arm to pivot about the valve pivot shaft 410. This serves to lower the rearwardly extending valve sensor flag 342 thereby interrupting the tube present sensor optical switch 346 by the flag 342 moving into the interstice 348 of the tube present sensor optical switch 346 and interrupting the light beam extending thereacross, as shown in FIG. 17. A return spring 350 serves to bias the tube sensor arm to a position wherein, should the tube 5 not be present, the tube sensor blade tip 344 rests on the associated valve anvil.
THE TUBELOADER SUB-ASSEMBLY
As shown in FIGS. 18 and 19, the tubeloader sub-assembly utilizes two shafts associated with chassis 14. These two shafts are the tubeloader camshaft 510 and the tubeloader layshaft 512. These two shafts 510, 512, in conjunction with the valve pivot shaft 410, provide the primary datum points for the relative locations of the various assemblies and associated elements thereof, throughout the pump. The locations of these three shafts is shown in FIG. 3. By referencing all points in the pump to these shafts, and thereby to the chassis 14, the pump structure can be indexed without the necessity of a wide variety of precision machined parts, whilst maintaining the requisite accuracy of the completed assembly.
The tubeloader layshaft 512 provides an axis about which all parts which are driven by camshaft 510 rotate save the values and slide clamp. Moving upstream along layshaft 512, the most outboard of the elements associated therewith are the downstream tubeloader pawls 514. The downstream tubeloader pawls each consist of an annular body 516 which is adapted to ride on the tubeloader layshaft 512 and is fixed thereto by the associated helical pin 518 which extends through the pawl annulus 516 and the layshaft 512 and into the opposed area of the annulus, thereby positively fixing the associated pawl 514 to the layshaft 512. Extending forward of the pawl annulus or collect 516 is the pawl arm 518. The pawl arm has a substantially linear section 520 and an arctuate section 522 extending outwardly and downward from the pawl collet 516.
The shape of the arctuate section 522 of the pawl 514 is such that when the pawl 514 is fully lowered, the tube 5 is firmly wedged against the downstream platen 500, thereby encircling the tube 5 between the pawl 514 and platen 500.
In greater detail, the interior angled surface 526 of the pawl tip 524 intersects the tube 5 at an approximately 45 degree angle with respect to horizontal and is thereby operative to urge the tube 5 downwardly and inwardly against the tube detent 501 in the downstream platen 500.
The pawl tip 524 encompasses a plurality of areas. The interior side of the tip defines a horizontal tube engaging surface 525, an angled tube engaging surface 526, a vertical tube capture surface 528, a horizontal tube misload activating surface 530 and an externally facing tube rejection surface 532 on the exterior side thereof; and the aforementioned surfaces are disposed on the periphery of the pawl tip. These surfaces operate in concert with the downstream platen 500.
The design comprehended by tubeloader pawl tip 524 is repeated on the lower edge of the upper pump jaw 220 and serves an identical function as shall be described herein.
When an operator is loading a tube into pump 10 and actuates the tubeloading cycle by means of an appropriate actuator, or a control button or switch, the tubeloader pawl tips 524 are lowered over tubeway 8 which, in combination with the lowering of the upper jaw 220, serves to completely close off the longitudinal slot or opening on the outboard side of tubeway 8. Should a tube be partially inserted into the pump 10, yet remain wholly outside the tubeway 8, the tube reject surface 532 will operate in combination with nesting slots 582, which are also resident on lower jaw 222, to expel the tube 5 from the pump. In the event of a tube 5 being loaded partially within the tubeway and partially exterior thereto, the misload activating surface 530 will serve to pinch the tube 5 between the misload activating surface 530 and the associated section of either the downstream platen 500, the upstream platen 800, or the lower jaw 220 and thereby actuate a misload detection as described herein. Another possibility contemplated in the design of the pawl tip 524 is wherein the tube 5 is inserted into the tubeway 8 yet has not been fully drawn into contact with the tubestops 576. In this event, the tube capture surface 528 will serve to draw the tube 5 rearwardly and into contact with the tubestops 576 and thereby execute a correct loading of the tube. The combination of the tube reject surface 532, the misload activating surface 530 and the tube capture surface 528 provides for a sharp discontinuity between the various possibilities for loading scenarios aforementioned.
The vertical tube capture surface 528 additionally works in combination with the angled tube engaging surface 526 and the horizontal tube engaging surface 525 to hold the tube 5 securely against the tube stops 576 and to provide for a deformation of the tube 5 by co-action of the angled surface 526, the horizontal surface 525 and the tube stop 576 to lock the tube securely into the tubeway 8 when the longitudinal tubeway aperture is closed as well as to provide substantially full face engagement of the tube 5 with the associated sensors
The downstream platen 500, or the corresponding upstream platen 800, are preferably constructed of a molded plastic such as glass filled polyphenylsulfide. The downstream platen 500 serves a variety of functions.
The tubeloader bearing cup 502 provides for a mounting area for the tubeloader powertrain.
Gearbox sidewalls 503A serve to house the tubeloader gearset 560 which comprises two helical gears 562, 564 in a perpendicular arrangement so as to transfer rotation from a fore and aft mounted tubeloader motor 550 to the transverse tubeloader camshaft 510. The downstream platen 500 gearbox housing further comprehends a camshaft bushing race 566 which serves to support the downstream camshaft bushing 568 in which the camshaft moves. The forward section of the downstream platen 500 comprises the downstream valve anvil 570 as well as the temperature sensors ports 572 and the lower air sensor transducer housing 574. Abaft of these areas are a plurality of tube stops 576 which serve to support the tube 5 rearwardly so as to provide controlled conformation of the tube 5 when in the loaded condition.
Abaft of the tube supports 576, the downstream platen 500 further provides for the downstream sensor pivot slot 578 which, in concert with associated apparatus, serves to correctly locate the downstream sensor array as shall be described. The rear barrier wall 580, cooperative with chassis 14, serves as a fluid barrier between tube 5 and the electrical components behind the rear barrier wall 580. The rear barrier wall 580 is affixed to the chassis 14 by fasteners and additionally serves a fastening point for the downstream tube present sensor switch 346.
Returning to the foreward edge of the downstream platen 500, a plurality of tubeloader pawl nesting slots 582 are seen. These pawl slots 582, in combination with the tubeloader pawls 514 and the chamfered forward edge 584 of the downstream platen 500, serve to promote a correct loading of the tube 5 into the pump 10 by allowing the pawls 514 to lift and push the tube rearwardly against the tube stops 576. Outward of the outermost of the pawl nesting slots 582, a tube retaining detent 584 serves to retain the tube 5 in a position adapted to be captured by the pawls 514 during initial placement of the tube 5 within the tubeway 8 defined by the raised pawls 514 and the downstream platen 500 when the tubeloading assembly is in a state allowing the tube 5 to be loaded.
As aforedescribed, the tubeloader motor 550 drives, by means of a plurality of gears, the tubeloader camshaft 510. The tubeloader motor 550 is a d.c. motor. The tubeloader motor 550 further comprises a speed reduction gearset 534 operative to provide sufficient torque to rotate camshaft 510 against the drag placed thereon by the components in contact therewith and resident on layshaft 512.
The tubeloader motor shaft 536 extends forwardly from the tubeloader motor 550 and passes through the tubeloader motor mount 538 by way of a central aperture 540 therein.
The tubeloader motor shaft 536 has a flat 542 defined therein which is operative to provide a seat for the tubeloader drive gear setscrew 544 which is inserted through a threaded setscrew aperture 546 in the tubeloader drive gear 562 and thereby fix the rotation of the tubeloader drive gear 562 to that of the tubeloader motor shaft 536.
The tubeloader drive gear 536 is a helical cut gear wherein the teeth thereof are about the circumferential periphery thereof. These teeth engage corresponding teeth on the face of the tubeloader camshaft gear 564, thereby allowing perpendicular actuation of the transversely mounted camshaft 510 by the longitudinally mounted tubeloader motor 550.
The tubeloader camshaft gear 564 is releasably engaged with the camshaft 510 by means of a slideable engagement pin 588.
The camshaft clutch pin 588 is cooperative with a clutch slot 590 on the rear or inboard facing face of the camshaft gear 564. The clutchpin 588 resides transversely to the camshaft 510 in a longitudinal clutchpin slot 592 defined through the camshaft 510. A longitudinal actuator pin 594 coaxially emplaced within the camshaft 510 and in endwise contact with the clutchpin 588 serves to selectively insert and allow the withdrawal of the clutch pin 588 from engagement with the clutch slot 590 on camshaft gear 564. A biasing spring 596 is located within the camshaft 510 and in opposition to the longitudinal actuator pin 594. The outboard end 598 of the actuator pin 594 is rounded to allow sliding contact therewith by the associated component.
Handwheel 600 provides a housing for a pivoting clutch tab 602 which comprises on its inboard facing surface a clutch cam 604 which is in sliding engagement with the outboard end 598 of actuator pin 594. The clutch tab 602 is interior to handwheel 600 and is hinged thereto by a clutch tab pivot pin 606. In operation, actuation of the clutch tab 602 by tilting same about clutch tab pivot pin 606 will cause the clutch cam 604 to impinge on and depress the outboard end 598 of the actuator pin 594 causing the actuator pin 594 to move inwardly against clutch biasing spring 596 and moving clutch pin 588 inwardly and out of contact with the clutch slot 590 in camshaft gear 564, thereby allowing the camshaft 510 to be freely rotated manually by means of handwheel 600 without rotating the camshaft gear 564.
The camshaft 510 is one of the three primary datum shafts resident in the pump 10. The camshaft supports two compound cams denoted as the downstream cam 610 and the upstream cam 620.
The downstream and upstream cams 610, 620 comprise, moving outwardly from chassis, a camshaft deadstop 612, 622, a tubeloaded pawl cam 614, 624 which is itself a compound cam, and valve loading cam 618, 628.
The camshaft deadstops 612, 622 work in cooperation with the chassis rotator stops 28, 30 to provide a positive stop for camshaft rotation. Associated electronics sense the stall condition of the tubeloader motor 550 and interrupt power thereto when the camshaft deadstops 612, 622 are in contact with the chassis rotator stops 28, 30 during an initial indexing cycle of the tubeloader assembly, thereafter the tubeloader 550 in combination with the tubeloader encoder 702, 704, 705 will back-count from the rotator stops 28, 30 and under control of associated software interrupt power to the tubeloader motor 550 prior to the deadstops 612, 622 making contact with the chassis rotator stops 28, 30.
Moving outwardly from the camshaft deadstops 612, 622, the tubeloader pawl cams 614, 624 serve to actuate the tubeloader pawls 514. Additionally, each of the tubeloader pawl cams 614, 624 has a locking surface 616, 626 which serves to activate a second, rigidly affixed lifting follower associated with the tubeloader layshaft 512 so as to provide a positive fixation of the associated elements when the layshaft 512 reaches the end of its travel.
Outward of the pawl cams 614, 624 are the valve loading cams 618, 628. These cams serve to lift the valves 412, 414 out of the tubeway 8 during the loading operation. The valve loading cams accomplish this lift in cooperation with the valve loading tangs 440 as aforedescribed.
Outermost on the camshaft 510 reside the sensor arm cams 630, 632. The downstream sensor arm cam 630 comprises a single surface and is operative to raise or lower the downstream sensor arm.
The upstream sensor arm cam 632, however, is a compound cam having a sensor arm actuating surface 634 and, located outwardly therefrom and integral therewith, the slide clamp loader crank 650.
All of the cams associated with camshaft 510 are fastened thereto by helical pins driven transversely through the hubs of the various cams and through the camshaft 510.
The tubeloader layshaft 512 supports all of the loading members associated with placing the tube 5 in the tubeway 8. Additionally, the layshaft serves to pivotally support other elements which are driven at differing rates than the tubeloader pawls 514. Innermost along layshaft 512, wherein innermost defines that area closer to chassis 14, are the upper jaw pawls 652, 654.
The upper jaw pawls are biased in an upward position by means of helical pre-load springs 656 which are wound about layshaft 512 and are hooked to and have one end hooked to the torsion spring stops 45 and 47, associated with the tubeloader layshaft apertures 44, 46. The other end of the preload spring 656 being hooked onto the respective upper jaw carrier 652, 654. Each of the upper jaw carriers 652, 654 further comprises a forwardly extending arm portion 658 which has a downwardly aimed terminus 660. Forwardly extending arm portion 658 is adapted, in combination with upper jaw tie rod 662, to support the upper pump jaw 220.
The downwardly extending termini 60 of the upper jaw carrier 652, 654 further define a distinctive tubeloading tip shape, as mentioned in the description of the tubeloader pawls 514.
Located rearward of the forwardly extending arm portion 658, a spring slot 664 is formed in the upper jaw carrier 652, 654 and is operative to retain the associated torsion springs 656 therein. The upper jaw carrier 652, 654 have further defined a bifurcated central portion 667 which is adapted to retain the upper jaw carrier locking tangs 668 in the interstice of the bifurcated central portion 667 of the associated upper jaw carrier 652, 654.
Extending rearwardly of the central area 667, an upper jaw carrier cam follower arm 670 has defined therein an upper jaw cam follower port 672 which is adapted to receive the upper jaw carrier arm cam followers 674. The upper jaw cam followers 674 are slidingly retained in the upper jaw cam follower ports 672 and are biased against tubeloader pawl cam 614, 624 by preload-spring 675. The purpose behind this being that should a tube 5 be misloaded beneath the upper jaw 220 or pawls 514, a sensor associated with the position of the upper jaw 220 and in combination with a tubeloader encoder 702, 704, 705, associated with the tubeloader motor armature shaft 701, will detect that the upper jaw 220 and layshaft 514 have ceased their motion while the tubeloader motor continues to rotate as the clearance between the upper jaw carrier cam follower arm 670 and the radially extensive seat 676 of the upper jaw cam follower 674 is closed. An electronic detection circuit will record this differential motion and cause the tubeloader motor 550 to reverse its rotation, opening the upper jaw 220 and tubeloader pawls 514 thereby expelling the tube 5.
To assure a final fixed registration of the upper jaw 220 and the other assemblies driven by layshaft 514, the locking follower 668 rides up on the locking surfaces 616, 626 of the tubeloader pawl cam or layshaft drive cam 614, 624, and is adjustably fixed relative to the upper jaw carrier arm 652, 654 by means of adjustment screws 680. The upper jaw carriers are fixed to layshaft 512 by means of spiral pins so as to actuate a co-rotation thereof.
As seen in FIG. 16, moving outwardly from the upper jaw carrier arms are the valve spring retainers 450. Outward of the valve spring retainers 450 resides the innermost of the tubeloader pawls 514 as aforedescribed.
Associated with, and pivotal about layshaft 512, are the upstream and downstream sensor carrier arms 690. As it is necessary for the tube 5 to be completely loaded in the tubeway 8 before the application of the associated sensors, the sensor carrier arm 690 is actuated by a separate and delayed cam with respect to action of the rest of the components affixed to layshaft 512. Associated with each of the sensor carrying arms 690 is a downwardly extending sensor arm cam follower 692 having a downward biased spring 694 associated therewith. Affixed to a central portion of the sensor carrying arm 690 and in substantially opposing contact with the sensor arm cam 630, 632 is the sensor arm opening spring 696 which, in the preferred embodiment is a leaf spring. This arrangement allows for both the opening of and the closure of the sensor array associated with the upstream or downstream sensor carrier arm 690 by a single cam respectively.
As can be seen in FIG. 16, the sensor arm 690 further comprises a forward forcipate end 698 which is operative in combination with a sensor handle pin 799 inserted thereacross, to support the associated sensor sub-assembly.
SENSORS ASSOCIATED WITH THE TUBELOADER SUB-ASSEMBLY
As recited previously, there are a plurality of sensors associated with the sensor arm 690 of the tubeloader sub-assembly. The most downstream of these sensors is the ultrasonic air detection apparatus or transducer 728 as shown in FIG. 22. The ultrasonic transducer 728 acts in concert with a second transducer element located in the downstream platen 500, as aforedescribed. The ultrasonic transducer 728 is housed in a compoundly pivotal housing 720. This sensor housing 720 comprises a vertically split housing body including a transducer cavity 724. The housing 720 further comprises a substantially horizontally axially extensive suspension slot 722 which, itself, comprehends an oval joining ring 725, which is defined by a substantially oval and longitudinally extensive sensor arm pin retainer 723. The suspension slot 722 serves to capture the sensor handle pin 799, while allowing the sensor assembly 720 to move in fore and aft relation thereto. The sensor assembly 720 is further restrained by the vertically disposed sensor arm pivot slot 578 in combination with sensor housing lift pin 721, which is retained in lift pin ports 726 and 746 allowing vertical axial motion thereof, to allow the sensor 720 to roll over or tilt against the top of tube 5 when the sensor arm cam 630 actuates the substantially downward motion of the forward forcipate end of the sensor arm 690. This ability to roll over, or conversely execute a rocking motion with respect to the tube 5, allows the sensor housing 720 to come into a substantially vertical compressive contact with the tube 5. This allows the tube to be extended or stretched equally across the face of the associated sensor, thereby eliminating either a volumetric or stress gradient in the tube 5 beneath the associated sensor so as to improve the accuracy of response of the sensor associated with, or connected to, housing 720. Essentially all of the sensors associated with, or actuated by, sensor arm 690 execute the above described motion so as to achieve the above described result.
The next sensor located inboardly of the ultrasonic air detection transducer 720 is the downstream pressure sensor which resides in housing 734. The sensor itself comprises a fairly standard, full bridge array on a deflection beam 740. The deflection beam 740 is actuated by a sensing foot 730 which includes a substantially hemispherical tip 738. The hemispherical tip 738 is surrounded by a conical extension of the housing 734. The deflectability of the deflection beam 740 is controlled by seat pin 742 and stiffener 744 in conjunction with sensor foot fastener 743. The hemispherical foot tip 738, in combination with a conical circumferential enclosure thereof has, to achieve maximum accuracy, the requirement that the combination of the foot tip 738 and the conical enclosure be emplaced on the tube 5 in an essentially normal orientation thereto which is achieved by use of a compound rocker arrangement, as previously described, associated with the transducer housing 720 as shown FIG. 21. In this sensor, being contiguous with the ultrasonic detector 720, the compound rocking motion thereof is actuated by the lift pin 721 and oval rocker slot 722 of the transducer housing 720.
The corresponding upstream pressure sensor resident in housing 750, 760 provides an essentially similar layout save that the rocker assembly is unitary with the housing halves 750, 760 and the rocker slot associated herewith is denoted as upstream slot 758 defined in the upstream rocker handle 756 which includes oval inserts 754 and further comprises a separate lift pin 752 riding in an associated vertical slot 810 in the upstream platen 800. Also associated with the tubeloader assembly is the tubeloader motor encoder as aforementioned. The encoder comprises an encoder flag wheel 702 which, in the preferred embodiment, comprehends a tubeloader encoder flag wheel hub 702A and a plurality of flags 702F, resident therebehind is the tubeloader encoder support collar 703 which serves to support the tubeloader encoder optical switches 704, 705 and is affixed to motor 550 via pinch clamp 706 and further supports the optical switch printed circuit board 707.
The downstream platen 500 also serves to support a plurality of temperature sensors which consist of thermistors 754T and 755T which are gasketed to the downstream platen 500 by means of gaskets 760T and are supported from below by the thermistor support 762T.
THE SLIDE CLAMP LOADER SUB-ASSEMBLY
The slide clamp loader sub-assembly and its related sensors are generally associated with the upstream platen 800. The upstream platen 800 comprises a rearward facing fluid barrier wall 801 which is connected by fasteners to chassis 14. The fluid barrier wall 801 serves with the rear wall of the chassis and the rear wall of the downstream platen 500 to effectively seal the electronic assemblies from fluid ingress. Mirroring the downstream platen 500, the upstream platen 800 further has defined thereon a tube sweep chamfer 812. With the substantially identical chamfer resident on the shuttle facing interior side of the downstream platen 500, the upstream tube sweep chamfer 812 accounts for the vertical motion of the tube during the pumping cycle. The forward facing edge of the upstream platen 800 future defines a plurality of tubeloader pawl nesting slots 803 which are identical functioning to the tubeloader pawl nesting slots 582. Furthermore, the upstream platen further has defined therein a similar forward facing chamfer as the downstream platen chamfer 584.
The upstream platen further has defined thereon the upstream valve anvil 805 and a plurality of tube stops 809 of similar function to the tube stops 576 associated with the downstream platen 500. The upstream platen further receives support from the upstream end of the valve pivot shaft 410 residing in carrier 807. The upstream-most end of the upstream platen 800 further has defined on the exterior peripheral edge thereof a upstream tube retaining detent 842 which is identical in function and cooperative with the corresponding downstream tube retaining detent 584. The base of the upstream platen 800 further has defined thereon a slide clamp loading groove 856. This groove, in combination with the upper slide clamp channel 824 resident in slide clamp carrier 814, serves to capture the slide clamp 895 through which passes tube 5. Additionally, present in the slide clamp channel 824 are a plurality of slide clamp locating pins 824A, 824B which serve to provide, in combination with an asymmetric slide clamp 895, a preferred orientation of the slide clamp 895 and thereby as the slide clamp 895 is already resident on the tube 5, a preferred loading direction of the tube 5 into the pump 10.
The slide clamp loader assembly is driven by camshaft 510 and is actuated by the slide clamp loading crank 650. The slide clamp loading crank 650 has inserted therein a slide clamp loading crank pin 804 upon which rides a slide clamp actuator bushing 802. The rotation of this crank is converted into a substantially linear motion by cooperative movement of the slide clamp actuator bushing 802 and the slide clamp traveler 815 by means of motion of the slide clamp actuator bushing 802 and the slide clamp traveler bushing race 813. The slide clamp traveler 815, in cooperation with the slide clamp clam pin 826, provides substantially fore and aft motion of the slide clamp clams 820, 830, which are operative to grasp and releasably retain the slide clamp 895. The slide clamp clams 820, 830 are in a substantially scissorlike arrangement with respect to each other and reside in the slide clamp clam shell 832, which is operative to allow fore and aft motion of the slide clamp clams 820, 830 therein. The slide clamp traveler 815, in its forward motion, as actuated by crank 650 further serves to raise the slide clamp shield 811 by impinging upon the slanted longitudinal surfaces of the shield arm 812. This ensures that the slide clamp 895 will not be accidentally removed from the pump 10 as the position of the slide clamp traveler 815 provides that shield or visor 811 will be in a lowered position at such time as the pump 10 is in operation, thereby precluding removal of the slide clamp from the slide clamp groove 856.
As aforementioned, slide clamp 895 is adapted to be gripped by the slide clamp clams 820, 830. This is achieved by a cooperation between the slide clamp 895, having detents or grippable elements impressed therein, and the slide clamp loader clam tips 820, 822 which are essentially barblike so as to ensure retention of the slide clamp 895 when the clams are engaged.
In operation the slide clamp loader functions in concert with the tubeloader assembly to ensure correct loading of the tube 5 and the associated slide clamp 895. After the tubeloader pawls 514 close about the tube 5, the slide clamp loading assembly, specifically the slide clamp clams 820, 830, close onto the slide clamp resident about the tube 5 and within the slide clamp groove 856. As the pawls 514 close, and the upper jaw 220 lowers into its operating position, and subsequent to the valves 412, 414 lowering to close off the tube 5, the clams 820, 830 draw the slide clamp 895 into the slide clamp groove 856, thereby opening the slide clamp as it slides past tube 5 which is being retained by the upstream tube stops 844.
The cam arrangement between the valve loading cam races 120, 122 and the tube loader cams assures that the slide clamp will be closed by a reverse of the aforerecited motion of the slide clamp 895 with respect to the tube 5 prior to the tube being in a condition allowing removal thereof from the tubeway 8.
SENSORS ASSOCIATED WITH THE SLIDE CLAMP LOADER
The slide clamp loader has two primary sensors associated therewith. The first of these sensors is resident in the upstream platen 800 about the slide clamp groove 856. This sensor is denoted the slide clamp positioning sensor. The slide clamp positioning sensor is located on sensor base 880. Resident on sensor base 880 are two light emitting diodes 872 and 876 which are positioned in a fore and aft arrangement on a first side of the slide clamp groove 856. Diametrically opposed to the light emitting diodes 872, 876 across the slide clamp groove 856, are a corresponding pair of photocells 870, 874. The photocells 870, 874 are also arranged fore and aft to align with the diodes 872, 876. The diodes 872, 876 emit light into a first or transmitting pair of light pipes 864, 868 which extend upwardly above the upstream platen 800 on one side of the slide clamp groove 856. The light pipes 868, 864 terminate in 45 degree internal reflecting surfaces 863 which serve to bend the output of the diodes 872, 876 into horizontal beams transverse to the slide clamp groove 856 at a height suitable for intersection of the beams with a slide clamp 895 present in the groove 856. A corresponding set of receiving light pipes 860, 862 across from the transmitting light pipes 864, 868 serve to receive the light beam emitted by the diodes 872, 876 and transmit same down to the receiving photocells 870, 874 thus putting the light sources and sensors in photonic communication. The receiving light pipes 860, 862 also comprehend 45 degree internal reflecting surfaces 863 in opposing relation to those of transmitting light pipes 864, 868.
In operation the slide clamp sensors serve to identify both the position and presence of a slide clamp 895 in the slide clamp loader sub-assembly. The two sensor sets corresponding to the outer photocell 874 and the inner photocell 870 work in concert to accurately display the location of the slide clamp 895 within the loader sub-assembly. Specifically, the two sensors 874 and 870 determine the location of the slide clamp 895 according to the following truth table wherein high denotes a beam transmitted across the slide clamp groove 856 and low denotes a condition wherein reception of a specific beam is absent.
______________________________________ Outer beam Inner Beam______________________________________No slide clamp High HighClamp present and open Low LowClamp present and closed Low High______________________________________
As can be seen from this table, the duality of the sensor array allows not only a detection of the presence or absence of the slide clamp 895, but also detection of the position thereof within the slide clamp groove 856 and, therefore, as the tube 5 is in a fixed location within the tubeway 8, an indication of the state of the slide clamp 895, namely opened or closed, is also provided.
Also associated with the slide clamp loader sub-assembly, a micro switch 882 in combination with an actuator 882A, which is operated by crank pin 804, serves to detect operation of the tubeloader camshaft 510 by means of handwheel 600 and with associated electronics will register an alarm when handwheel 600 is rotated.
THE PUMP HOUSING
The last of the major sub-assemblies associated with the pump 10 is the pump housing 900. In general aspect, the housing 900, as well as the pump assembly 10, is adapted to be stackable vertically so as to allow, in an alternative embodiment, a plurality of pumps 10 to be driven off of a single associated control module.
The pump housing 900 provides for an attachment and fixation point for the motor mount strap 955 which serves to support the pump motor 24 and the tubeloader motor 550, which are supported in resilient grommets 960, 965, which have associated therewith rotation-suppressing indents 970, 972 which serve to hold securely the two motors 24, 550 and suppress torsional vibration thereof with the co-action of the indents 970, 972 and the corresponding indent-engaging keys 972A, 972B.
The case 900 further consists of a tubeway access slot 904 which has an upstream end 902 and a downstream end 901, wherein both the upstream end 902 and the downstream end 901 are geometrically adapted to form drip loops in the tube 5 by means of a downwardly angled orientation of each of the tubeway access slot ends 901, 902. This geometric adaptation of the tubeway slot ends 901, 902 serves to ensure a conformation of the tube 5 which serves to prevent fluid ingress of the pump 10 from leaks associated with fluid delivery components exterior to the pump 10. The housing 900 further has defined therein an access port 906 adapted to receive therein the tubeloader camshaft handwheel 600 so as to provide access thereto by an operator.
CONCLUSION
This description of the preferred embodiment of the instant invention is indicative of that embodiment presently preferred and should not be deemed to restrict the scope of the instant invention in any way more restrictive than the scope of the Claims appended hereto, and other and equivalent embodiments of the instant invention are to be deemed as expressly included in the claimed elements of the instant invention. | A medical infusion pump is disclosed which provides for greatly improved accuracy in the delivery of medicaments to a patient. Among the various features included in the instant invention is a pumping body which serves to deform and reform a tube so as to maintain the initial cross-section thereof and thereby preserve the output accuracy of the pump. Also disclosed with regard to the pumping body is a wholly mechanical synchronization of the pumping body and valves associated therewith and coactive with the aforementioned synchronization a mechanical linearization of output of the pumping body per each pumping cycle. Additionally, several features which serve to enhance the utility of the instant invention are also included therein among which is an associated assembly operative to automatically load or disload a tube or IV set into or out of the pumping body. Associated with the assembly operative to automatically load or disload a tube and disclosed herein is is an assembly operative to selectively open or close a slide clamp associated with the tube in such a way as to ensure that the tube is occluded such that in combination with the valves associated with the pumping body, a condition of free-flow of medicament is never realized. Additionally disclosed are sensor housings adapted to measure various quantities associated with fluid flowing through the tube wherein the housings are with associated components adapted to achieve a substantially normal orientation with respect to the sidewall of the tube and in the achieving of such normal orientation, expressing an essentially zero elastic stress gradient across the tube. | 8 |
RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application Ser. No. 08/142,707 filed Oct. 25, 1993.
FIELD OF THE INVENTION
The present invention relates to transparent soap formulations and corresponding methods of manufacture. More particularly, the invention is a transparent soap formulation prepared by combining high and low molecular weight fatty acids in the presence of polyhydric alcohols. Adjustments to pH are accomplished with citric acid.
BACKGROUND OF THE INVENTION
As used in this specification, the term "transparent soap" refers to a one-quarter inch soap section through which a person having 20/20 vision can read 14 point boldface type. This term is not restricted to those soaps which are clear or colorless because it is often desirable to add color to transparent soap. The present invention contemplates both colored and clear transparent soaps.
For commercial acceptance, transparent soaps must retain all the quality characteristics of conventional, opaque soap (such as good lather, hardness, mildness, minimum sluffing and the like). These products must remain transparent under normal use for extended periods of time. U.S. Pat. Nos. 3,793,214 and 3,926,828 describe known, but inferior, formulations made by neutralizing a mixture of saturated fatty acids and aliphatic monocarboxylic acid with a pH adjusting agent containing alkanolamines.
The present invention includes, inter alia, the production of transparent soaps comprised of sodium tallowate, sodium cocoate and non-volatile polyhydric alcohols, in which the pH is adjusted with citric acid. Transparent products made from the presently disclosed soap formulations have all of the desired qualities of conventional, opaque soap and additional features which permit economic and safe production.
Currently known soap formulations do not retain transparency when remelted, making it impractical to economically recycle excess waste. Conventional techniques also require aging, a process which evaporates volatile, short-chain monohydric alcohols. This aging process is time-consuming, expensive and potentially hazardous to production personnel.
The ability of soap to be remelted and retain all of its original qualities is critical for reducing costs. During production, a large reserve of scrap soap accumulates. This scrap is frequently discarded because it cannot be remelted to form a product which exhibits the original features. Lages U.S. Pat. No. 3,969,259; Verite U.S. Pat. No. 4,980,078 and Lindberg U.S. Pat. No. 4,468,338 disclose state-of-the-art transparent soap preparations which are subject to these deficiencies. These and other references demonstrate the need for a remeltable formulation to dramatically reduce production costs.
The traditional method for making transparent soap involves forming a solution of ingredients in a volatile solvent (commonly ethanol), casting the pourable mixture into large mold frames and allowing the volatile solvent to evaporate. Solidified soap is semi-opaque when initially cast. Solvent evaporation creates the transparent qualities of each formulation. But, evaporation is time-consuming and commonly causes a weight loss in excess of 15 percent.
For example, soap bars produced according to Chambers U.S. Pat. No. 4,988,453 must initially contain 6 to 15 percent volatile, low molecular weight alcohols (such as methylated spirits, ethanol and isopropanol) which require an aging period of several days to achieve transparency. In addition, the aging-evaporation procedure releases alcohol vapors which require expensive measures to reduce the hazards of exposure.
Other problems are known to the art. Typical casting methods cause shrink deformation resulting from the evaporation of alcohol and moisture. Transparent bars frequently have inferior end-use properties, despite higher retail prices when compared to opaque counterparts. Known transparent soaps frequently develop a sticky, opaque surface layer when placed in contact with water. And, high alkaline content can cause skin dryness. Soap bars which typically display these problems are produced according to the disclosures of Fromont U.S. Pat. No. 2,820,768; Poper U.S. Pat. No. 4,290,904 and Jungermann U.S. Pat. No. 4,758,370. They are sold commercially under the trade name "Neutrogena."
The present disclosure provides, inter alia, formulations which include sodium soap and polyhydric alcohols in critical weight percent ranges. These ingredients are mixed with specific acids to adjust the pH condition. Disclosed formulations produce soap products that do not require aging to obtain transparency, can be remelted and have the ability to accept color. This invention also provides a mild formulation which exhibits all the qualities of a conventional, high quality soap.
It is an object of the present invention to provide formulations and methods for making transparent soaps which do not require lengthy aging procedures or the use of hazardous, volatile, low molecular weight alcohols to achieve transparency.
Another object is to provide a transparent soap which can be remelted to achieve acceptable transparency using recycled production scrap.
A further object is to provide formulations for making transparent soaps which do not form undesirable opaque sluff-residues during or after end use application.
Yet another object is to provide transparent soap bars with exceptional gloss-like clarity and enhanced stability to light, heat and oxygen.
Still another object is to provide transparent soaps having excellent odor profiles with or without incorporation of a fragrance.
SUMMARY OF THE INVENTION
The present invention includes formulations and methods for making a transparent soap composition which contains polyethylene glycol, propylene glycol, glycerin, triethanolamine lauryl sulfate, alkoxylated cetyl alcohol, sodium hydroxide, sucrose, sodium cocoyl isethionate, unreacted free fatty acids, sodium tallowate, sodium cocoate and other minor ingredients such as fragrance, antioxidants, chelating agents, foam stabilizers, colorants and germicides.
Maintaining the correct balance of organic solvents and free fatty acids will produce an exceptional transparent product under the correct pH conditions. Organic solvents are preferably chosen from polyols having 2 to 6 carbon atoms. The term "polyol" generally defines a non-volatile, dihydric or higher, polyhydric alcohol such as polyethylene glycol, propylene glycol and glycerin.
The process for making the present transparent soaps essentially comprises the following steps.
1) Mixing a composite of polyethylene glycol, propylene glycol, glycerin, triethanolamine lauryl sulfate, alkoxylated cetyl alcohol and tetrasodium EDTA, while heating, until a temperature range between about 150° F. to 155° F. is attained.
2) Adding an aqueous sodium chloride solution and agitating while applying heat until the temperature range between about 150° F. to 155° F. is re-achieved.
3) Adding a blend of stearic acid, palmitic acid, myristic acid, oleic acid and lauric acid, and mixing the resulting batch while raising the temperature to a range between about 160° F. to 165° F.
4) Neutralizing the batch by slowly adding a 50% aqueous solution of sodium hydroxide over at least a 15 minute period while ensuring the temperature does not exceed about 195° F. After all sodium hydroxide has been added, the mixture is kept between about 175° F. to 195° F. for at least thirty minutes to ensure the reaction is complete and all solids are dissolved.
5) Adding sucrose to the batch and mixing until the sucrose is solubilized.
6) Slowly adding sodium cocoyl isethionate and vigorously agitating over at least a 15 minute period until all solids are dissolved, while maintaining a temperature range between about 175° F. to 190° F.
7) While maintaining agitation, cooling the batch to a temperature range between about 160° F. to 165° F., and adding to the cooled batch, pentasodium pentatate and tetrasodium etidronate.
8) Adjusting batch pH with citric acid to a range between pH 8.9 to 9.6 while maintaining agitation and a batch temperature range between about 160° F. to 165° F.
9) Cooling the pH adjusted batch to a temperature range between about 150° F. to 155° F. and slowly adding fragrance and color while gently agitating the cooled batch. The composite is then poured into molds and allowed to solidify.
As the description below further illustrates, the transparent soaps of the present formulation are made without lengthy processing and aging procedures. The method of the present invention does not require the use of volatile, low molecular weight alcohols to achieve transparency. Present formulations also provide a product that is compatible with hot water wash conditions without formation of the undesirable, opaque residues that develop with known transparent products.
The soap bar of this invention has exceptional gloss-like clarity, enhanced stability to light, heat and oxygen, as well as excellent odor characteristics with or without incorporation of a fragrance. Further, the unique formulation provides the delivery of other cosmetic materials and benefits, such as emolliency and deodorancy, while maintaining clarity and superior after-feel. These and other advantageous of the present invention are further described in this specification.
DETAILED DESCRIPTION OF THE INVENTION
The preferred formulations for the present transparent soaps contain the ingredients and ranges outlined in the following chart. All values are expressed in weight percents.
______________________________________ MIN- RANGE MAX- IMUM OPTIMUM IMUMINGREDIENT W/W % W/W % W/W %______________________________________Polyethylene Glycol 0.1 9.60 15.0Propylene Glycol 0.1 10.90 20.0Glycerin 0.1 12.76 20.0Triethanolamine Lauryl 0.1 10.45 20.0SulfateAlkoxylated Cetyl Alcohol 0.1 0.67 3.0Tetrasodium Edta 0.1 0.14 0.5Tallow/Coconut Fatty Acid 17.0 19.00 21.0Sodium Hydroxide (50%) 6.0 7.60 9.0Sucrose 3.0 7.84 12.0Sodium Cocoyl Isethionate 1.0 3.80 10.0Sodium Chloride 0.1 0.71 2.0Pentasodium Pentatate 0.0 0.05 0.2Tetrasodium Etidronate 0.0 0.05 0.2Citric Acid 0.1 0.77 1.5Water 5.0 11.04 15.0Fragrance 0.0 1.0 3.0______________________________________
A broad range of molecular weight fatty acids could be substituted to achieve similar results. For instance, soaps prepared from fatty acids having a distribution of coconut or other tropical nut oils may provide a lower end of the broad molecular weight spectrum (i.e., fatty acids with 6 to 14 carbon atoms); while soaps prepared from fatty acids having the molecular weight distribution of peanut oil, grapeseed oil or tallow may provide the upper end. In the preferred embodiment, the starting formulations have fatty acid components with 70 to 85% tallow and 15 to 30% coconut fatty acids.
The amount of fatty acid to be neutralized with a stoichiometric amount of a polyol or polyol blend is preferably in range ratio of about 1:1 to 1:3, and more preferably within the range of 1:1.9 to 1:2.5, with the optimum ratio being about 1:2.2. In addition to the neutralizing role, the presence of non-volatile polyols enhances the clarity of the end product and prevents shrinkage of the bar during storage and use. The sodium hydroxide in the indicated ranges provides further neutralizing activity for production of optimum transparency.
A correct pH range and the use of an adjusting agent are critical for achieving transparent soap bars from starting formulations. It has been unexpectedly discovered that adjusting the pH within a range of 9.1 to 9.5 will result in the desired end products. The optimum pH is approximately 9.2. Obtaining a pH outside the preferred range will opacify the product. Excess free alkalinity will also produce an opaque soap bar. A free fatty acid content in the range of 0.1 to 5.0% will provide transparent products. The preferred free fatty acid range is between 2.0 to 4.0%.
Water is an important ingredient because the hardness and clarity of the finished bar are strongly dependent on its total moisture content. There are several sources of water in this formulation such as the caustic soda solution and the water generated during the formation of sodium tallowate and sodium cocoate produced by the neutralization reaction. Water is also introduced with the addition of triethanolamine lauryl sulfate, alkoxylated cetyl alcohol and the like. The addition of free water to the bar formulation will also influence the final product. Generally, water addition of less than 5% total (not formed in situ or introduced by other ingredients) will usually result in a bar that is too hard and tends to form crystals with associated loss of clarity. Free water addition in excess of about 15% will usually result in a bar that is too soft.
Ingredients to improve mildness are also contemplated by the present formula. These ingredients may include sodium cocoyl isethionate and alkoxylated cetyl alcohol.
Foam boosters are also included in the formula to ensure sufficient lather characteristics. These compositions include triethanolamine lauryl sulfate and sodium cocoyl isethionate. But, the primary foam characteristics are provided by the reaction of fatty acid with sodium hydroxide.
A preferred formulation according to this invention comprises the following list of ingredients. All values are expressed in weight percents.
31.36% polyol component which is comprised of 10.88% glycerine, 10.88% propylene glycol and 9.60% polyethylene glycol
19.00% fatty acid component which is comprised of 5.32% stearic acid, 5.13% palmitic acid, 2.95% myristic acid, 2.84% oleic acid and 2.76% lauric acid
12.33% triethanolamine lauryl sulfate
7.84% sucrose
7.65% sodium hydroxide (50% aqueous solution)
3.80% sodium cocyl isethionate
0.77% citric acid
0.71% sodium chloride
0.66% alkoxylated cetyl alcohol
0.14% tetrasodium EDTA
0.05% pentasodium pentatate
0.05% tetrasodium etidronate
q.s. water
Additionally, the transparent soap bar can comprise about 98.00% of the above formulation plus about 1.75% of fragrance and about 0.25% of color tint.
EXAMPLE 1
TRANSPARENT SOAP BARS
Table 1, below, lists the ingredients and weight percents for a formula which was used to prepare test soap bars of the present invention. Additional examples demonstrate various properties of soap bars prepared according to this invention.
TABLE 1______________________________________FORMULAINGREDIENTS PERCENTAGE______________________________________Polyethylene Glycol 9.6000Propylene Glycol 10.8800Glycerin 12.7618Triethanolamine Lauryl Sulfate 10.4500Alkoxylated Cetyl Alcohol 0.6650Tetrasodium Edta 0.1425Tallow/coconut Fatty Acid 19.0000sodium Hydroxide (50%) 7.6000Sucrose 7.8400Sodium Cocoyl Isethionate 3.8000Sodium Chloride 0.7125Pentasodium Pentatate 0.0500Tetrasodium Etidronate 0.0500Citric Acid 0.7722Water 12.0560______________________________________
Polyethylene glycol, propylene glycol, glycerin, triethanolamine lauryl sulfate, akloxylated cetyl alcohol and tetrasodium EDTA were added to a tank equipped with a heating jacket and variable speed mixer. This composite was heated and mixed until a temperature of 150°-155° F. was attained.
A 85% tallow acid/15% coconut oil fatty acid blend was heated to approximately 150° F. and added to the mixed composite. The new composite was further mixed and heated until a temperature of 160°-165° F. was achieved.
A 50% aqueous solution of sodium hydroxide was slowly added to the mixture. Since the neutralization of the fatty acid is an exothermic reaction, sodium hydroxide addition must be controlled so the temperature will not exceed 195° F. After all of the sodium hydroxide was added, the composite was mixed for 15 minutes at approximately 195° F.
Water and the sodium chloride were mixed and heated in a side kettle. After the sodium chloride was totally solubilized, the water/sodium chloride solution was added to the mixing tank, followed by sucrose and sodium cocoyl isethionate. This composite was mixed vigorously, at approximately 170°-185° F. for 15 minutes, or until all of the ingredients were in solution.
After the ingredients were solubilized the temperature was reduced to approximately 160°-165° F. Pentasodium pentetate and tetrasodium etidronate were added after cooling. The composite was mixed for 10 minutes to achieve uniformity. At the same time, the temperature was lowered to 150°-155° F. and the mixer speed was reduced to minimize entrapped air bubbles.
The pH conditions were monitored during cooling. A 10% solution of citric acid was added until the pH was reduced to 9.1-9.5 and the free fatty content was between 2.0 and 4.0%. After the pH and free fatty acid were in an acceptable range, the composite was placed in molds to solidify.
EXAMPLE 2
MOISTURE CONTENT
This example demonstrates the importance of maintaining the correct moisture content. Transparent soap bars (Batch Nos. 141, 144, 151 and 152) were prepared in accordance with the formula and procedure of Example 1 (with different water content). Moisture content was measured and corresponding transparent qualities were noted for the various conditions. Objective criteria for acceptable transparency are described in the Background section. Results are indicated in Table 2.
TABLE 2______________________________________BATCH % TRANSPARENCYNO. MOISTURE ACCEPTABLE UNACCEPTABLE______________________________________141 20.05 X 19.65 X 19.29 X 18.59 X 18.37 X 17.47 X 17.14 X 16.60 X 15.91 X144 16.19 X151 13.23 X152 14.17 X______________________________________
In Batch 141 the soap base was maintained at 150°-155° F. in a holding tank and periodically sampled. Results showed that transparency was maintained as long as the moisture content was greater than 17%. Batches 144, 151 and 152 were also prepared with moisture values below 17%. In each instance, the transparency of the product was rated as "unacceptable."
EXAMPLE 3
pH AND FREE FATTY ACID CONTENT
Experiments were conducted to show the critical balance between pH and free fatty acid content in order to obtain an acceptable transparent product. Soaps were made according to Example 1 with modifications for pH values. Batches were identified as numbers 163, 165 and 166. Free fatty acid content and pH were measured as citric acid was added, then later correlated with objective observations for transparency in the relevant end products. Adding citric acid increased the free fatty acid content of the product while decreasing pH.
As shown by Table 3A, the transparency of end products was maintained as long as the pH did not fall below 9.1 and the free fatty acid content did not exceed 4.0%.
TABLE 3A______________________________________ TRANSPARENCYBATCH % FATTY UNACCEPT-NO. pH ACID ACCEPTABLE ABLE______________________________________163 9.44 2.01 X 9.31 2.87 X 9.19 3.62 X 9.02 5.83 X______________________________________
It was discovered that end products should have a free fatty acid content of about 2.0-4.0%. Soaps which had higher relative free alkalinity (about 0.055%) demonstrated unacceptable transparency. Measurement of free alkalinity in separate experiments confirmed these findings. The results are set forth in Table 3B.
TABLE 3B______________________________________BATCH NO. % FREE ALKALINITY TRANSPARENCY______________________________________165 0.055 UNACCEPTABLE166 0.055 UNACCEPTABLE______________________________________
EXAMPLE 4 REMELTABILITY
Tests were conducted to demonstrate the ability of the present formulations to be remelted and retain transparent qualities. Batch No. 150 was prepared according to the formula and procedure of Example 1 with modifications for moisture content. Because test conditions were designed to simulate high temperature recycling, the water content was raised above the ranges previously disclosed in this specification.
In the first set of experiments, the formulations were held at a high temperature for the time periods indicated in Table 4. At each time interval, moisture content and objective transparent qualities were noted.
TABLE 4______________________________________BATCH NO. 150TIME INTERVALPERCENT TRANSPARENCY150-160° F. WATER ACCEPTABLE UNACCEPTABLE______________________________________0 Hour 20.87 X1 Hour 20.09 X2 Hours 19.63 X3 Hours 17.92 X4 Hours 20.11* X5 Hours 18.32 X6 Hours 19.40* X7 Hours 17.40 X8 Hours 15.35 X______________________________________ *Water was added to keep moisture content in the desired range.
The Table 4 results demonstrate that the present formulations are able to maintain transparency even at extreme temperatures, as long as proper moisture content is maintained. For instance, at 4 and 6 hours, the addition of water maintained transparent qualities without sacrificing hardness.
The above product was discharged from the tank and allowed to solidify. After 24 hours, the solidified product (Batch No. 151, simulating scrap soap) was placed in a reaction tank and remelted at 150°-160° F. As shown by Table 4B, the correct moisture content was achieved by adding approximately 5% water. Remelted products had acceptable transparency resulting from the higher moisture content.
TABLE 4B______________________________________BATCH NO. 151TIME INTERVALPERCENT TRANSPARENCY150-160° F. WATER ACCEPTABLE UNACCEPTABLE______________________________________0 Hour 18.17 X1 Hour 18.79 X2 Hours 16.59 X3.5 Hours 13.23 X______________________________________
It is to be noted that the definition for the term "transparent soap" (one-quarter inch soap section through which a person having 20/20 vision can read 14 point boldface type) as used in this specification is on a variable scale depending on the thickness and the amount of color tint added. For example, the boldface type may not be read as clearly if up to 2.0% by weight of formulation is color tint and the ultimate product is about one inch thick.
Various modifications and alterations to the present invention may be appreciated based on a review of this disclosure. These changes and additions are intended to be within the scope and spirit of this invention as defined by the following claims. | Formulations for transparent soaps and methods of preparation are disclosed. The transparent soaps are prepared by combining high and low molecular weight fatty acids in the presence of polyhydric alcohols. Citric acid is added to adjust pH. The formulations do not require volatile, short-chain monohydric alcohols to achieve transparency and the end products are able to retain transparent qualities when exposed to hot water conditions. Suitable formulations can be remelted to reduce waste. | 2 |
RELATED APPLICATIONS
This application is a divisional application of prior U.S. patent application Ser. No. 10/341,867, filed on 14 Jan. 2003, now U.S. Pat. No. 6,894,188 the disclosure of which is hereby incorporated by reference in its entirety. Both the instant application and the parent U.S. application claim the foreign priority of Indian Patent Application Serial No. 503/DEL/2002, filed 30 Apr. 2002, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzenesulfonamide, a metabolite of the α 1 -adrenergic blocking agent tamsulosin. The invention concerns methods for the preparation of the optically active compound, novel pharmaceutical compositions comprising the same and methods of treatment comprising administration of such compositions.
BACKGROUND
Several sulfamoyl substituted phenethylamine derivatives having strong α-adrenergic blocking activity are disclosed in U.S. Pat. No. 4,703,063. U.S. Pat. No. 4,731,478 discloses the (−) isomer of 5-[2-[2-(2-ethoxyphenoxy)ethylamino]-2-methylethyl]-2-methoxybenzene sulfonamide, that is, tamsulosin, having the following formula:
Tamsulosin is used in the treatment of benign prostatic hyperplasia (BPH), a condition characterized by enlargement of prostatic tissue, which results in obstruction of proximal urethra.
Tamsulosin primarily metabolizes to mainly five metabolites, one of which M 4 of Formula I has been found to be almost equipotent to tamsulosin with respect to α 1 adrenoreceptor binding (Taguchi et al., J. Pharmacol. Exp. Ther., 1997, 280 (1), 1–5). The authors specify that M 4 was used in its racemic form. The optically-active single enantiomer of this metabolite could not be obtained viz., Xenobiotica, (1996), 26(3), 355–365; and Xenobiotica, (1996), 26(6), 637–645.
Enantiomers are structurally identical compounds, which differ only in that one isomer is a mirror image of the other and the mirror images cannot be superimposed. This phenomenon is known as chirality. Most biological molecules exist as enantiomers and exhibit chirality. Although structurally identical, enantiomers can have profoundly different effects in biological systems: one enantiomer may have a specific biological activity while the other enantiomer has no biological activity at all, or may have an entirely different form of biological activity.
Therefore, there is a need to develop a method for the preparation of optically active compound of Formula I in order to explore the potential of the compound as α 1 -adrenoceptor antagonist. Our attempts to obtain the desired compound directly from tamsulosin by selective O-demethylation of tamsulosin have been unsuccessful.
SUMMARY
It has now been found that the compound of Formula I may be prepared by a simple and convenient process using convenient starting materials. The compound can be prepared in an isolated state. Accordingly, the present invention provides synthetic compound of Formula I, which has the chemical name R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzene-sulfonamide and, pharmaceutically acceptable acid addition salts thereof. The compounds of the present invention have strong α 1 -adrenergic blocking activity.
Further, methods are provided for preparing the compound of Formula I, and pharmaceutically acceptable acid addition salts thereof, which comprise condensing a chiral primary amine of Formula II or a salt thereof, with an aldehyde of
Formula III in the presence of sodium cyanoborohydride, followed by isolation of the enantiomer of Formula I as the free base, or a pharmaceutically acceptable acid addition salt thereof.
The process gives the compound of Formula I in an isolated state for the first time. The compound of Formula I can be isolated in optical purity of for example at least about 51% with respect to the other corresponding enantiomer, or for example in optical purity of at least about 60%, or at least about 75%, or at least about 80%, or at least about 90%. In some particular embodiments, the compound of Formula I can be prepared in an isolated state corresponding to at least about 95% optical purity, or at least about 98%, or at least 99%, or at least about 99.5% optical purity with respect to the other corresponding enantiomer. The process is advantageous in that the conversion of compound of Formula II to compound of Formula I is achieved in a single step as the imine formation and its reduction to amine proceed simultaneously. Also, no protection/deprotection of the aldehyde of Formula III is required.
Chiral phenethylamine compounds of formula II are not previously known, and are key intermediates of the process of the present invention.
The present invention provides a method for the preparation of a chiral primary amine intermediate of Formula II, and pharmaceutically acceptable acid addition salts thereof, which comprises reacting a chiral phenethylamine compound of Formula IV or a salt thereof, with
a Lewis acid, and hydrogenating the obtained 2-hydroxybenzenesulfonamide compound of
Formula V or a salt thereof, to get an intermediate of Formula II, which may then be converted to a salt if desired.
The process gives a chiral amine of Formula II in good optical purity and no racemization or inversion is observed.
Pharmaceutical compositions of compound of Formula I and pharmaceutically acceptable acid addition salts thereof, in admixture with a solid or liquid pharmaceutical diluent or carrier can be employed for methods of producing α 1 -adrenergic antagonistic action in mammals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a graph of the effect of the log of the concentration of tamsulosin and of the compound of Formula I on the mean arterial blood pressure in normotensive rats, as expressed in percentage change in mean arterial pressure (MAP).
FIG. 1 b is a graph of the effect of log of the concentration of tamsulosin and of the compound of Formula I on the heart rate of normotensive rats, as expressed in change of heart rate in beats per minute.
DETAILED DESCRIPTION
Compounds of Formula I can form pharmaceutically acceptable acid addition salts with inorganic or organic acid. Examples of such inorganic acids are hydrochloric, hydrobromic, hydroiodic, sulfuric, sulfamic, phosphoric and nitric acid, while examples of such organic acids are maleic, fumaric, benzoic, ascorbic, succinic, oxalic, methane sulfonic, ethane disulfonic, formic, acetic, propionic, tartaric, salicyclic, citric, gluconic, aspartic, stearic, palmitic, glycolic, p-aminobenzoic, glutamic, and benzenesulfonic acid. A particular example is the hydrochloride salt.
Intermediate compounds of Formulas II, IV and V may also be prepared or used in the form of acid addition salts, which may be the same or different from each other, and from the salt of Formula I. Any suitable inorganic or organic acid commonly used in synthetic chemistry may be used for salt formation. Examples of such acids include the acids given above for the compound of Formula I. A particular example is the hydrochloride salt.
The compound of Formula I can be prepared having at least 90% by weight of the R(−) isomer, and 10% or less of the S(+) isomer. For example, the compound of Formula I can be prepared having at least 95% by weight of the R(−) isomer, or at least 98% by weight of the R(−) isomer, or at least 99% by weight of the R(−) isomer. In some embodiments, the compound of Formula I can be prepared having at least 99.5% by weight of the R(−) isomer, and 0.5% or less of the S(+) isomer. The same and higher optical purities can be achieved for the compound of Formula II.
The compound of Formula I of this invention and its salts may exist in unsolvated or solvated form with pharmaceutically acceptable solvents such as water, ethanol, isopropanol and the like.
The chiral primary amine intermediate of Formula II is condensed with aldehyde of Formula III in the presence of sodium cyanoborohydride. The reaction may be carried out in a protic solvent such as methanol, ethanol, isopropanol, and mixtures thereof. Methanol is a particular example. Reaction can be performed at ambient temperature.
The starting aldehyde of Formula III may be prepared by the process of reference Example 1 of Canadian patent CA 1,282,077.
The starting chiral compound of Formula IV, used for the preparation of the key intermediate of Formula II, can be prepared easily by methods known in the art, such as J. Labelled Compd. Radiopharm., (1989), 27(2), 171–180, or by the preparation of (3-sulfonamido-4-methoxyphenyl)-2-propanone and conversion into the compound of Formula IV. The compound of Formula IV for use in preparation of the compound of Formula II can be prepared having at least 90% by weight of the R,R(+) isomer, and 10% or less of the R,S isomer. For example, the compound of Formula IV can be prepared having at least 95% by weight of the R,R(+) isomer, or at least 98% by weight of the R,R(+) isomer, or at least 99% by weight of the R,R(+) isomer. In some embodiments, the compound of Formula IV can be prepared having at least 99.5% by weight of the R,R(+) isomer, and 0.5% or less of the R,S isomer.
The compound of Formula IV is subjected to O-demethylation reaction in the presence of a Lewis acid. Suitable Lewis acids include halides of aluminum, boron, zinc, iron, tin, bismuth, antimony and titanium. Examples of such Lewis acids include aluminum chloride, aluminum bromide, boron tribromide, born trifluoride, zinc chloride, zinc iodide, ferrous chloride, stannous chloride, bismuth chloride, antimony pentachloride, titanium tetrachloride, and the like. Aluminum chloride is one particular example.
The reaction may be carried out in any organic solvent, which is inert under the reaction conditions. Suitable solvents include halogenated solvents such as 1,2-dichloroethane dichloromethane, and the like or hydrocarbons such as xylene, toluene, and the like. Toluene is one particular example. The reaction can be carried out at 30 to 80° C.
The compound of Formula V is hydrogenated to cleave the phenethyl group and obtain an intermediate of Formula II. The reaction is carried out in a protic solvent over a palladium/carbon catalyst. Suitable protic solvents include methanol, ethanol, isopropanol, water, and mixtures thereof. Methanol is a particular example. The reaction is preferably carried out at 40 to 60° C. and 4 to 5 atmosphere pressure.
Acid addition salts of the compounds of Formulas I, II, IV and V may be prepared by methods known in the art. The base is reacted with a calculated amount of acid in a water miscible solvent such as acetone, ethanol or methanol, with subsequent isolation of salt by concentration and cooling. Alternatively, the base is reacted with an excess of the acid in a water immiscible solvent such as ethyl acetate, with the salt separating out spontaneously.
Methods known in the art may be used with the process of this invention to enhance any aspect of the process. The product obtained may be further purified by any techniques known to a person skilled in the art for example, by filtration, crystallization, column-chromatography, preparative high pressure liquid chromatography, preparative thin layer chromatography, extractive washing in solution or a combination of these procedures.
Pharmaceutical Compositions
The compound of Formula I, the enantiomers thereof or their mixtures, and the pharmaceutically acceptable acid addition salts thereof may be formulated into ordinary dosage forms such as, for example, tablets, capsules, pills, solutions, etc. and in these cases, the medicaments can be prepared by conventional methods, including a therapeutically effective amount of a compound of Formula I, or its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, as described herein, along with a pharmaceutically acceptable carrier, and optionally but desirably, pharmaceutically acceptable excipients. In addition to the common dosage forms set out about, the compound of the present invention may also be administered by controlled release means and/or delivery devices. These compositions can be employed for methods of producing α 1 -adrenergic antagonistic action in mammals.
Formulation of the pharmaceutical compositions may be carried out in conventional manner using one or more physiologically and/or pharmaceutically acceptable carriers or excipients. Thus, the compounds and their pharmaceutically acceptable salts and solvates may be formulated for administration by inhalation or insufflation (either through the mouth or the nose) or oral, buccal, parenteral, or rectal administration.
Preparations for parenteral administration of the pharmaceutical compositions described herein include sterile aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's, or fixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers (such as those based on Ringer's dextrose), and the like. Preservatives and other additives may also be present such as, for example, antimicrobials, anti-oxidants, chelating agents, and inert gases and the like.
For oral administration, the pharmaceutical compositions may take the form of, for example, tablets or capsules prepared by conventional means with pharmaceutically acceptable excipients such as binding agents (for example, pregelatinized maize starch, polyvinylpyrrolidone, or hydroxypropyl methylcellulose); fillers (for example, lactose, microcrystalline cellulose or calcium hydrogen phosphate); lubricants (for example, magnesium stearate, talc or silica); disintegrants (for example, potato starch or sodium starch glycolate); or wetting agents (for example, sodium lauryl sulphate). The tablets may be coated by methods well known in the art. Liquid preparations for oral administration may take the form of, for example, solutions, syrups or suspensions, or they may be presented as a dry product for constitution with water or other suitable vehicle before use. Such liquid preparations may be prepared by conventional means with pharmaceutically acceptable additives such as suspending agents (for example, sorbitol syrup, cellulose derivatives or hydrogenated edible fats); emulsifying agents (for example, lecithin or acacia); non-aqueous vehicles (for example, almond oil, oily esters, ethyl alcohol or fractionated vegetable oils); and preservatives (for example, methyl or propyl-p-hydroxybenzoates or sorbic acid). The preparations may also contain buffer salts, flavoring, coloring and sweetening agents as appropriate. Preparations for oral administration may be suitably formulated to give controlled release of the active compound.
For buccal administration, the compositions may take the form of tablets or lozenges formulated in conventional manner.
For administration by inhalation, the compounds for use according to the present invention are conveniently delivered in the form of an aerosol spray presentation from pressurized packs or a nebulizer, with the use of a suitable propellant, for example, dichlorodifluoromethane, trichlorofluoromethane, dichlorotetrafluoroethane, carbon dioxide, or other suitable gas. In the case of a pressurized aerosol the dosage unit may be determined by providing a valve to deliver a metered amount. Capsules and cartridges of, for example, gelatin for use in an inhaler or insufflator may be formulated containing a powder mix of the compound and a suitable powder base such as lactose or starch.
The compounds may be formulated for parenteral administration by injection, for example, by bolus injection or continuous infusion. Formulations for injection may be presented in unit dosage form, for example, in ampoules or in multi-dose containers, with an added preservative. The compositions may take such forms as suspension, solutions or emulsions in oily or aqueous vehicles, and may contain formulatory agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient may be in powder form for constitution with a suitable vehicle, for example, sterile pyrogen-free water, before use.
In addition to the formulations described previously, the compounds may also be formulated as a depot preparation. Such long-acting formulations may be administered by implantation (for example, subcutaneously or intramuscularly) or by intramuscular injection. Thus, for example, the compounds may be formulated with suitable polymeric or hydrophobic materials (for example, as an emulsion in an acceptable oil) or ion exchange resins, or as sparingly soluble derivatives, for example, as a sparingly soluble salt.
The compounds may also be formulated in rectal compositions such as suppositories or retention enemas, for example, containing conventional suppository bases such as cocoa butter or other glycerides.
The compositions may, if desired, be presented in a pack or dispenser device which may contain one or more unit dosage forms containing the active ingredient. The pack may for example comprise metal or plastic foil, such as a blister pack. The pack or dispenser device may be accompanied by instructions for administration.
By “therapeutically effective amount” is meant the quantity of a compound or composition according to the invention necessary to prevent, cure or at least partially arrest the symptoms of the disorder and its complications. Amounts effective to achieve this goal will, of course, depend on the severity of the disease and the weight and general state of the patient. Typically, dosages used in vitro may provide useful guidance in the amounts useful for in situ administration of the pharmaceutical composition, and animal models may be used to determine effective dosages for treatment of particular disorders. Various considerations are described, for example, in Gilman et al., eds., 1900, “Goodman and Gilman's: The Pharmaceutical Bases of Therapeutics,” 8 th ed., Pergamon Press; and Remington's Pharmaceutical Sciences,” 1990, 17 th ed., Mack Publishing Co., Easton, Pa., each of which is hereby incorporated by reference.
Methods of Treatment
The invention provides a method of producing α-adrenergic antagonistic action in a mammal, including the administration of a therapeutically effective amount of a compound having the structure of Formula I, or its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, esters, enantiomers, diastereomers, N-oxides, polymorphs, prodrugs or metabolites, as described herein.
The methods include administering to a mammal a therapeutically effective amount of a compound having the structure of Formula I, or its pharmaceutically acceptable salts, or pharmaceutically acceptable solvates as described herein.
The compound of Formula I and the acid addition salts thereof provided by the present invention exhibit α 1 -adrenergic blocking action, and thus they can be utilized for various treatments such as for benign prostatic hyperplasia, lower urinary tract dysfunction, prostatic hypertrophy, erectile dysfunction, detrusor instability, high intraocular pressure, sympathetically mediated pain, migraine ( Headache, 1997, 37, 107–108), and high cholesterol. The compound of Formula I and the acid addition salts thereof provided by the present invention may have better tolerability profile than tamsulosin as indicated by the differences in the affinity profile of compound of Formula I and tamsulosin for α 1A , α 1B , 5HT 1A and D 3 receptors and the per se hypotensive effect in anaesthetized normotensive rats.
The administration of pharmaceutical compositions can be by injection or by gradual infusion over time. The compositions can be administered intravenously, intraperitoneally, intramuscularly, subcutaneously, intracavity, or transdermally. Preferred methods for delivery of the compositions include orally, by encapsulation in microspheres, by aerosol delivery to the lungs, or transdermally by iontophoresis or transdermal electroporation. Other methods of administration will be known to those skilled in the art.
EXAMPLES
The invention will be further described in the following examples, which demonstrate general synthetic procedures for the preparation of the disclosed compounds, as well as tests of properties of the prepared compounds. The examples do not limit the scope of the invention described in the claims.
The α 1 -adrenoceptor antagonist tamsulosin has also been reported to have subnanomolar affinity for 5-HT 1A and D-3 receptors. The reported selectivity for affinity at α 1A adrenoceptor vs 5-HT 1A and D-3 receptors is 6 and 2 fold respectively ( J. Med. Chem., 2000, 43, 2183–2195).
Central 5HT 1A agonism is known to result in hypotension via systemic vasodialation ( Pharmacology, 1998, 56(1), 17–29; J. Hypertens., 1988,6(2), 565–68). 5HT 1A receptors have been demonstrated to be involved in reflex activation of parasympathetic pregangalionic neurons to heart, ( Br. J. Pharmacol., 1998, 25,409–417) ciliary muscle, ( J. Psychopharmacol., 1999, 13, 391–397) and bladder ( J. Pharmacol. Exp. Ther., 1999, 290, 1258–1269). Similarly, D 3 receptors are also known to regulate cardiovascular and kidney function ( Curr. Opin. Nephrol. Hypertens., 2002, 11(1), 87–92; Acta Physiol. Scand., 2000, 168(1), 219–23; J. Hypertens., 2002, 20 (S3), S55–8; Clin. Exp. Hypertens., 2001. 23(1–2), 15–24). Thus, 5HT 1A and D 3 receptors are involved in modulation of cardiovascular system, which is linked to the manifestation of the adverse effects of α 1 -adrenoceptor antagonists.
The affinities of compound of Formula I, its corresponding (S) isomer, the corresponding racemate and tamsulosin were determined for α 1 -adrenoreceptor subtypes. Also, the affinity of compound of Formula I, and tamsulosin for 5HT 1A and D 3 receptors was evaluated.
Test 1: Activity at α 1 -adrenoceptor Subtypes
a) Radioligand-receptor Binding Assays (Human Recombinant Receptors)
The affinities of compound of Formula I, its corresponding (S)-isomer, the corresponding racemate and tamsulosin were determined for α 1 -adrenoreceptor subtypes in radioligand-receptor binding experiments conducted using human recombinant receptors.
Chinese hamster ovary (CHO) cells which had been stably transfected with human α 1A , α 1B , or α 1D -adrenoceptors (Keffel et al., Biochem. Biophys. Res. Commun., 2000, 272, 906–11) were cultured in an atmosphere of 5% CO 2 /95% air at 37° C. in F-12 HAM medium supplemented with 10% heat-inactivated fetal calf serum, 1 mM glutamine, 100 U/ml penicillin and 0.1 mg/ml streptomycin. Selection pressure was maintained by regular addition of geneticin to the culture medium.
Competitive radioligand binding to the cloned subtypes of α 1A -adrenoceptors was performed using [ 3 H]prazosin as the radioligand as described by Michel et al, Br. J. Pharmacol., 98, 883–889 (1989) with minor modifications. Experiments were performed in binding buffer consisting of 50 mM Tris, 10 mM MgCl 2 and 0.5 mM EDTA at pH 7.5 in a total assay volume of 1000 μl. The protein content typically was 40–60 μg/assay. The mixtures were incubated at 25° C. for 45 minutes. Incubations were terminated by rapid vacuum filtration over GF/C filters followed by two washes of the filters each with 10 ml ice-cold incubation buffer. Non-specific binding was defined as binding in the presence of 10 μM phentolamine.
The IC 50 & Kd were estimated by using the non-linear curve fitting program using G Pad Prism software. The value of inhibition constant Ki was calculated from competitive binding studies by using Cheng & Prusoff equation [Cheng & Prusoff, Biochem. Pharmacol., 22, 3099–3108 (1973)], Ki=IC 50 /(1+L/Kd), where L is the concentration of [ 3 H] prazosin used in the particular experiment. K d of [ 3 H] prazosin was determined from saturation binding studies. The values were tabulated as mean±SEM of pKi values, where pKi is the −log of Ki value. The results are summarized in Table I.
TABLE I
Radioligand Receptor Binding Assays:
Human Recombinant receptors
pKi
Compound
α 1A
α 1B
α 1D
Tamsulosin
10.32 ± 0.10
9.16 ± 0.08
10.09 ± 0.12
Formula I
10.66 ± 0.09
9.49 ± 0.06
9.97 ± 0.27
(S)-isomer
8.65 ± 0.05
7.66 ± 0.16
8.10 ± 0.29
Racemate
10.08 ± 0.08
8.96 ± 0.05
9.67 ± 0.23
The compound of Formula I has 102 fold greater affinity for α 1A -adrenoreceptor subtype than the corresponding (S)-isomer.
b) In-vitro Functional Studies
In order to study selectivity of action of compound of Formula I, and tamsulosin towards different α 1 -adrenoceptor subtypes, the ability of the compounds to antagonize α 1 -arenreceptor agonist-induced contractile response on aorta (α 1D ), prostate (α 1A ) and spleen (α 1B ) was studied. Aorta, prostate and spleen tissues were isolated from urethane anaesthetized (1.5 gm/kg) male wistar rats. Isolated tissues were mounted in organ bath containing Krebs Henseleit buffer of following compostion (mM): NaCl 118; KCl 4.7; CaCl 2 2.5; MgSO 4. 7H 2 O 1.2; NaHCO 3 25; KH 2 PO 4 1.2; glucose 11.5. Buffer was maintained at 37° C. and aerated with a mixture of 95% O 2 and 5% CO 2 . A resting tension of 2 g (aorta) or 1 g (spleen and prostate) was applied to tissues. Contractile response was monitored using a force displacement transducer and recorded on chart recorders. Tissues were allowed to equilibrate for 2 hours. At the end of equilibration period, concentration response curves to norepinephrine (aorta) and phenylepinephrine (spleen and prostate) were obtained in absence and presence of tested compound (at concentrations of 0.1, 1 and 10 mM). Antagonist affinities were calculated and expressed as pK B vales in Table II.
To compare the differences in pK B at the α 1 -arenrenoceptor subtypes one-way ANOVA followed by Dunett ‘t’ test was applied. A p<0.05 was considered statistically significant.
TABLE II
In vitro functional studies: Potency
for rat α 1 -adrenoceptor subtypes
pK B
α 1A
α 1B
α 1D
Tamsulosin
10.51 ± 0.17
9.56 ± 0.15*
10.54 ± 0.15
Formula I
10.79 ± 0.24
9.30 ± 0.20*
11.23 ± 0.14
*p < 0.05 (as compared to pK B at prostate tissue).
In the functional assays the compound of Formula I has significantly greater α 1A versus α 1B selectivity (31 fold) as compared to tamsulosin, which exhibits 9 fold selectivity.
Test 2: Activity at 5-HT 1A Receptors
a) Radioligand-receptor Binding Assays (Human Recombinant Receptors)
Receptor binding assays were performed using human recombinant 5HT 1A receptors. The affinities of compound of Formula I, and tamsulosin for 5HT 1A were evaluated in the radioligand binding assays conducted according to Martin et al., Neuropharmacol., 1993, 33, 261 with minor modifications, using [ 3 H]8-OH-DPAT as the radioligand. Non-specific binding was defined by 10 μM Metergoline. The results are displayed in Table III.
TABLE III
Radioligand Receptor Binding Assays:
5HT 1A Human recombinant receptors
PKi
Tamsulosin
9.10
Formula I
8.01
The compound of Formula I has 12.6 fold lower affinity for 5HT 1A receptors than tamsulosin. Also, the compound of Formula I has 27 fold greater α 1A versus 5HT 1A selectivity as compared to tamsulosin (Tables I and III).
Test 3: Activity at D 3 Receptors
a) Radioligand-receptor Binding Assays (Human Recombinant Receptors)
Receptor binding assays were performed using human recombinant D 3 receptors. The affinities of compound of Formula I, and tamsulosin were evaluated as described by Sokoloff et al., Nature, 1999, 347, 146 with minor modifications, using [ 3 H]Spiperone as the radioligand. Non-specific binding was defined by 25 μM S(−)Sulpiride. Results are displayed in Table IV.
TABLE IV
Radioligand Receptor Binding Assays:
D 3 Human recombinant receptors
PKi
Tamsulosin
9.55
Formula I
8.75
The compound of Formula I has 6 fold lower affinity for D 3 receptors than tamsulosin. Also, the compound of Formula I has 14 fold greater α 1A versus D 3 selectivity as compared to tamsulosin (Table I and IV).
Test 4: Hypotensive Effect in Rats
Male normotensive rats were anaesthetised with urethane (1.2 g/kg, i.p.). Carotid artery and femoral vein were cannulated for recording blood pressure and administration of test compounds respectively. Trachea was cannulated to maintain the airway patency. Rats were divided into two groups of 10 rats each. Group I received compound of Formula I, and Group II received Tamsulosin. Compounds were administered cumulatively at dose level of 0.01, 0.03, 0.1, 0.3, 1 & 10 μg/kg and effects on blood pressure and heart rate were monitored. Each subsequent dose in cumulative dose range was administered after previous response had stabilized.
Blood pressure and heart rate were recorded before and after drug treatment on a Grass polygraph using a Statham pressure transducer and tachograph. Effect on blood pressure was expressed as percentage change from the basal level. ED 20 was calculated by fitting the cumulative dose response data in non-linear regression analysis and the value was taken from the curve. Effect on heart rate was expressed as change in beats/min.
To compare the difference amongst the dose groups one-way ANOVA followed by Dunett ‘t’ test was applied. A p of <0.05 was considered statistically significant. The results are displayed in Table V.
TABLE V
Hypertensive effect in anaesthetised normotensive rats
ED 20 (ng/kg)
Tamsulosin
300
Formula I
520
ED 20 : Effective dose to produce a fall in blood pressure by 20%.
The compound of Formula I and tamsulosin resulted in dose dependent fall in blood pressure. The per se hypotensive effect was significantly greater for tamsulosin (ED 20 300 ng/kg) as compared to the compound of Formula I (ED 20 520 ng/kg). In tamsulosin treated animals fall in the blood pressure was accompanied by decrease in the heart rate, whereas in animals treated with the compound of Formula I this decrease in blood pressure is accompanied by increase in heart rate, as shown in FIGS. 1 a & 1 b.
Example 1
Preparation of (3-sulfonamido-4-methoxyphenyl)-2-propanone
4-methoxyphenyl acetone was added slowly to chlorosulphonic acid (20 ml) at −5 to +5° C. with stirring. The temperature was raised to 15° C. and the reaction mixture stirred for 4 hours at the same temperature. The reaction mixture was then added slowly to a mixture of ethyl acetate (100 ml) and water (200 ml) at 0° C. The temperature was raised to 20° C., the organic layer was separated and washed with brine. The organic layer was concentrated under reduced pressure to dryness and toluene (10 ml) was added to the residue. The solution obtained was stirred, toluene was recovered completely under vacuum and the residue was dissolved in THF at 40° C. The solution was cooled to 10° C. and NH3 gas purged slowly to attain pH˜8.8–9.8 at 8–12° C. The temperature was raised to 20–25° C. and stirred for 15 hours maintaining pH˜9.0. The solid obtained was filtered, washed with THF, water and then methanol and dried under vacuum at 60° C. to get 4.2 g of the title compound.
Example 2
Preparation of R,R-2-Methoxy-5-[2-(1-phenylethylamino)-propyl]benzenesulfonamide, hydrochloride (Formula IV)
(3-sulfonamido-4-methoxyphenyl)-2-propanone obtained from Example 1 was added to methanol (300 ml) and activated Raney Ni (1.5 g) in a hydrogenation flask. R(+)-1-phenyl ethylamine (1 g) was added and hydrogen gas was applied at a pressure of 3.5 bar. Temperature was raised to 50° C. and pressure raised to 5.5. bar. The reaction mixture was cooled to room temperature and Raney Ni filtered through hyflo bed. The filtrate was concentrate under reduced pressure at 50° C. and toluene (10 ml) was added. The resultant solution was concentrated at 50–60° C. under reduced pressure to recover toluene completely and get a thick oil (3 g approx.) of the title compound.
Example 3
Preparation of R,R-2-hydroxy-5-[2-(1-phenylethylamino)propyl]benzenesulfonamide (Formula V)
R,R-2-Methoxy-5-[2-(1-phenylethylamino)-propyl]benzenesulfonamide, hydrochloride (Formula IV, 12 g, 0.03 moles) and anhydrous aluminium chloride (24.0 g, 0.18 mmoles) were added to toluene (120 ml) at room temperature. Temperature of the reaction mass was raised to 80° C. and the mixture was stirred at this temperature for around two hours. Reaction mixture was then cooled to room temperature and poured on crushed ice. The water/toluene mixture was decanted to get a sticky mass. The product was dissolved in water (100 ml) under warming. Aqueous ammonia was added to increase pH to about 9 to 10. The basic solution was extracted with ethyl acetate and the solvent was removed under reduced pressure. Crude product so obtained was recrystallized from ethyl acetate to get the title compound (7.0 g).
The mass spectrum showed a peak at (MH + ): 335. The 1 H-NMR spectrum showed (DMSO-d 6 ; δ, ppm); 0.77 (d, 3H), 1.22 (d, 3H) 2.27–2.35 (m, 1H), 2.44–2.51 (m, 1H), 2.76–2.82 (m, 1H), 3.88–3.93 (m, 1H), 6.85 (d, 1H), 7.04–7.38 (m, 7H). The infrared spectrum showed (KBr, cm −1 ); 3378, 3280, 2972, 1687, 1604, 1461, 1302.
Example 4
Preparation of R-5-(2-aminopropyl)-2-hydroxybenzenesulfonamide (Formula II)
The compound from Example 3 (6.0 g, 0.018 moles) and palladium/carbon catalyst (3.0 gm, 5%) were added to methanol (200 ml) and stirred under hydrogen pressure of 5.0 kg at 50° C. for around 20 hours. The reaction mixture was cooled and the catalyst filtered off. The filtrate was concentrated under reduced pressure to obtain the title product as a solid (3.35 g).
The mass spectrum (MH + ) showed: 231. The 1 H-NMR spectrum showed (DMSO-d 6 ; δ, ppm); 1.02 (d, 3H), 2.34–2.50 (m, 1H), 2.66–2.73 (m, 1H), 3.07–3.16 (m, 1H), 6.83 (d, 1H), 7.11 (d, 1H), 7.38 (s, 1H). The infrared spectrum (KBr, cm −1 ) showed: 3172, 1602, 1469, 1312.
Example 5
Preparation of R,R-2-hydroxy -5-[2-(1-phenylethylamino)propyl]benzenesulfonamide, hydrochloride (Formula V, hydrochloride)
R,R-2-hydroxy-5-[2-(1-phenylethylamino)-propyl]benzenesulfonamide, (10 g, 0.03 moles) was dissolved in methanol (50 ml) by addition of methanolic hydrogen chloride slowly to get a pH of about 3. Methanol was removed under reduced pressure and acetone (60 ml) was added to the residue. The solvent (50 ml) was removed under reduced pressure and acetone (200 ml) was further added to the residue with stirring. The solid was separated out. The suspension was then cooled to 0° C. and stirred for one hour. The solid was filtered, washed with acetone and dried to get the title compound (9.0 g) as a white solid.
The melting point was: 237.7° C. The optical rotation was [α] D : +31.71°(c=1.0, methanol). The mass spectrum (MH + ) showed: 335. The 1 H-NMR spectrum (DMSO-d 6 ; δ, ppm) showed: 1.11 (d, 3H), 1.65 (d, 3H) 2.50–2.61 (m, 1H), 2.89 (bs, 1H), 4.60–4.63 (m, 1H), 6.9–7.1 (m, 4H), 7.32 (s, 1H), 7.4–7.75 (m, 5H), 9.32 (bs, 1H), 10.0 (bs, 1H), 10.74 (s, 1H). The infrared spectrum (KBr, cm −1 )showed: 3275, 3064, 2973, 2810, 1612, 1587, 1500, 1455, 1426.
Example 6
Preparation of R-5-(2-aminopropyl)-2-hydroxybenzenesulfonamide, hydrochloride (Formula II, hydrochloride)
The compound from Example 5 (5.0 g, 0.0135 moles) and palladium/carbon catalyst (2.50 gm, 5%) were added to methanol (50 ml) and stirred under hydrogen pressure of 5.5 kg at 50° C. for around 2 hours. The reaction mixture was cooled and the catalyst filtered off. The filtrate was concentrated under reduced pressure. Ethyl acetate (50 ml) was added to the residue and 50% of the solvent was distilled off. The resulting suspension was cooled to 0 to 5° C. The solid was filtered, washed with ethyl acetate and dried to obtain the title product (3.35 g).
The melting point was 267.1° C. (decomposition). The optical rotation was [α] D : −6.51° (c=1.0, methanol). The mass spectrum (MH + ) showed: 231. The 1 H-NMR spectrum (DMSO-d 6 ; δ, ppm) showed: 1.11 (d, 3H), 2.58–2.66 (m, 1H), 2.94–3.0 (m, 1H), 3.25–3.4 (m, 1H), 6.92 (s, 1H), 7.02 (d, 1H), 7.27 (dd, 1H), 7.50 (d, 1H), 8.12 (bs, 3H), 10.73 (s, 1H). The infrared spectrum (KBr, cm −1 ) showed: 3527, 3351, 3039, 1608, 1502, 1427, 1322.
Example 7
Preparation of R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzenesulfonamide, hydrochloride (Formula I, hydrochloride)
The compound from Example 6 (2.0 g, 0.0087 moles) and 2-(2-ethoxyphenoxy) acetaldehyde (1.8 g, 0.01 moles) were added to methanol (100 ml) at room temperature followed by sodium cyanoborohydride (0.63 g, 0.1 moles). The reaction mixture was then stirred for around 20 hours. Methanol was then removed under reduced pressure. Water (10 ml) and acetic acid (0.001 g) were added to the residue and the product was extracted from the resulting solution with ethyl acetate. The organic layer was concentrated under reduced pressure and the residue was dissolved in methanol. Concentrated hydrochloric acid was added to the methanolic solution till a pH of about 3.0. The hydrochloride salt was precipitated by adding ethyl acetate. It was filtered and dried to obtain the title compound (0.6 g).
The mass spectrum (MH + ) showed: 395. The 1 H-NMR spectrum (DMSO-d 6 ; δ, ppm) showed: 1.15 (d, 3H), 1.26 (t, 3H), 2.62 (t, 1H), 3.22–3.27 (m,1H), 3.43–3.50 (m, 3H), 4.02 (q, 2H), 4.29 (brt, 2H), 6.88–7.08 (m, 7H), 7.28 (d, 1H), 7.54 (s, 1H), 9.20 (brs, 2H), 10.75 (brs, 1H). The infrared spectrum (KBr, cm −1 ) showed: 3198, 2978, 2486, 1592, 1505, 1424, 1339.
Example 8
Preparation of R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzenesulfonamide (Formula I)
The compound from Example 7, (2.0 g, 0.0075 mole) was taken in methanol (10 ml) and 2-(2-ethoxyphenoxy)acetaldehyde (2.35 g. 0.013 mole) was added, and the mixture was cooled to 10° C. Sodium cyanoborohydride (0.47 g, 0.0075 moles) was added slowly. Reaction mixture was then stirred at room temperature for about 20 hours. Hydrochloric acid (dilute) was added slowly to the reaction mixture to get a pH˜3.0 and stirred the solution for 30 min. Thereafter methanol was removed under reduced pressure. A mixture of ethyl acetate, diisopropyl ether water and was added and stirred at 50–55° C. for 15 minutes. Aqueous layer was separated, cooled to 10° C. and basified with liq. NH 3 to pH˜9.0. The suspension was stirred for 1 hour at 10° C. The solid obtained was filtered, washed with water and dried to obtain 1.86 gm of the title product (crude). The crude product was refluxed in methanol and then cooled to 0.5° C. Filtration and washing with methanol yielded the title product (1.61 g) in pure form.
The melting point was 159.5° C. The optical rotation was [α] D : −3.59° (c=1.0, 0.1N methanolic HCl). Optical purity (by HPLC): 99.93%. The mass spectrum showed (MH + ): 395. The 1 HNMR spectrum (DMSO-d6, δ, ppm) showed: 0.92 (d, 3H), 1.29 (t, 3H), 2.37–2.44 (dd, 1H), 2.69–2.75 (dd, 1H), 2.81–2.91 (m, 3H), 3.83–4.0 (m, 5H), 6.88–6.96 (m, 5H), 7.21 (d, 1H), 7.46 (s, 1H). The infrared spectrum (KBr, cm − ) showed: 3194, 2924, 1589, 1506, 1463, 1412, 1321.
Example 9
Preparation of R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzenesulfonamide, hydrochloride (Formula I, hydrochloride)
The compound from Example 8 was dissolved in methanol. Concentrated hydrochloric acid was added to the methanolic solution till a pH of about 3.0. The hydrochloride salt was precipitated by adding ethyl acetate. It was filtered and dried to obtain the title compound (1.3 g).
The melting point was 153.7° C. The optical rotation was [α] D : −3.21° (c=1.0, methanol). Optical purity (by HPLC): 99.77%.
While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention. | The optically active compound, R (−)-5-[2-[[2-(2-ethoxyphenoxy)ethyl]amino]propyl]-2-hydroxybenzenesulfonamide in good optical purity, a metabolite of the α 1 -adrenergic blocking agent tamsulosin, and methods for the preparation thereof. Pharmaceutical compositions including the optically active compound and methods of treatment comprising administration of an effective α 1 -adrenergic antagonistic amount of such compositions to mammals. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an improved seal strip for a suction roll, which is manufactured by hardening an extruded mass into a shape, most of the mass being polymer and graphite. The invention also relates to a method for manufacturing the seal strip.
BACKGROUND OF THE INVENTION
[0002] Suction rolls are used particularly in paper machines, to remove water from the paper web. The suction roll has a perforated shell and a stationary suction box inside, so that the part of the jacket next to it is subjected to suction. The seal, i.e. the seal strip is arranged in a holder in the structure of the suction box, this generally being a U-shaped holder, in the bottom of which, and possibly on the sides of which there are loading hoses, for pressing the seal initially against the shell. Later, the suction holds the seal against the shell.
[0003] The suction box, which is elongated in the longitudinal direction of the roll, is bounded by long side seals, the first of which, i.e. the seal strip on the wet side, is narrower than the second, i.e. the seal strip on the dry side. In addition, there are ends seals at the ends of the suction box, set at a small gap from the shell. U.S. Pat. No. 5,746,891 discloses the seal construction of one such suction roll.
[0004] Seal wear has become a quite important problem. In addition, the noise and loss of power caused by the seals are important factors. Though wear resistance is thus a primary requirement in seals, a low noise output and power demand would also be desirable properties.
[0005] Seal strips, seals in brief, are of vulcanized rubber-graphite compounds. The typical configuration of a seal strip is a continuous piece, which is the same length as the suction box (3-12 m). Multi-piece seal strips exist, but these require special machining and installation. The material wears during operation and must be replaced at relatively frequent intervals. The nature of the material is that it is a rigid, brittle structure. The seals are sent to the mill in rigid containers with space for the entire length of the strip. The length and rigidity of the package result in considerable shipping and storage costs. The brittleness of the seal material results in a lowered yield in manufacturing and breakages during shipping and installation.
[0006] During operation, the seal strips are loaded against the inner shell of the roll by means of so-called loading hoses. Though the flexibility of the loading means permits some alignment of the seal strip from end to end, the rigidity of the seal strip prevents local conformity with the roll shell. Therefore all irregularities due to the manufacture of the shell, or deflection can be compensated for only with the aid of wear. As the seal is intended to be a critical element, its useful life is shortened.
[0007] The most common material for constructing a seal strip is a vulcanized rubber-graphite compound. It is used in the vast majority of rolls today.
[0008] Publication U.S. Pat. No. 5,649,719 (Beloit) discloses the use of graphite impregnated with resin for the manufacture of a suction roll seal strip. Publication U.S. Pat. No. 4,714,523; Sawyer, discloses a seal-strip construction, in which a PTFE strip is set inside a graphite strip, in order to improve its sliding properties. Publication U.S. Pat. No. 4,915,787 (Cline Company) discloses a seal-strip construction, in which a long seal strip is formed from short pieces, the ends of which are specially shaped to form overlapping joints between the strips. Publication U.S. Pat. No. 5,876,566 (Appleton) discloses a seal strip, which is formed from nitrile rubber, graphite, carbon black, PTFE, and optionally phenol resin. U.S. Pat. No. 2,893,487 (Beloit) discloses a suction-box solution, in which, in the rearward seal strip, grooving is formed against the shell on the trailing edge of the strip. This reduces the detrimental effects, such as noise, of a sudden change in pressure.
[0009] A combination of graphite and rubber is desirable because it provides good lubricating properties, does not wear excessively in normal operation, and is easy to manufacture. It can be manufactured in all the lengths required by papermaking equipment.
[0010] All rubber graphite seals strips are made in the following manner:
[0011] A rubber graphite mixture is milled to an acceptable consistency for extrusion
[0012] The compound is extruded to the approximate shape of the end product, or of a part product
[0013] The shaped strips are vulcanized to the final rigid condition
[0014] The rigid strips are machined to their final shape.
[0015] Fundamentally, all rubber graphite strips have the same physical characteristics, are made the same way, and perform similarly. They are all limited by shipping and handling constraints, due to their rigid and brittle nature.
[0016] The usual vulcanizing temperature is about 150° C. and the processing time is 3 hours. Additives are used, for instance, to create a suitable chemical structure in the end product. Certain additives, for example, sulphur, affect the number of carbon links. Some additives act as accelerating agents.
[0017] Other materials have been tried as seal strips, but none have been as successful are rubber graphite.
SUMMARY OF THE INVENTION
[0018] The present invention is intended to create an improvement over the known seals.
[0019] Accordingly, a suction roll seal strip, which is manufactured from a mixture, which mostly consists of nitrile rubber and graphite, is characterized in that the mixture includes wax. The amount of wax in the mixture is set in such a way that the flexibility of the seal strip permits it to be bent onto a reel, the radius of which is less than 130 cm.
[0020] A method for manufacturing a suction roll seal strip from a mixture, which mostly consists of nitrile rubber and graphite, and from which mixture a seal blank is formed, which is hardened at a chosen temperature, is characterized in that the mixture to be hardened includes wax. In a specific embodiment the amount of wax is 1-15%, preferably 2-4%. The amounts of nitrile rubber and graphite are within the ranges: nitrile rubber 30-60% volume, and graphite 30-60% volume.
[0021] The method is characterized in that the hardening temperature is in the range 140-160° C., preferably in the range 145-155°, and the hardening time is in the range 3-5 hours. The mass includes 1-15% sulphur or peroxide and the graphite used is natural graphite. Alternatively, the graphite used is synthetic graphite.
[0022] The method can be further characterized in that the melting point of the wax used is more than 100° C., preferably within the range 110-150° C.
[0023] The amount of wax is arranged to create flexibility in the seal strip, which will permit it to be rolled onto a reel with a radius of less than 1.5 m.
[0024] The seal strip according to the invention is so flexible that it can be rolled up. Besides flexibility, the invention gives a seal quieter operation and reduces the power it requires. Shipping and handling damage is reduced, as the material is less brittle than previously.
[0025] These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] In the drawings:
[0027] [0027]FIG. 1 shows a schematic view of the construction of a suction box;
[0028] [0028]FIG. 2 shows a comparison of the wear in a conventional seal strip and in a seal strip (FlexSeal) according to the invention;
[0029] [0029]FIG. 3 a shows a comparison of the power required by a conventional seal strip and by a seal strip (FlexSeal) according to the invention; and
[0030] [0030]FIG. 3 b shows a comparison of the noise levels when using a conventional seal strip and when using a seal strip (FlexSeal) according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] With reference to FIG. 1, the reference number 10 indicates a general view of a suction-box arrangement in a paper machine. This includes a stationarily supported suction box 12 located inside a perforated cylindrical roll 14 , which rotates around the suction box 12 . The cylindrical roll 14 has an inner surface 16 and an outer surface 17 and it is manufactured from, bronze, stainless steel, or a similar material. The suction box 12 has a gap opening 18 against the cylindrical roll 14 , with U-shaped gaps 21 and 23 , in practice particularly holders, in which seal strips 20 and 22 are placed, at both of its edges. The latter of these is generally the wider. The seal strips 20 , 22 are loaded from below by corresponding loading hoses 24 and 25 . The seal strips 20 and 22 wipe against the inner surface of the cylindrical roll 14 as it rotates.
[0032] The inner part of the suction box 12 is connected to a vacuum source (not shown), so that a suction effect acts on the inner surface 16 of the cylindrical roll 14 in the area of the gap 18 . The seal strips 20 and 22 extend over the length of the suction box 12 (thus covering the width of the web being dried) while there are special end seals (not shown) at the ends of the suction box 12 .
[0033] Previously, the following recipe, for example, was used in the manufacture of the mass:
EXAMPLE 1
[0034] [0034] % weight a) Polymer Nipol N612B 20 b) Nipol 1312 Liquid Rubber 10 a and b have together 30% acrylonitrile rubber stearic acid 0.6 magnesium oxide 1.5 graphite 56 accelerator MBTS 0.4 sulphur 12
[0035] The mass was mixed, ground carefully, and extruded through a mould, to create a strip blank. The blank was transferred to an autoclave, in which the processing lasted for 3 hours at 150° C. During processing, the chemical reactions were completed. The result obtained from the mould was a somewhat flexible solid piece (density 1.63 g/cm 3 ), which was transported fully extended, because the strip, with a cross-section of about 1.9×4.8 cm, could not be bent to a practicable curve.
[0036] In the invention, an solution to the shipping and storage problems of seal strips has been sought, as these are mainly due to the rigidity of the known strips. These problems are solved by using a new seal material, in which the following substances are used (as % volumes):
relative specific gravity NBR rubber 30-60%, preferably 40-50% 0.98 Graphite 30-60%, preferably 40-50% 2.25 Wax 1-20%, preferably 2-6% 0.97
[0037] It is advantageous to use small amounts of known auxiliary substances and additives. These include vulcanizing agents, such as sulphur; accelerating agents, such as peroxides; stabilizing agents, such as stearic acid; machining agents, such as MgO and ZnO.
[0038] In one manufacturing series according to the invention, the following recipe was used:
EXAMPLE 2
[0039] [0039] % weight PHR % volume NBR rubber 28 100 45 graphite 66 235 46 wax 3 10.5 4.5 vulcanizing agent 3 10 4.5
[0040] The product was extruded, vulcanized, and machined in a known manner. The vulcanizing temperature was 150° C., the processing time being 3 hours. At a lower temperature the reactions are slower and at a higher temperature faster, which in turn affects the processing time.
[0041] In the composition of the basic material, there is NBR rubber (acrylonitrile rubber), which is a copolymer of butadiene and acrylonitrile. The NBR rubber used in the example was Nipol N612B, Zeon Chemicals. The graphite used in the example was synthetic, but it can also be natural graphite.
[0042] The following table gives the most usual sizes of seal strips and their bending radii
minimum size (cm) bending radius (cm) Example 1 1.9 × 4.76 infinite (prior art) 7 × 4.76 infinite Example 2 1.9 × 4.76 30-100 (invention) 2 × 4.1 30-100 7 × 4.76 <130 7 × 4.4 <130
[0043] The essential new component is wax, which is preferably N, N′-ethylene bis-stearamide wax, for example, Advawax, Rohm & Haas, or Acrawax C, Lonza, or some other corresponding EBS wax (ethylene bis-stearamide wax), or some other bis-stearamide wax, or hydroxy stearamide wax, or hydroxy bis-stearamide waxes. Other synthetic or natural waxes, for example, carnauba wax, esparto wax, etc. can also be considered. Examples of synthetic waxes, in addition to those aforementioned, are polyolefin waxes and other amide waxes. A suitable wax should have a high melting point of more than 100° C., preferably in the range 110-150° C.
[0044] The wax significantly increases the flexibility of the product. A seal of the same size as that above (1.9×4.8 cm, density 1.59) can be bent to a relatively small curvature (R=30 cm) and the product can be formed into a reel, for example, for shipping. As a general rule, enough wax is used for the flexibility of the seal strip to be sufficient for shipping (bending onto a reel, in which the radius R<1.5 m). Even larger seal strips manufactured using the recipe according to the invention meet this criterion.
[0045] The use of synthetic graphite makes the seal anisotropic. The graphite is preferably used in the form of flakes or crystals.
[0046] The vulcanizing agent used in the example was Vulcup 40KE, Hercules, T-butylperoxy-diisopropyl benzene, but other vulcanizing peroxides, along with sulphur, can also be considered. Reactor accelerators, for example, thiazols such as benzothiazyl sulphide (e.g., MBTS, Vulkacit DM, Akrochem), or n-cyclohexylbenzo thiazyl sulphamide (Santocure MOR, Monsanto) can be used.
[0047] The seal strip (FlexSeal) manufactured using the method according to the invention was compared in several tests with known commercially available seal strips.
[0048] According to FIG. 2, the seal according to the invention wears relatively less than a conventional seal strip. As loading increases, the seal strip according to the invention behaved reliably compared to a conventional seal strip, which was observed to show a sudden increase in wear at a specific loading, if the loading increased further. The seal according to the invention has low wear in both wet and dry conditions.
[0049] According to FIG. 3 a , the seal strip according to the invention demands less operating power than a conventional seal strip. Similarly, the level of noise production was considerably lower using a seal strip according to the invention compared to a conventional seal strip, FIG. 3 b.
[0050] Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims. | The invention relates to a suction roll seal strip and a method for manufacturing it from a mixture, which mostly consists of nitrile rubber and graphite. A seal blank is formed from the mixture and hardened at a chosen temperature. The mixture to be hardened includes wax. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2014 012 963.2 filed Sep. 8, 2014, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to an actuating device, especially for a shading system, for actuation with a string element, which is associated with a first partial structure, which is detachably fastened to a second partial structure, whereby the first partial structure is detachable from the second partial structure with a simultaneous pull on a first strand and on a second strand of the string element when a predetermined pulling force is exceeded, and with at least one first coupling element, which is associated with the first partial structure and which meshes, in a locking position, with a second coupling element associated with the second partial structure, whereby the first partial structure is pivoted into the locking position with a pull on a single strand, and the first partial structure is pivoted with a simultaneous pull on the two strands of the string element into a released position for detaching the first partial structure from the second partial structure, whereby the first partial structure and the second partial structure are connected to one another by means of a detachable connection in the released position.
BACKGROUND OF THE INVENTION
[0003] Such an actuating device is known from U.S. Pat. No. 6,116,325 A. In this case, webs are formed from a flexible material, whereby, with a simultaneous pull on the two strands with a sufficiently great force, the webs are bent apart in such a way that the first partial structure is detached from the second partial structure. With a pull on a single strand, the first partial structure is pivoted in such a way that the first coupling element of a web of the first partial structure comes to rest on a second coupling element of the second partial structure. Consequently, a bending upward of the respective web and thus a detachment of the coupling elements lying on one another is prevented.
[0004] The disadvantage in this connection is that an unintentional bending upward of the webs or a detachment of the first and second coupling elements in the locking position cannot be completely ruled out. Further, it is disadvantageous that the webs or the first coupling elements for detaching the first partial structure from the second partial structure have to be bent away from each other. In this connection, there is the risk that the first partial structure is not detached from the second partial structure in a timely manner or only with an unduly great force. Furthermore, the use of flexible or elastic webs may lead to material fatigue and in the worst case to a material rupture. Consequently, there is the risk that the actuating device may not perform its intended function permanently.
[0005] Furthermore, it is known that the string element in shading systems with free-hanging string elements, especially when this string element forms a free-hanging loop, must be loosened with a pulling weight of 6 kg or more to meet the DIN standard EN 13120 in order to avoid an injury to a person or a child, especially because of strangulation.
SUMMARY OF THE INVENTION
[0006] A basic object of the present invention is to further develop an actuating device of the type mentioned in the introduction in such a way that, on the one hand, the risk of an unintentional detachment of the first partial structure from the second partial structure in the intended use can be avoided as much as possible and, on the other hand, a detachment of the first partial structure from the second partial structure is made possible with as low as possible forces to avoid injuries. In particular, a basic object of the present invention is that, on the one hand, an as high as possible pulling force can be transmitted with a selective actuation of the first strand or the second strand without the risk of an undesired separation of the two partial structures, and, on the other hand, a presettable, as low as possible pulling force for detaching the two partial structures is sufficient with a simultaneous pull on the first strand and the second strand. The risk of material fatigue shall preferably be reduced.
[0007] Basic objects of the present invention are accomplished by an actuating device of the type mentioned in the introduction, which is characterized in that the first coupling element does not mesh with the second coupling element in the released position, and in that with an interaction of the first coupling element with the second coupling element in the locking position, a detachment of the first partial structure from the second partial structure is prevented because of a positive-locking connection between the first coupling element and the second coupling element.
[0008] It is advantageous in this case that the first coupling element interacts with the second coupling element only in the locking position, as a result of which the connection between the first partial structure and the second partial structure is reinforced. Consequently, higher forces can be transmitted without the risk of an undesired detachment with a pull on a single strand in the locking position, in which the first partial structure is pivoted in relation to the second partial structure. Especially in the released position, the first coupling element is arranged in a functionless and/or contactless manner in relation to the second partial structure. Thus, the first coupling element cannot prevent a detachment of the first partial structure from the second partial structure in the released position. Consequently, the first coupling element and/or the second coupling element may be designed, for example, as solid and/or rigid. In particular, the first coupling element is fastened to the first partial structure and/or the second coupling element is fastened to the second partial structure.
[0009] Because of a, for example, rigid design of the first coupling elements and of the second coupling elements, an especially exclusively positive-locking connection can be established, as a result of which an especially loadable connection can be established between the first partial structure and the second partial structure with a pull on a single strand. In particular, the entire first partial structure and/or the entire second partial structure, preferably except for the components for forming a detachable connection in the released position, has a rigid design. Consequently, the risk of material fatigue can be reduced considerably. Moreover, because of the positive-locking connection between the first partial structure and the second partial structure with a pull on a single strand, the risk of an undesired detachment of the first partial structure from the second partial structure can be practically entirely avoided during normal use.
[0010] The first partial structure can especially be moved into a locking position with a pulling force and/or a pull only on a single strand. Thus, during a usual actuation of the actuating device for normal operation, because of a pulling on the first strand or the second strand, a positive-locking connection can be established between the first partial structure and the second partial structure. Consequently, high pulling forces can be transmitted, whereby the risk of an unintentional separation of the connection between the first partial structure and the second partial structure is considerably reduced. The pulling force acting on the first strand and/or the second strand or the acting pull may have a vertical, perpendicular and/or downward directed force component. Preferably within the framework of the present invention, a pull and/or a pulling force on only a single strand is also defined as the case that a higher pulling force and/or a higher tension acts on this strand than on the other strand.
[0011] The actuating device especially has a first detachable connection in the released position between the first partial structure and the second partial structure. This first connection may be designed as a locking connection. The first connection is detachable with a simultaneous pull on the first strand and on the second strand of the string element when a predetermined pulling force is exceeded. Preferably, the actuating device has, in the locking position, a second connection in addition to the first connection, which is formed by means of the first coupling element and the second coupling element.
[0012] The first partial structure is preferably arranged in the released position with no pulling force acting only on the first strand or only on the second strand. In particular, the first partial structure is in the released position with an especially essentially identical pulling force acting simultaneously on the first strand and on the second strand. Preferably, in the released position an especially positive locking connection, in addition to the detachable first connection, is not established between the first partial structure and the second partial structure. Thus, the detachable first connection in the released position can be released, preferably in a destruction-free manner, as a result of which the first partial structure is detachable from the second partial structure. At least one perpendicular, vertical and/or downward directed force component is preferably necessary for separation of the first connection of the first partial structure from the second partial structure. The released position can be arranged between a first locking position and a second locking position. The released position may be designed as a central position here.
[0013] The first partial structure is preferably movable, especially pivotable between a released position and two locking positions. In particular, the first partial structure is held in the released position exclusively by a detachable first connection, especially a locking connection, on the second partial structure. In each case, a first coupling element of the first partial structure preferably interacts with a second coupling element of the second partial structure for establishing the especially positive-locking and/or second connection in a locking position. Thus, the first partial structure and/or the second partial structure may each have two first coupling elements and two second coupling elements. In the locking position or because of the especially positive-locking and/or second connection, the two partial structures cannot be detached from one another in a destruction-free manner. In particular, the actuating device, especially the second connection, is designed in a locking position for accommodating high pulling forces, preferably with a pulling weight of more than 2 kg, especially of more than 4 kg, and especially preferably of more than 6 kg.
[0014] With an interaction of a first coupling element with a second coupling element, a detachment of the first partial structure from the second partial structure is preferably prevented because of a positive-locking and/or nonpositive-locking connection between the first partial structure and the second partial structure. The first coupling element may be designed as a first locking element, especially a locking hook, here. Furthermore, the second coupling element may be designed as a second locking element. The second locking element is especially designed as corresponding to the first locking element. For example, the second locking element is a locking hook mount. The two first coupling elements of the first partial structure may be facing one another or facing away from one another. Especially in case of first coupling elements facing one another, the second coupling elements of the second partial structure are aligned facing away from one another. Analogously hereto, the second coupling elements may be facing one another when the first coupling elements are facing away from one another.
[0015] According to one variant, the first partial structure is pivoted in the direction of the second strand with a pull only on the first strand. The first coupling element adjacent to the first strand interacts in a positive-locking and/or nonpositive-locking manner especially with the second coupling element associated with the first strand. The first partial structure can be pivoted in the direction of the first strand with a pull only on the second strand. The first coupling element adjacent to the second strand interacts in a positive-locking and/or nonpositive-locking manner especially with the second coupling element associated with the second strand. The pivoting motion of the first partial structure is preferably limited by the interaction of the first coupling element with the second coupling element. Because of the pivoting motion of the first partial structure, a respective first coupling element may be guided into a locking position with a respective second coupling element. Preferably, the first partial structure swings back into the released position automatically, especially because of the acting gravity, when a previously pulled strand is released. The released position can be arranged centrally between the two locking positions.
[0016] The first partial structure can preferably be moved into a first locking position with a pulling force only on the first strand and/or with a pulling force only on the second strand. The string element may be designed as flexible. The string element is especially a cord, a chain, a ball chain, a belt and/or a strap. Furthermore, the string element may be designed as an endless loop. Preferably, the string element has two string sections aligned essentially parallel to one another, whereby a first string section may be designed as the first strand and a second string section may be designed as a second strand. In the mounted state, the string element or the first strand and the second strand of the first structure may hang downwards, especially vertically. The first strand or the second strand is pulled essentially downwards and/or away from the first partial structure especially for actuating the actuating device for an adjustment of a shading curtain.
[0017] The actuating device especially has a basic structure consisting of a first partial structure and a second partial structure, especially for actuating a shading system and/or for actuation with a string element with a first strand and a second strand. The string element is associated with the first partial structure, whereby the first partial structure and the second partial structure can be connected to one another by means of a detachable connection. The, especially first, connection or locking connection is detachable with a simultaneous pull on the first strand and on the second strand when a predetermined pulling force is exceeded. The first partial structure preferably has two webs directed in the direction of the second partial structure, at the free ends of which a first coupling element each is arranged for interacting with a second coupling element of the second partial structure. The webs, the first coupling elements and/or the second coupling elements are especially designed as rigid for establishing a preferably additional, second and/or positive-locking, connection of the first partial structure to the second partial structure with a pull on a single strand.
[0018] According to another embodiment, the first partial structure is designed as a lower housing part and/or the second partial structure is designed as an upper housing part. The first partial structure may have at least one housing side with an axle for the rotatable mounting of a first gear wheel. The axle is especially arranged on an inner side of the housing side. Preferably, the first partial structure and/or the second partial structure has two housing sides arranged spaced apart from one another and essentially parallel to one another. Between the inner sides of the two housing sides of the first partial structure and/or of the second partial structure, an axle can, especially in each case, be connected in a nonrotatable manner and/or in one piece with the housing sides.
[0019] The first partial structure especially has a first gear wheel and/or the second partial structure has a second gear wheel. The gear wheels of the first partial structure and of the second partial structure especially mesh with each other, when the especially detachable and/or first connection between the first partial structure and the second partial structure is established. Regardless of the position of the first partial structure to the second partial structure, the two gear wheels mesh with each other. A rotary motion of the first gear wheel can be transmitted to a rotary motion of the second gear wheel especially in case of an established additional or second connection between a first coupling element and a second coupling element and/or in a locking position. The first gear wheel preferably has mounts for the string element. Thus, the first gear wheel can be generated into a rotary motion about the mount or the axle of the first partial structure by means of a pulling on the string element. By means of the first gear wheel, the second gear wheel can be displaced into a rotary motion about the axle of the second partial structure.
[0020] A pivoting of the first partial structure in relation to the second partial structure preferably takes place because of an interaction of the first gear wheel with the second gear wheel. In particular, a string element meshes with the first gear wheel of the first partial structure and/or is guided at least partly about the first gear wheel. The stronger the first strand or the second strand of this string element is pulled, the stronger is the pivoting of the first partial structure in relation to the second partial structure. Preferably, the first gear wheel is guided and/or pivoted coaxially about the axle of the second gear wheel with a pull on the first strand or the second strand of the string element interacting with the first gear wheel.
[0021] The first partial structure especially has an essentially U-shaped side wall, whose legs form webs directed in the direction of the second partial structure. A first coupling element can be arranged at each of the free ends of the webs for interacting with a second coupling element of the second partial structure. Preferably, the width of the side wall defines the distance between the two housing sides of the first partial structure. The first gear wheel can be accommodated within the side wall and/or be partly surrounded or enclosed by the side wall. The second partial structure may likewise have an essentially U-shaped side wall, whereby its legs are facing the first partial structure. The second gear wheel can be arranged within the side wall of the second partial structure. The second coupling elements can be arranged in the area of the free ends of the legs of the U-shaped side wall of the second partial structure. The legs and/or webs of the first partial structure especially have each a first coupling element and the legs and/or webs of the second partial structure have each a second coupling element.
[0022] Preferably, the first partial structure and the second partial structure have each a housing side on two sides facing away from each other. The housing sides of the first partial structure and of the second partial structure, which are arranged especially spaced apart from one another and/or parallel to one another, preferably interact for establishing the especially first connection of the first partial structure to the second partial structure, which is detachable with a simultaneous pull on both strands. The housing sides are especially arranged in such a way that they at least partly overlap. For example, the housing sides of the second partial structure may partly overlap the housing sides of the first partial structure. The first partial structure may especially be partly inserted and/or plugged into the second partial structure for establishing the detachable, especially first, connection. Preferably, the first partial structure and/or the second partial structure, especially the housing sides of the first partial structure and/or the housing sides of the second partial structure, may be designed as flexible and/or elastic at least in the area of the detachable, especially first, connection.
[0023] According to one variant, the detachable, especially first, connection between the first partial structure and the second partial structure makes possible at least a partial pivoting of the first partial structure about an axle in the area of the second partial structure. Preferably, the pivoting axle corresponds to the position of the axle of the second partial structure for accommodating the second gear wheel. The detachable, especially first, connection especially has an arc-shaped groove and a preferably correspondingly designed arc-shaped groove and a preferably correspondingly designed arc-shaped web, which meshes with the arc-shaped groove for establishing the detachable locking connection. The especially arc-shaped web and the arc-shaped groove are especially inserted into the housing sides of the first partial structure and the second partial structure. For example, an arc-shaped groove is inserted into the outer side of the housing sides of the first partial structure. An especially arc-shaped web can be inserted into the inner side of the housing sides of the second partial structure. The first partial structure can be inserted between the two housing sides of the second partial structure in such a way that the especially arc-shaped webs of the second partial structure lock into the arc-shaped grooves of the first partial structure. The arc-shaped web especially has a markedly lower width and/or arc length than the arc-shaped groove for making possible the pivotability of the first partial structure in relation to the second partial structure.
[0024] According to another embodiment, the first coupling elements and the second coupling elements form a first coupling device. In this case, the first coupling device is used for establishing an especially rigid, positive-locking and/or second, connection between the first partial structure and the second partial structure in order to prevent an unintentional detachment of the second partial structure from the second partial structure with a pull on a single strand. In particular, the first coupling device is separated functionally and/or spatially from the detachable, especially first, connection in the released position.
[0025] A second coupling device separate from the first coupling device is preferably present for establishing an additional, especially rigid, positive-locking and/or third, connection of the first partial structure with the second partial structure with a pull on a single strand. Thus, a second coupling device, in addition to the first coupling device, acting especially independently of the first coupling device, is provided. Thus, two especially positive-locking connections between the first partial structure and the second partial structure can be simultaneously established with a pull on a single strand. Consequently, it can be guaranteed in an especially reliable manner that the first partial structure is not unintentionally detached from the second partial structure. In addition, a redundancy is consequently achieved, as a result of which the functionality of the actuating device is maintained without restrictions even with a total failure of the first coupling device or of the second coupling device.
[0026] Preferably, the second coupling device has at least one essentially T-shaped locking head and at least one essentially T-shaped locking head mount designed corresponding to the locking head. The second coupling device is especially integrated into the housing sides of the first partial structure and of the second partial structure. For example, the locking head is arranged in the first partial structure and the locking mount in the second partial structure or vice versa. The locking head is preferably detachable from the locking head mount with a simultaneous pull on both strands in a contactless manner. A leg of the T-shaped locking head can mesh in a positive-locking manner with a correspondingly designed leg mount of the T-shaped locking head mount with a pull on a single strand. Consequently, the positive-locking connection can be established by means of the second coupling device.
[0027] Preferably, a third coupling device is present for establishing an especially positive-locking and/or fourth connection of the first partial structure to the second partial structure with a pull on a single strand or in the locking position of the first partial structure. In this case, the design of the third coupling device may correspond essentially to the design of the second coupling device. The second coupling device and the third coupling device may be arranged on two sides of the actuating device facing away from one another, especially in two housing sides of the first partial structure and of the second partial structure.
[0028] A shading system, especially a blind, a pleated blind and/or a roller blind, with an actuating device according to the present invention is especially advantageous. The actuating device makes possible, on the one hand, the transmission of a high pulling force with a selective actuation of the first strand or of the second strand without the risk of an undesired separation of the connection of the first partial structure from the second partial structure. This is made possible by at least one first coupling device, by means of which, for example, a rigid, positive-locking connection can be established between the first partial structure and the second partial structure. In this case, the coupling device is designed separate from a detachable first connection, which holds the first partial structure in the released position on the second partial structure. On the other hand, the detachable first connection between the first partial structure and the second partial structure can be designed in such a way that a low pulling force is sufficient for detaching the first connection with a simultaneous pull on the first strand and on the second strand. The first connection, preferably as a locking connection, between the first partial structure and the second partial structure is detachable in the released position, especially without destruction, with a pulling weight simultaneously on the first strand and the second strand of at least 6 kg. Consequently, for example, the requirement of DIN standard EN 13120 can be met.
[0029] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] In the drawings:
[0031] FIG. 1 is a schematic, perspective view of an actuating device according to the present invention;
[0032] FIG. 2 is a schematic, partially open, perspective view of the actuating device according to FIG. 1 ;
[0033] FIG. 3 is a schematic, open, perspective view of the actuating device according to FIGS. 1 and 2 ;
[0034] FIG. 4 is a schematic, cut partial sectional view of an actuating device according to the present invention;
[0035] FIG. 5 is a schematic, perspective view of the actuating device according to the present invention according to FIG. 1 with a detached first partial structure; and
[0036] FIG. 6 is another sectional view of the schematic, cut partial section according to FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Referring to the drawings, FIG. 1 shows a schematic, perspective view of an actuating device 10 according to the present invention. In this exemplary embodiment, the actuating device 10 is designed as a chain wheel coupling. The actuating device 10 is used to actuate a shading system, which is not shown here in detail. A string element 44 is provided for this. In this exemplary embodiment, the string element 44 is a ball chain. The string element 44 has a first strand 45 and a second strand 46 .
[0038] The actuating device 10 has a basic structure 11 that has a first partial structure 12 and a second partial structure 13 . Here, the first partial structure 12 is designed as a lower housing part and the second partial structure 13 is designed as an upper housing part. An upper area of the first partial structure 12 is inserted partly into a lower area of the second partial structure 13 . The first partial structure 12 has an end 14 facing away from the second partial structure 13 . An access opening 15 , which has a gap-like design, for example, here, is associated with the end 14 . By means of the access opening 15 , the string element 44 can be guided as a first string element 44 into and out of the first partial structure 12 . During use, the string element 44 is suspended from the access opening 15 and forms a loop, not shown in detail here, at its end facing away from the actuating device 10 . The second partial structure 13 has an additional access opening 17 at an end 16 facing away from the first partial structure 12 . The additional access opening 17 has a gap-like design, for example, here and is used for guiding an additional or second string element 47 into or out of the second partial structure 13 .
[0039] The second partial structure 13 has housing sides 18 , 19 arranged parallel to one another and spaced apart from one another. A side wall 20 is arranged between the housing sides 18 , 19 in the area of the outer circumference of the housing sides 18 , 19 . The side wall 20 of the second partial structure 13 has an essentially U-shaped cross section.
[0040] Furthermore, the first partial structure 12 has two housing sides 21 , 22 arranged parallel to one another and spaced apart from one another. A side wall 33 , which has an essentially U-shaped cross section, of the first partial structure 12 is arranged in the area of the outer circumference of the housing sides 21 , 22 and spaces the housing sides 21 and 22 apart from one another.
[0041] In this exemplary embodiment, the width of the side wall 23 of the first partial structure 12 is smaller than the width of the side wall 20 of the second partial structure 13 . Essentially, the difference of the widths between the side walls 20 , 23 corresponds approximately to the sum of the thickness of the two housing sides 18 , 19 . In addition, the side wall 20 of the second partial structure 13 has a setback in relation to the housing sides 18 , 19 in an area facing the first partial structure 12 . Consequently, a partial pushing in of the first partial structure 12 into an area facing away from the end 16 of the second partial structure 13 as shown is made possible.
[0042] FIG. 2 shows a schematic, perspective, partially open view of the actuating device 10 according to FIG. 1 . A part with the housing side 18 is removed from the second partial structure 13 , as a result of which the second partial structure 13 is opened and the inner structure can be seen.
[0043] The first partial structure 12 has two webs 24 , 25 aligned in the direction of the second partial structure 13 and essentially parallel to one another. In this exemplary embodiment, the webs 24 , 25 are designed as legs of the essentially U-shaped side wall 23 of the first partial structure 12 . A first coupling element 26 or 27 each is arranged at the free ends of the webs 24 , 25 facing the second partial structure 13 . Here, the first coupling elements 26 , 27 are designed as locking hooks. The locking hooks 26 , 27 are aligned facing one another.
[0044] The second partial structure 13 has second coupling elements 28 , 29 , which are each designed for interacting with one of the first coupling elements 26 , 27 , in an area facing the first partial structure 12 . Thus, the second coupling elements 28 , 29 in this exemplary embodiment are designed as locking hook mounts. The second coupling element 28 is associated with the first coupling element 26 and the second coupling element 29 is associated with the first coupling element 27 . The first coupling elements 26 , 27 and the second coupling elements 28 , 29 form a first coupling device and are designed as rigid.
[0045] According to the view according to FIG. 2 , the first partial structure 12 is located in a released position, in which neither of the first coupling elements 26 , 27 interacts with a second coupling element 28 , 29 . Rather, the first coupling elements 26 , 27 are shown in the released position spaced apart from the second coupling elements 28 , 29 in such a way that the two first coupling elements 26 , 27 can be directed in a contactless manner past the second coupling elements 28 , 29 for detaching the first partial structure 12 from the second partial structure 13 . Thus, the first coupling elements 26 , 27 in the released position do not mesh with the second coupling elements 28 , 29 .
[0046] The first partial structure 12 has a groove 30 in an area facing the second partial structure 13 . The groove 30 has an arc-shaped design and is embedded into the outer side of the housing side 21 of the first partial structure 12 . A groove designed analogously hereto is also located in the housing side 22 of the first partial structure 12 . The center of the radius of the arc-shaped groove 30 corresponds to the center of an axle 31 , which is associated with the second partial structure 13 . The inner sides of the housing sides 18 , 19 of the second partial structure 13 have a web, not shown in detail here, which meshes with the groove 30 for establishing a detachable locking connection. The web is designed as sufficiently flexible for establishing and detaching the locking connection.
[0047] In the released position shown here, the web is arranged essentially centrally in the groove 30 . The arc length of the groove 30 is greater than the width or the arc length of the web. As a result of this, the locking connection makes possible a pivoting of the first partial structure 12 about the center or the central axis of the axle 31 of the second partial structure 13 .
[0048] FIG. 3 shows a schematic, perspective, open view of the actuating device 10 . A part with the housing side 18 is removed from the second partial structure 13 and a part with the housing side 21 is removed from the first partial structure 12 , as a result of which the two partial structures 12 , 13 are open and their inner structure can be seen.
[0049] According to this view, the first partial structure 12 is pivoted into a first locking position. In this first locking position, the first coupling element 26 meshes with the second coupling element 28 for establishing a positive-locking connection. As an alternative to the first locking position shown here, the first partial structure 12 can be pivoted in such a way that the first coupling element 27 interacts with the second coupling element 29 for establishing a positive-locking connection, whereby the first partial structure 12 is then located in a second locking position. Because of the positive-locking connection between the rigid first coupling element 26 and the rigid second coupling element 28 in the first locking position or between the rigid first coupling element 27 and the rigid second coupling element 29 in the second locking position, an undesired detachment of the first partial structure 12 from the second partial structure 13 with a pull on a single strand of a string element, not shown here in detail, is prevented.
[0050] The first partial structure 12 has an axle 32 , which is used for the rotatable mounting of a first gear wheel 33 . The first gear wheel 33 is connected in a nonrotatable manner to a coaxially arranged chain wheel 34 . By means of a string element 44 , interacting with the chain wheel 34 and not shown in detail here for better clarity, the first gear wheel 33 can thus be displaced into a rotation about the axle 32 . The first gear wheel 33 is in active connection with a second gear wheel 35 , which is associated with the second partial structure 13 . The second gear wheel 35 is mounted rotatably about the axle 31 of the second partial structure 13 . In this exemplary embodiment, the second gear wheel 35 is connected in a nonrotatable manner to a coaxially arranged chain wheel 36 . Thus, a movement of a first string element 44 , which is guided about the first gear wheel 33 , can be transmitted to a second string element 47 , which is guided about the chain wheel 36 .
[0051] The first gear wheel 33 and the second gear wheel 35 are actively connected to one another in such a way that a pivoting of the first partial structure 12 can be brought about because of the interaction between the two gear wheels 33 , 35 . The stronger the first strand 45 or the second strand 46 of the first string element 44 is pulled, the stronger is the first partial structure 12 pivoted in relation to the second partial structure 13 . In this case, the first gear wheel 33 is coaxially guided about the outer circumference of the second gear wheel 35 or the axle 31 .
[0052] The second string element 47 may be connected to a drive for driving a shading system. As an alternative, the second gear wheel 35 may have no chain wheel and instead be connected directly to a drive axle.
[0053] FIG. 4 shows a schematic, cut partial section of an actuating device 10 according to the present invention. The first partial structure 12 has a third coupling element 37 at an end facing the second partial structure 13 . The third coupling element 37 is designed for interacting with a fourth coupling element 38 of the second partial structure 13 . The third coupling element 37 and the fourth coupling element 38 form a second coupling device. In this exemplary embodiment, the third coupling element 37 is designed as an essentially T-shaped locking head. The fourth coupling element 38 is designed here, for example, as an essentially T-shaped locking head mount. The fourth coupling element 38 is arranged at an end of the second partial structure 13 facing the first partial structure 12 . In this exemplary embodiment, the third coupling element 37 is arranged in the plane of the housing surface 18 and the fourth coupling element 38 is arranged in the plane of the housing surface 21 .
[0054] The third coupling element 37 and the fourth coupling element 38 are arranged essentially centrally to a conceived vertical axis of the first partial structure 12 and of the second partial structure 13 . Furthermore, the third coupling element 37 and the fourth coupling element 38 are designed in such a way that the third coupling element 37 can be guided in a contactless manner from the fourth coupling element 38 in the released position, shown here, of the first partial structure 12 in relation to the second partial structure 13 . Thus, in the released position, the third coupling element 37 and the fourth coupling element 38 do not mesh with one another. For this, a base or base opening 39 of the fourth coupling 38 is designed as somewhat wider than the T-shaped locking head of the third coupling element 37 . The third and fourth coupling elements 37 , 38 are designed as rigid.
[0055] In a locking position, not shown in detail here, of the first partial structure 12 , a leg 40 or 41 of the third coupling element 37 meshes with a correspondingly designed leg mount 42 or 43 . A positive-locking connection between the first partial structure 12 and the second partial structure 13 can thus be established in the locking position.
[0056] The third coupling element 37 is arranged in the area of the housing side 21 of the first partial structure 12 and the fourth coupling element 38 in the area of the housing side 18 of the second partial structure 13 . Analogous to the third coupling element 37 and the fourth coupling element 38 , a fifth coupling element designed analogously hereto and a sixth coupling element may be provided, which are arranged in the area of the housing sides 19 , 22 and thus form a third coupling device designed analogously to the second coupling device.
[0057] FIG. 5 shows a schematic, perspective view of the actuating device 10 according to the present invention according to FIG. 1 with a detached first partial structure 12 . The first partial structure 12 has two assembled housing halves 48 , 49 . The housing halves 48 , 49 are connected to one another by means of a locking connection in this exemplary embodiment.
[0058] The second partial structure 13 has two assembled housing halves 50 , 51 , which are connected to one another by means of a separate fixing element 52 in this exemplary embodiment. The fixing element 52 may be used as a securing means for a locking connection of the two housing halves 50 , 51 . The fixing element 52 is designed here as a screw, which is guided through the axle 31 . In this case, the axle 31 according to FIGS. 2 and 3 is designed as a hollow axle. By means of the fixing element 52 , an especially reliable connection between the housing halves 50 , 51 can be established. As an alternative or in addition, the first partial structure 12 may have an analogously designed fixing element.
[0059] The housing halves 48 , 49 , 50 , 51 have different designs in this exemplary embodiment. As an alternative, the housing halves 48 , 49 of the first partial structure 12 or the housing halves 50 , 51 of the second partial structure 13 may have an identical design.
[0060] In the released position, the first partial structure 12 is in active connection or meshes with the second partial structure 13 by means of the groove 30 . With a sufficiently strong pull or essentially equally strong pull on both strands 45 , 46 of the string element 44 , for example, due to the gravity of a child suspended in a loop of the string element 44 , this single connection is detached from the second partial structure 13 by a bending up of the housing sides 18 , 19 at least in the area of the groove 30 , as a result of which the first partial structure 12 is completely detached from the second partial structure 13 as shown here.
[0061] FIG. 6 shows another sectional view of the schematic, cut partial section according to FIG. 4 . The single detachable connection between the first partial structure 12 and the second partial structure 13 in the released position can be seen in this view. This detachable active connection is designed as a detachable locking connection in this exemplary embodiment. Here, a web 53 of the second partial structure 13 meshes with the groove 30 of the first partial structure 12 . The groove 30 is inserted into a front side of the housing side 21 of the first partial structure 12 . The web 53 is arranged on the inner side of the housing side 18 of the second partial structure 13 .
[0062] Analogously hereto, an additional web 55 of the second partial structure 13 meshes with an additional groove 54 of the first partial structure 12 . The additional groove 54 is inserted into a front side of the housing side 22 of the first partial structure 12 . The additional web 55 is arranged on an inner side of the housing side 19 of the second partial structure 13 .
[0063] As an alternative, the detachable position between the first partial structure 12 and the second partial structure 13 in the released position may have at least one pin or a plurality of pins instead of a web 53 , 55 . The pins or the webs 53 , 55 may have a flexible design in order to guarantee a detachment of the first partial structure 12 in the released position with a sufficient pulling force on both strands 45 , 46 . As an alternative or in addition, the housing sides 18 , 19 may be flexible or elastic in the area of the locking connection or of the webs 53 , 55 .
[0064] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
[0000]
APPENDIX
List of Reference Numbers
10
Actuating device
11
Basic structure
12
First partial structure
13
Second partial structure
14
End
15
Access opening
16
End
17
Access opening
18
Housing side
19
Housing side
20
Side wall
21
Housing side
22
Housing side
23
Side wall
24
Web
25
Web
26
First coupling element
27
First coupling element
28
Second coupling element
29
Second coupling element
30
Groove
31
Axle
32
Axle
33
First gear wheel
34
Chain wheel
35
Second gear wheel
36
Chain wheel
37
Third coupling element
38
Fourth coupling element
39
Base opening
40
Leg
41
Leg
42
Leg mount
43
Leg mount
44
String element
45
First strand
46
Second strand
47
Additional string element
48
Housing half
49
Housing half
50
Housing half
51
Housing half
52
Fixing element
53
Web
54
Groove
55
Web | An actuating device ( 10 ) actuates a shading system with a string element ( 44 ). An unintended detachment of a first partial structure ( 12 ) from a second partial structure ( 13 ) in the intended use is avoided as much as possible and a detachment of the first partial structure ( 12 ) from the second partial structure ( 13 ) is possible with low forces for avoiding injuries. The actuating device ( 10 ) includes a first coupling element ( 26, 27 ) that in the released position does not mesh with a second coupling element ( 28, 29 ), and in the locking position, with an interaction of the first coupling element ( 26, 27 ) with the second coupling element ( 28, 29 ), a detachment of the first partial structure ( 12 ) from the second partial structure ( 13 ) is prevented because of a positive-locking connection between the first coupling element ( 26, 27 ) and the second coupling element ( 28, 29 ). | 4 |
TECHNICAL FIELD
[0001] The present invention relates to a method and a device for providing a substrate with a coating layer of a polymeric material. The invention has especially been developed for, but is not limited to, the coating of a packaging laminate with a polymer layer.
PRIOR ART
[0002] The coating of a web-shaped substrate, such as a packaging laminate, with a layer of polymeric material, is performed commercially by extrusion of a polymer layer onto the substrate or by coating the substrate with a dispersion or solution of a polymeric material. The polymer layer may have the function of a barrier layer, against penetration of gas or liquid, a sealing layer etc.
[0003] Even though the today known methods of extrusion and coating are functioning well, there are drawbacks of such techniques. Of all known drawbacks, only a few will be mentioned in the following. By such techniques, it is e.g. difficult to coat parts of the surface of the substrate or to coat non-uniform surfaces or surfaces in different planes. Furthermore, the known techniques require that the polymeric material that during its manufacturing has taken a pulverous form, is processed by e.g. granulation, which means that the original properties of the polymer are affected, often in a negative way. By the known techniques, it is also difficult to be able to apply a very thin coating layer.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention aims at providing an alternative technique of coating a substrate with a coating layer of a polymeric material. The invention also aims at providing such an alternative technique by which the above mentioned drawbacks of known techniques are overcome or at least diminished. The invention aims primarily at providing such a technique for coating a substrate for a packaging laminate, especially for packaging of liquid foods, with a polymeric material.
[0005] These and other objectives are achieved by the invention as defined in the claims.
[0006] Hence, the method according to the invention relates to a method of providing a substrate with a coating layer of a polymeric material, comprising the steps that:
a) a pulverous, polymeric material is suspended in a fluid, b) the fluid is pressurised, c) the pressurised suspension is ejected onto the substrate to form the coating layer, d) the polymeric material is, during any one of steps a-c, heated to a temperature above its softening temperature.
[0011] The invention is based on the idea that a coating layer of a polymeric material on a substrate can be achieved from a pulverous polymeric material that is being heated to a temperature above its softening temperature, but preferably below its melting temperature, and thereafter is brought by great force to hit the substrate. Together, the softened surface of the pulverous particles and the great force of impact result in a “sintering-like” coating of the substrate.
[0012] One advantage of the method according to the invention, is that the used pulverous particles of polymeric material may be the pulverous particles as formed directly in connection with the manufacturing of the polymeric material, i.e. the pulverous form that the polymeric material has taken during its manufacturing in a reactor. Usually, the pulverous, polymeric material has a mean particle size of 1-100 μm, preferably 1-50 μm, and even more preferred 1-25 μm. If it is only the surface of the pulverous particles that is softened, the original properties of the polymeric material will largely be intact in the formed coating layer, which is a major advantage.
[0013] Another advantage of the method according to the invention, is that it is easily controlled to enable forming of very thin coating layers, such as layers having a thickness of 0.1-5 μm, preferably 0.1-2 μm, and even more preferred 0.1-1 μm. Moreover, the method allows for forming such coating layers also on substrates that are non-uniform or are arranged in different planes, thanks to the method advantageously being contactless in relation to the substrate. Furthermore, the method allows for essentially the entire surface of one side of the substrate to be coated with a homogeneous and continuous coating layer, or that the coating layer is only partially applied, on chosen parts of the surface on one side of the substrate. In the latter case, a coating layer may be formed to have a chosen pattern and/or e.g. only on the parts of the substrate surface that are to be sealed against each other (in case the coating layer is a sealing layer). Besides being a sealing layer, it may for example be conceived, but not limited to, that the coating layer is an aroma barrier layer, a gas barrier layer, a gloss contributing layer, a layer for improved gripping, a scavenging layer, a delamination layer, an adhesive layer, or a liquid barrier layer, and that the polymer is one or more polymers suitable therefore according to what is well known to the person skilled within the field.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0014] In the following, the present invention will be described in greater detail with reference to a preferred embodiment and with reference to the enclosed FIG. 1 that schematically and by principle shows a device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Detail no. 1 in FIG. 1 generally denotes mixing equipment for mixing a pulverous, polymeric material 2 with a fluid 3 , in the shown case a liquid or more specifically water. Other conceivable liquids may be of the type that they affect the surface properties of the polymer particles, such as their surface tension. The polymeric material may be any type of polymeric material that is suitable to form a coating layer on a substrate, especially a packaging laminate for liquid foods, and that is insoluble in the chosen fluid. A preferred polymeric material is a polyolefin, such as a polyethylene of any suitable grade.
[0016] A suspension of polymer particles in liquid is formed in mixing equipment 1 . The mixing equipment may also comprise a heating system 4 for heating the suspension, such as to 50-99° C. if the polymer is a polyolefin. The drawing symbolically shows an agitator, but any other mixing equipment is conceivable, such as a mixing equipment comprising a revolving drum.
[0017] From the mixing equipment 1 , the suspension is led to pressurising equipment 5 , such as a pump, in which the suspension is pressurised up to a pressure of 100 bar. Also in connection with the pressurisation, the suspension can be additionally heated, preferably by indirect heat transfer 6 . As long as the polymer particles are in the liquid suspension, i.e. at least until they leave the nozzle 9 (see below), the temperature on the surface of the polymer particles should however not be brought to exceed the melting temperature of the polymer.
[0018] The increase in fluid temperature, where appropriate the water temperature, can be achieved by for example microwave equipment. By microwaves, the energy content of the water, i.e. its temperature, may be much more increased than that of the polymer granulate.
[0019] Now, the suspension is supplied to flow controlling equipment 7 . The flow controlling equipment 7 is also provided with an outlet/a nozzle 9 , through which the suspension is ejected/sprayed under pressure. In the shown case, the flow controlling equipment 7 is provided with a flow controlling needle 8 that can be vertically displaced in the outlet, but other means for flow controlling are also conceivable, e.g. comprising vibrators.
[0020] If the entire surface of the substrate is to be coated, the open cross-section of the nozzle 9 is elongated over the width of the substrate 10 . Optionally, several elongated nozzles can be arranged consecutively (not shown), so that layer upon layer of the coating is formed on the substrate. If only parts of the substrate are to be coated, the nozzle will instead be of circular shape or possibly elongated but only extending over a part of the width of the substrate 10 .
[0021] After the nozzle, there is a heating zone 11 , in which heating equipment 12 heats the suspension jet ejected from the nozzle 9 , normally to a temperature above the softening temperature for the polymer but below its melting temperature. It should not be excluded however that the method according to the invention may work also if the suspension or polymer is heated to a temperature above the melting temperature of the polymer, in any of the heating steps. At the heating, the liquid is evaporated from the suspension jet 16 , and the polymer particles are softened, at least on their surface. Therefore, the polymer particle jet is essentially free from liquid as it hits the substrate 10 . An exhaust 14 is arranged to remove evaporated liquid fumes. As the polymer particles thereafter hit the substrate 10 by great force, thanks to the pressurisation of the system, a sintering-like coating 13 will be formed on the substrate, whereby the individual polymer particles are united to each other. Optionally, additional heating treatment or some other post treatment may follow (not shown), in order for the coating to acquire the desired properties.
[0022] The heating in the heating zone 11 is preferably direct but contactless, and makes use of controllable high power heating equipment 12 , such as irradiation, laser, microwaves or similar; or some other high power technique/equipment.
[0023] Upstream and in direct connection with the coating position, the substrate 10 may optionally be pretreated, preferably for increased adhesion by activation of its surface (increasing the surface energy), by e.g. flame treatment, symbolised by arrow 15 . Preferably, the substrate is a substrate for a packaging laminate, preferably comprising one or more layers in the group that consists of a fibre based core layer, a polymer core layer, a gas barrier layer (such as of aluminium or a polymeric material), an adhesive layer, a liquid barrier layer and a sealing layer.
[0024] Optionally, the surface of the polymeric pulverous particles may be affected/pretreated, e.g. to counteract agglomeration of the pulverous particles in the suspension, preferably by treating the pulverous particles or by addition to the suspension of an agent that affects the surface, such as a tenside.
[0025] The invention is not restricted to the shown embodiment but can be varied within the scope of the claims. It may for example be conceived that the liquid is initially heated and/or pressurised, before the pulverous polymer is suspended therein. If the liquid is pressurised before the heating is completed in the initial heating step(s), it is of course possible to heat to a temperature above the boiling point of the liquid, if so is desired depending on choice of polymer. If the fluid is gaseous, such as air or an inert gas, the evaporation step is of course excluded, but the heating remains with the purpose of achieving a softening of the surface of the polymer particles. The ratio of polymer/fluid may initially be 10/90 to 50/50 (%), independent of the type of fluid. | A method and device for providing a substrate ( 10 ) with a coating layer ( 13 ) of a polymeric material, comprising the steps: a) a pulverous, polymeric material ( 2 ) is suspended ( 1 ) in a fluid ( 3 ), b) the fluid ( 3 ) is pressurised ( 5 ), c) the pressurised suspension is ejected ( 16 ) onto the substrate ( 10 ) to form the coating layer ( 13 ), d) the polymeric material is, during any one of steps a)-c), heated ( 4, 6, 11 ) to a temperature above its softening temperature. | 3 |
This application claims priority under 35 U.S.C. § 119(e) from Provisional Application No. 60/102,545, filed Sep. 30, 1998, the contents of which are hereby incorporated by reference in their entirety.
GOVERNMENT SUPPORT
Applicants' invention was supported in part by Public Health Service Grant AI-21628 from the National Institute of Allergy and Infectious Diseases. Therefore, the government may have certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates to methods of identifying substances that combat infections and diseases caused by prokaryotes, and more particularly to methods of identifying substances that exhibit anti-bacterial/anti-microbial effects.
BACKGROUND OF THE INVENTION
As a consequence of the widespread use and perhaps even misuse of antibacterial drugs, strains of drug-resistant pathogens have emerged. Antibiotic-resistant bacterial strains have been associated with a variety of infections, including tuberculosis, gonorrhea, staphylococcal and pneumococcal infections, and the bacteria most commonly associated with pneumonia, ear infections and meningitis. More importantly, infectious disease remains the largest cause of mortality in the world.
The typical response to an ineffective antibiotic has simply been change antibiotics. Unfortunately, this alternative no longer offers a guarantee of success. For example, certain strains of enterococci are resistant to vancomycin—a drug formerly considered to be the ultimate weapon against many different types of bacteria. The World Health Organization has expressed concern that the development of new drugs is not keeping pace with the numbers of antibiotics which become ineffective. World Health Report 1996: Fighting Disease, Fostering Development, Executive Summary (World Health Organization 1996). Despite ongoing research, there remains a pressing need to develop new antibiotics. There is also a need for antibacterials that are effective in treating disease while not stimulating the emergence of resistant strains.
Bacteria respond to nutritional stress by the coordinated expression of different genes. This facilitates their survival in different environments. Among these differentially regulated genes are the genes responsible for the expression of virulence determinants. The expression of these genes in a sensitive or susceptible host allows for the establishment and maintenance of infection or disease. Virulence genes encode toxins, colonization factors and genes required for siderophores production or other factors that promote this process.
Virulence genes in bacteria express a variety of factors that allow the organism to invade, colonize and initiate an infection in humans and/or animals. These genes are not necessarily expressed constantly (constitutively), however. That is, the bacterium is not always “infectious”. In many circumstances, the expression of virulence genes is controlled by regulatory proteins known as repressors in conjunction with a corresponding operon(s) or operator(s). In prokaryotes, one class of repressors is activated upon binding to or forming a complex with a transition metal ion such as iron or zinc. When the repressor is activated, it binds the operator thereby preventing production of virulence determinants.
Virulence determinants are most often expressed when the bacterial pathogen is exposed to nutritional stress. An iron-poor environment is an example of such a condition. In this environment, insufficient iron is present to maintain the repressor in its active state. In the inactive form, the repressor cannot bind to target operators. As a result, virulence genes are de-repressed and the bacterium is able to initiate, establish, promote or maintain infection.
The expression of these virulence determinants is in many bacterial species is co-regulated by metal ions. In many instances the metal co-factor that is involved in vivo is iron. In the presence of iron, the repressor is activated and virulence gene expression is halted.
This pattern of gene regulation is illustrated by the following example. The bacterium that causes diphtheria produces one of the most potent toxins known to man. The toxin is only produced under conditions of iron deprivation. In the presence of iron, the bacterial repressor (which in this species is known as diphtheria toxin repressor protein, abbreviated “DtxR”) binds iron and undergoes conformational changes that activate it and allow it to bind a specific DNA sequence called the tox operator. The tox operator is a specific consensus DNA sequence found upstream of the gene that produces the diphtheria toxin. Binding of DtxR to this site thereby prevents toxin expression. Typically, during infection of a human or animal host the diphtheria bacillus (or other pathogenic/opportunistic bacteria) grows in an environment that rapidly becomes restricted in several key nutrients. Paramount among these essential nutrients is iron, and when iron becomes limiting the diphtheria bacillus begins to produce the toxin. Moreover, the constellation of virulence genes that DtxR controls becomes de-repressed and the diphtheria bacillus becomes better adapted to cause an infection. In the case of diphtheria, the toxin kills host cells thereby releasing required nutrients including iron.
SUMMARY OF THE INVENTION
The present invention is directed to a simple and accurate method for identifying substances that repress or prevent or attenuate virulence gene expression in an infectious microorganism and phenotypically convert it to a non-pathogen. The method may be practiced to identify substances effective against any pathogenic (infectious) prokaryote whose pattern of virulence determinant expression (or a portion thereof) is under the regulatory control of a metal ion-dependent repressor. Thus, Applicants' invention can be employed to identify substances that provide a therapeutic or medicinal benefit to humans and animals.
A first aspect of the present invention is directed to a method for screening test substances to identify non-metal ion activators of a metal ion-dependent repressor of virulence determinants expression in a virulent or opportunistic prokaryotic pathogen. Substances that are identified as activators of the repressor may be developed as antibiotics or anti-bacterial substances. Accordingly, this method involves:
(a) providing recombinant cells comprising a first recombinant DNA segment containing a first promoter operably linked to a first regulatory gene encoding a first repressor native to or functional in a given prokaryote, a second DNA segment containing a second promoter operably linked to a first operator that binds said first repressor and a second regulatory gene encoding a second repressor, and a third recombinant DNA segment comprising a third promoter operably linked to a second operator that binds the second repressor, and a reporter gene;
(b) culturing said recombinant cells in medium substantially free of metal ion activators of said first repressor and which contains a selection agent that directly or indirectly causes a detectable response upon expression or lack of expression of the reporter gene;
(c) adding a non-metal ion test substance to said medium; and
(d) determining whether the response occurs as an indication of whether said test substance activates said first repressor.
In preferred embodiments, the first regulatory gene encodes a diphtheria tox repressor (DtxR) protein that is the native DtxR protein, or a fragment, variant or homologue of DtxR, and the first operator binds the DtxR protein and is native tox operator (toxo) or a toxo fragment, or a variant of a DtxR consensus binding sequence. In more preferred embodiments the second regulatory gene encodes the tetracycline repressor (TetR), the second operator comprises the tetracycline operator (tetO), the reporter gene encodes chloramphenicol acetyltransferase and the selection agent is chloramphenicol. The medium comprises a chelating agent that binds metal ion activators of the first repressor.
In other preferred embodiments, the first and second recombinant DNA segments are contained in a first vector, preferably a plasmid, and the third recombinant DNA segment is contained in a second vector such a lysogenic phage.
Another embodiment of this aspect of the invention entails providing a solution containing (a) purified repressor native to or functional in a given prokaryote; (b) a DNA construct comprising in operable association, a promoter, an operator and a reporter gene; (c) a coupled transcriptional and translational system that allows expression of the reporter gene; (d) a chelating agent that binds metal activators of the repressor; and (e) a non-metal ion test substance to allow a reaction to occur; and detecting expression or lack of expression of the reporter gene as an indication of whether the test substance activates the repressor. This embodiment offers relative simplicity in terms of working in a cell-free system with fewer elements and genetic manipulations. In preferred embodiments, the coupled transcriptional and translational system contains bacterial extract and the reporter gene encodes β-galactosidase or luciferase or a readily assayable reaction product.
Another aspect of the present invention is directed to the various genetic constructs and compositions of matter useful in the disclosed methods. Accordingly, one preferred embodiment is directed to a composition of matter containing: a recombinant vector comprising a first DNA segment containing a first promoter operably linked to a first regulatory gene encoding a first repressor native to or functional in a given prokaryote, and a second DNA segment containing a second promoter operably linked to a first operator that binds the first repressor, and a second regulatory gene encoding a second repressor. The recombinant vector further may contain a third DNA segment containing a third promoter operably linked to a second operator that binds the second repressor, and a reporter gene. It is preferred, however, that the third DNA segment resides on a separate vector such as a lysogenic phage. This aspect of the present invention also provides recombinant host cells, e.g., E. coli containing the recombinant vector(s).
Another embodiment of this aspect of the present invention provides a composition of matter containing: (a) purified repressor protein native to or functional in a given prokaryote, a, (b) a DNA construct comprising in operable association, a promoter, an operator that binds the repressor protein and a reporter gene, (c) a transcriptional and translational system that allows expression of the reporter gene and (d) a chelating agent that binds metal ion activators of said repressor protein. The composition further may contain a non-metal ion test substance. In preferred embodiments, the coupled system comprises bacterial extract.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 schematically illustrates the plasmids and constructs employed by the PSDT ( p ositive s election of D txR homologue and t argets) system to identify iron-independent repressors. Randomly PCR generated mutants of the DtxR were cloned into the BamHl site of pBR322 and then co-transformed into the PSDT indicator strain E. coli TOP10λRS65T with pSC6. Alternatively, mutant dtxR genes were cloned into pSC6M1 and transformed into TOP10λRS65T. Iron independent mutants conferred Cm R were selected on Ap/Kn/Cm/DP (Ap=Ampicillin; Kn=Kanamycin; Cm=Chloramphenicol; DP=2, 2′-dipyridyl).
FIG. 2 is a graph of the β-galactosidase activity of E. coli DH5/αRS45T toxPO lacZ that carry plasmid pDRA expressing a wt dtxR gene[open circles], pDM2 [filled diamond], pDM3 [filled triangle], pDM11 [filled circle] or pDM5 [open diamond]. Plasmids pDM2, pDM3, pDM11 and pDM5. The β-galactosidase gene was placed under the control of the toxPO in place of the cat gene. The data show that as iron becomes limiting with the addition of increasing amounts of 2,2′-dipyridyl (DP) to the growth medium β-galactosidase activity increases in cells expressing the wild-type DtxR protein. In contrast, cells expressing mutant iron-independent repressors fail to de-repress the β-galactosidase gene and no β-galactosidase activity is detectable.
FIG. 3 is a schematic diagram of the PSDT system for the positive selection of DtxR binding sites or DtxR homologues. In the Presence of a functional DtxR-toxO circuit (pLS-1/pSA20) the tetR gene, carried by coliphage λRS65T, is repressed. Repression of TetR synthesis allows the de-repression of the cat gene which confers chloramphenicol resistance to the bacterial host, E. coli TOP1O. In the absence of either a dtxR target operator sequence (pLS-1/pSA18M 1) or DtxR, the constitutive expression of TetR represses the cat gene thereby rendering the bacterial host chloramphenicol sensitive even in the presence of 200 μM 2,2′-dipyridyl.
DETAILED DESCRIPTION OF THE INVENTION
The presently disclosed method is designed to identify non-metal ion substances that phenotypically convert a virulent or opportunistic pathogenic prokaryote such as a bacterium or microbe into a non-pathogenic microorganism. The method entails the use of genetic circuitry that mimics key, interrelated events that occur in vivo and cause a given prokaryote to become infectious or pathogenic. This system contains a small group of interrelated genetic elements. The introduction into the system of a test substance causes these genetic elements to respond in an easily detectable manner.
The regulatory units e.g., the first, second and third promoters, may be the same or different. They are functional in the cell of choice and they are constitutive or inducible in nature upon the addition of the appropriate inducer to the medium direct the continuous expression of the operably linked gene or genes. Regulatory units are well known in the art. Examples include lacI, lacO, trpR and trpO.
In preferred embodiments, the first repressor encodes DtxR or a functional fragment, variant or homologue (collectively referred to as “a DtxR protein”). DtxR is an iron-dependent DNA-binding protein having a deduced molecular weight of 25,316 and which functions as a global regulatory element for a variety of genes on the C. diphtheriae chromosome. See Tao et al., Proc. Natl. Acad. Sci. USA 89:5897-5901 (1992); Schmitt et al., Infect. Immun. 59:1899-1904 (1994). For example, DtxR regulates the expression of the diphtheria toxin structural gene (tox) in a family of closely related Corynebacteriophages. The DtxR gene has been cloned and sequenced in E. coli and its DNA and amino acid sequences have been reported. See Boyd et al., Proc. Natl. Acad. Sci. USA 87:5968-5972 (1990); Schmitt et al., supra. DtxR is activated by divalent transition metal ions (e.g., iron). Once activated, it specifically binds the diphtheria tox operator and other related palindromic DNA targets. See Ding et al., Nature Struct. Biol. 3(4):382-387 (1996); Schiering et al. Proc. Natl. Acad. Sci. USA 92:9843-9850 (1995); White et al., Nature 394:502-506 (1998).
Functional fragments or variants of DtxR, when activated, retain their binding activity to the tox operator (or a functional fragment thereof) and/or the DtxR consensus binding sequence. DtxR fragments and variants can be identified by standard techniques such as mutagenesis. It has been reported that the Cys102 residue in DtxR is important in binding the tox operator and substitutions with amino acids other than Asp abolish binding activity. Tao et al., Proc. Natl. Acad. Sci. USA 90:8524-8528 (1993). Other variants are disclosed in Tao et al., Mol. Microb. 14(2):191-197 (1994). Tao discloses that some DtxR alleles have different amino acid sequences, e.g., the DtxR allele from strain 1030(−) of C. diphtheriae was found to carry six amino acid substitutions in the C-terminal region, none of which affected the iron-dependent regulatory activity of DtxR (1030) (Tao 1994). See also Boyd et al., J. Bacteriol. 174:1268-1272 (1992) and Schmitt et al., Infect. Immun. 59:3903-3908 (1991).
Many other bacterial species employ regulatory circuits and repressor proteins that exhibit high degrees of sequence similarity to DtxR. Thus, DtxR homologues may also be employed in the methods of the present invention. Iron dependent regulator (IdeR), isolated from Mycobacterium tuberculosis , has been found to share 60% homology or sequence similarity with DtxR. See Schmitt et al., Infect Immun. 63(11):4284-4289 (1995). See also Doukhan et al., Gene 165(1):67-70 (1995), which reports and references DtxR homologues in Mycobacterium smegmatis and Mycobacterium leprae . DtxR homologues have been cloned from other gram-positive organisms including Brevibacterium lactofermentum and Streptomyces lividans . See Oguiza et al., J. Bacteriol. 177(2):465-467 (1995); Günter et al., J. Bacteriol. 175:3295-3302 (1993); and Schmitt et al., Infect. Immun. 63:4284-4289 (1995). Staphylococcal iron regulated repressor (SirR), native to Staphylococcus epidermitis , is another known DtxR homologue. These proteins bear a common feature—they share a remarkably high sequence similarity in the respective N-terminal 139 amino acids, especially those amino acids involved in DNA recognition and transition metal ion co-ordination. In addition to DtxR homologues, DtxR sensitive promoters and/or genes involved in a variety of cellular activities have been cloned from C. diphtheriae chromosomal libraries. See Schmitt et al., J. Bacteriol. 176:1141-1149 (1994), and Schmitt, J. Bacteriol. 179:838-845 (1997).
A collection of accession numbers for sequences that are homologous to DtxR, or contain the consensus toxO sequence, is presented in Table 1. See also, Altschul, et al., J. Mol. Biol. 215:403-410 (1990); Gish, et al., Nature Genet. 3:266-272 (1993); Madden, et al., Meth. Enzymol. 266:131-141 (1996); Altschul, et al., Nucleic Acids Res. 25:3389-3402 (1997); and Zhang, et al., Genome Res. 7:649-656 (1997). This degree of sequence similarity in the homologues and the distribution of the operator sequences indicates that the iron regulatory pathway that employs the DtxR-family of repressors is conserved in many important human and animal pathogens.
TABLE 1
DtxR Homologues
Pathogenic
Human/Veterinary
Applications
Other
CAA67572
S. epidermidis
*
L35906
C. glutamicum
Gi 1777937
T. pallidum
Z50048
S. pilosus
CAA15583
M. tuberculosis
*
Z50049
S. lividans
U14191
M. tuberculosis
*
U14190
M. smegmatis
L78826
M. leprae
*
L35906
B. lactofermentum
M80336
C. diphtheriae
*
M80337
C. diphtheriae
*
M34239
C. diphtheriae
*
M80338
C. diphtheriae
*
Selection of DNA Homologous to DtxR Identifiable in Current Databases
Gi 2622034 M.thermoautotrophicum
Stanford 382 S. meliloti
Gi 2621260 M.thermoautotrophicum
TIGR 1280 S. aureus
M50379 M. jannaschi
OUACGT S. pyogenes
Q57988 M. jannaschi
Sanger 518
B. bronchoseptica
O33812 S. xylosus
Sanger 1765
M. bovis *
Gi 264870 A fulgidus
Sanger 520
B. pertusis *
Gi 2648555 A fulgidus
WUGSC K. pneumoniea
Gi 2650396 A fulgidus
TIGR 76
C. crescentus
Gi2650706 A fulgidus
TIGR 24
S. putrificacieus
BAA79503 A. pernix
TIGR1351
E. faecalis
AAD18491 C. pneumoniae *
AE000783
B. burgdorferi
Gi 3328463 C. trachomatis
TIGR1313
S. pneumoniea *
CAB49983.1 P. abyssi
Snager 632
Y. pestis
BAA30263 P. horikoshi
AE000657
A. aeolius
Gi 2621260 M.thermoautotrophicum
TIGR 920
T. ferrooxidans
TIGR 1752 V. cholera
AE001439
H. pylori
* = species also contains toxO sequences
In the case where the first repressor is DtXR, the preferred first operator is the natively associated tox operator, toxO, a functional fragment thereof, or a variant of a DtxR consensus binding sequence. The native tox operator (i.e., 5′-ATAATTAGGATAGCTTTACCTAATTAT-3′ (SEQ ID NO:1)) is a 27 base pair interrupted palindromic sequence upstream of the diphtheria tox structural gene; it features a 9-base pair inverted repeat sequence that is separated by 9 base pairs. See Kaczorek et al., Science 221:855-858 (1983); Greenfield et al., Proc. Natl. Acad. Sci. USA 80:6853-6857 (1983); Ratti et al., Nucleic Acids Res. 11:6589-6595 (1983); and Fourel et al., Infect. Immunol. 57:3221-3225 (1989). It overlaps both the −10 region of the tox promoter and the transcriptional start sites at −45, −40 and −39 upstream of the diphtheria toxin structural gene. See Boyd et al., J. Bacteriol. 170:5940-5952 (1988). The minimal essential DNA target site, i.e., 5′-GTAGGTTAGGCTAACCTAT-3′ (SEQ ID NO:2), is a 19 base pair sequence that forms a perfect palindrome around a central C or G. It is described in Tao and Murphy, Proc. Natl. Acad. Sci. USA 91:9646-9650 (1994). In preferred embodiments, the native promoter P tOX is operably linked to the operator, resulting in the construct known as toxPO. Also preferred are variants of toxo based on the DtxR consensus-binding sequence (5′-ANANTTAGGNTAGNCTANNCTNNNN-3′ (SEQ ID NO:3)). The variants are defined by the following sequence: 5′-TWAGGTTAGSCTAACCTWA-3′ (SEQ ID NO:4).
In yet other preferred embodiments, the first repressor is fur (ferric uptake regulator), or a functional fragment or variant thereof. Fur functions as a metal ion-activated global regulatory element for a variety of genes in gram-negative bacteria, such as E. coli , Pseudomonas, Vibrio cholerae, Yersinia pestis , Pseudomonas and Salmonella. See, Althaus, et al., Biochem. 38:6559-6569 (1999), which reports that Fur is activated by zinc ions. Fur and fur-like proteins are also described in Hantke, Mol. Gen. Genet. 197:337-341 (1984); Schaffer et al., Mol. Gen. Genet. 200:111-113 (1985); Litwin et al., J. Bacteriol. 174:1897-1903 (1992); Prince et al., J. Bacteriol. 175:2589-2598 (199); and Staggs et al., J. Bacteriol. 173:417-425 (1991). As in the case of DtxR, the amino acid sequence of the Fur family of regulatory proteins and the nucleic acid sequences of their respective DNA binding sites have been found to be homologous. In embodiments wherein the first repressor is a Fur protein, the corresponding first operator is can be one of several fur box or iron box sequences for example; 5′-GATAATTGAGAATCATTTTC-3′, (SEQ ID NO:5) 5′-GATATTGAGAATCATTTTC-3′ (SEQ ID NO:6), 5′-GATACTGAGAATCATTTTC-3′ (SEQ ID NO:7), 5′-GATACTGAGAATCATGTTC-3′ (SEQ ID NO:8) as described in Stojiljkovic et al., J. Mol. Biol. 236:531-545 (1994)).
When the first repressor is a DtxR homologue, the corresponding first operator sequence may be obtained in accordance with routine screening as illustrated in example 2, below. In other embodiments, the first repressor/first operator pair are native to the target prokaryote. In general, however, the target prokaryote need not necessarily dictate the choice of these elements. To identify and develop an antimicrobial to treat Staphylococcus infections, for example, relatively large numbers of test substances may be screened first by using the more preferred pair, DtxR/toxO. The underlying assumption is that the interaction/affinity of repressors in other species for their cognate operators is similar or identical to DtxR/toxO. The next phase of development entails treating Staphylococcus infections with the test substances identified in the first as activators of DtxR. To the extent that any of the test substances are relatively ineffective, a second screen can be conducted, this time replacing DtxR with SirR and toxo with an operator identified from the method described in example 2 (using genomic DNA from Staphylococcal species). Thus, the first repressor is native to or functional in a given prokaryote in the sense that non-native proteins such as fragments and other variants retain binding activity for the corresponding operator, and thus would prevent virulence gene expression in vivo. That is to say, the first repressor co-regulates virulence gene expression in a given prokaryote.
The second DNA segment contains a second promoter, which may be the same as or different from the first promoter, the first operator and a second regulatory gene encoding a second repressor which is different from the first repressor. The second promoter is operably linked to the operator and the second regulatory gene so as to permit the continuous expression of the second regulatory gene unless the first repressor is activated and binds the first operator. The second repressor can be any repressor that will bind a corresponding operator sequence and prevent expression of a gene operably associated with the operator which in this case is the reporter gene. In a preferred embodiment, the second repressor is the tetracycline repressor (TetR) and the second operator on the third DNA fragment is the tetracycline operator (tetO). The nucleotide sequences of tetR and tetO are disclosed in Unger et al., Gene 31(3):103-108 (1984). The second repressor binds the operator of the third DNA segment and prevents expression of the reporter gene. Other second repressor/second operator pairs useful in the present invention include the lac repressor (lacI)/lac operator. The operator must be recognized by the respective repressor.
The third promoter of the third DNA segment is operably linked to the second operator and the reporter gene so as to permit the expression of the reporter gene unless the second repressor binds the second operator.
The choice of promoter for this segment is largely a matter of choice based on the host cell. In the case where the second operator is tetO, however, it is preferred that the promoter is the natively associated tetO promoter such that the resultant construct is tetAPO. In general, the reporter gene may be any gene whose expression product interacts with a corresponding selection agent so as to produce a detectable response. The response may be detected by optical, chemical or photochemical means. In a preferred embodiment, the reporter gene encodes chloramphenicol acetyltransferase. Cells that express this gene grow in the presence of chloramphenicol. If the chloramphenicol acetyltransferase gene is not expressed (e.g., because the candidate substance is not an activator of the first repressor), cell death occurs. Other examples of reporter gene/selection agent combinations are β-lactamase/ampicillin, kanamycin/aminoglycoside phosphotransferase and gentamycin/aminoglycoside acetyltransferase. Some reporter genes allow for selective growth complementation of an auxotroph. An example of such a reporter gene is the gene encoding amylase. In a system using the amylase gene as the reporter gene, cells grown in a medium using starch as the only carbon source (and as the selection agent) will require the expression of amylase to convert starch to carbon. Cells that do not express amylase (indicating that the test substance does not activate the first repressor) fail to grow in the presence of starch.
The DNA segments useful in this invention may be obtained in accordance with standard techniques. For example, they may be generated using standard chemical synthesis techniques. See, e.g., Merrifield, Science 233:341-347 (1986) and Atherton et al., Solid Phase Synthesis, A Practical Approach , IRL Press, Oxford (1989). Preferably, they are obtained by recombinant techniques. Standard recombinant procedures are described in Sambrook et al., 1989, Molecular Cloning, A Laboratory Manual , Second ed., Cold Spring Harbor, New York, and Ausubel et al., (eds.) Current Protocols in Molecular Biology , Green/Wiley, New York (1987 and periodic supplements). The appropriate sequences can be obtained from either genomic or cDNA libraries using standard techniques. DNA constructs encoding the DNA gene segments may also be prepared synthetically by established methods, e.g., in an automatic DNA synthesizer, and then purified, annealed, ligated and cloned into suitable vectors. Atherton et al., supra. Polymerase chain reaction (PCR) techniques can also be used. See e.g., PCR Protocols: A Guide to Methods and Applications , 1990, Innis et al. (ed.), Academic Press, New York.
The starting materials in which to make the vectors for use in this aspect of the invention are readily available from commercial sources, e.g., pBR322 and pACYC184 (both available from New England Biolabs). In preferred embodiments, two vectors are utilized. The first vector contains the first and second DNA segments. The choice the first vector is based mainly on the host cells. The second vector is preferably a single copy vector, e.g., a lysogenic phage such as a derivative of coliphage lambda (λ) (Simons et al., Gene 53:85-96 (1987)) such that only a single copy of this vector is introduced into the host cell. The presence of only a single copy of the second vector in the recombinant cell ensures that expression of the second repressor prevents expression of the reporter gene, which in turn reduces background noise and false positive results. In less preferred embodiments, the three DNA segments are contained in a single construct or vector. Alternatively, a one-vector system may be utilized, consisting of only three DNA segments. In these embodiments, two selectable marker genes are required. A first marker gene is present to assure maintenance of the vector within the host, and the second marker gene is present to allow detection of the activated first repressor.
Host cells useful in the invention include mammalian, yeast and bacterial cell lines. Bacterial cell lines are preferred. More preferred are E. coli cell lines, including DH5α, TOP10 and JM101.
The vectors are introduced into the cells in accordance with standard techniques such as transformation, co-transformation, transfection with a retroviral vector, direct transfection (e.g., mediated by calcium phosphate or DEAE-dextran) and electroporation.
The recombinant cells are cultured via standard techniques. Conditions may vary depending upon the system being used. In general, culturing is continued from about 24 to 48 hours at a temperature between about 30° C. and about 390C., preferably 37° C. The recombinant cells are cultured in a medium substantially free of metal ion that activate the first repressor. Iron is an essential element for both the bacterial pathogen and its animal host; thus, successful competition for this element is an essential component of the infectious process. The concentration of free iron in the mammalian host available to an invading bacterial pathogen is also extremely limited. As a result, the expression of virulence determinants (e.g., colonization factors, siderophores, hemolysins and toxins) by bacterial pathogens is regulated by iron. Accordingly, the cells are cultured in medium substantially free of iron and other metal ions, particularly divalent metal cations, because these elements are activators of DtxR and otherwise would compete with the test substance for binding and cause a false positive selection. A preferred way in which to remove contaminating amounts of the metal ions is to add a chelating agent such as 2,2′-dipyridyl, Chelex™100 (Biorad, Richmond, VA) or transferrin, to the medium. The preferred chelator, 2,2′-dipyridyl, is used at a final concentration of 150-200 μM.
A selection marker is added to the medium. When the chloramphenicol acetyltransferase gene is used as the reporter gene, the selection marker is chloramphenicol. Concentration of chloramphenicol ranges from about 10-15 μg/ml.
The test substance is added to the culture medium, typically at a concentration of no more than about 10 5 M. A wide variety of test substances may be screened by the present method. Test substances are not limited to any particular type of compound because there may not a preconceived notion as to the nature of the substance that will be recognized and bound by the bacterial repressor protein, and thus serves to activate the protein through tight binding or other chemical interaction. Thus, candidate substances used in the method may be organic or inorganic, polymeric or non-polymeric in nature.
Screening of test substances involves the detection of the expression of the reporter gene of the third DNA gene segment. In a preferred embodiment, the determination as to whether the test substance activates the repressor is made simply by observing whether cell growth occurs. Cell growth may be observed simply by visual inspection. In a preferred embodiment, cell growth is determined by measuring the optical density of a given culture.
Without intending to be bound by any particular theory of operation, the genetic circuitry entailed by the method as broadly described works as follows. If the test substance activates the first repressor, the repressor binds the first operator and prevents expression of the operably linked second regulatory gene (encoding the second repressor). The absence of the second repressor allows the expression of the reporter gene because the second operator is not bound with the second repressor. The reporter gene expression product inactivates the selection marker and thus allows the transformed cells to grow in the medium.
Conversely, if the test substance does not activate the first repressor, expression of the second regulatory gene occurs; the second repressor binds the second operator, and the reporter gene is not expressed. The lack of expression of the reporter gene renders the cells sensitive to the selection agent and results in the death of the transformed cells. Cell growth does not occur.
Stated in the context of the more preferred embodiment, a test substance that activates DtxR causes DtxR to bind the tox operator and prevent expression of the tetR gene. Because the tetR gene is not expressed, the tetracycline operator (tetO) on the second vector is not bound and the chloramphenicol acetyltransferase-encoding gene is expressed. Chloramphenicol is normally toxic to E. coli . Chloramphenicol acetyltransferase inactivates chloramphenicol thus allowing cells to grow in the presence of chloramphenicol. Conversely, if the test substance does not activate DtxR, toxO is not bound and tetR is expressed. Expression of tetR causes binding of TetR to teto, thus preventing expression of chloramphenicol acetyltransferase. In the absence of chloramphenicol acetyltransferase, chloramphenicol exerts its toxic effects and cell growth does not occur.
Thus, in a preferred embodiment, this system is simply a growth/no-growth assay, wherein growth indicates that the candidate substances and activator of DtxR, and the absence of growth (cell death) indicates that the candidate substance is not an activator of the virulence determinant repressor.
Another embodiment of the present invention entails a cell-free system. This embodiment is simpler in that is requires fewer elements and manipulations, namely: (a) purified repressor protein native to or functional in a given prokaryote, (b) a DNA construct comprising in operable association, a promoter, an operator that binds the repressor protein and a reporter gene, (c) a coupled transcriptional and translational system that allows expression of the reporter gene and (d) a chelating agent that binds metal ion activators of the repressor protein. The system is preferably a bacterial extract which is commercially available. The test substance is added and the expression of the reporter gene is detected as an indication of whether the test substance activates the repressor. If the test substance is an activator, the reporter gene is not expressed. Preferred reporter genes allow for direct detection of the expression product and include β-galactosidase (see, Miller, J. H. (1972) Experiments in Molecular Genetics (Cold Spring Harbor Lab. Press, Plainview, NY)) and luciferase or a readily assayable reporter gene product.
Test substances that test positively in the disclosed methods may then be subjected to additional tests to confirm whether they activate the first repressor. For example, a candidate substance that tests positively in the screening assay may be subjected to a gel electrophoresis mobility-shift assay. In this assay, the interaction among the candidate substance, a specific protein (the first repressor protein, e.g., DtxR) and a DNA molecule (e.g. the tox operator) is observed. If a test substance activates the first repressor, it will bind the first repressor. In its active form, the repressor will bind the first operator. If binding occurs, this complex formed will have an altered electrophoretic mobility compared to the toxO probe that is not complexed with an activated DtxR. Mobility shifts may be measured autoradiographically. Other confirmatory tests involve repression of other reporter gene expression.
The invention will be further described by reference to the following detailed examples. These examples are provided for purposes of illustration only, and are not intended to limit the scope of the invention described herein.
EXAMPLES
Example 1 describes the consequences of producing iron-independent DtxR repressors and assaying them in the PSDT system. In one embodiment the PSDT screen can be employed to pan compound libraries for non-metal ion activators. Such compounds would be anticipated to constantly activate DtxR and yield an iron-independent phenotype. The example describes how iron-independence can be detected using the PSDT system coupled with a library of mutant DtxR repressors. In this instance, the alteration in the repressor structure by genetic mutation gives rise to the iron-independent phenotype. The screening of mutants is essentially identical to the screening of compounds using the PSDT screen. Of particular importance are the results presented in FIG. 2 which demonstrate that the Self Activating DtxR (SAD) mutants pulled from a library of randomly generated mutants of dtxR repressor genes are iron independent. Thus the PSDT system is an effective tool for the rapid identification of iron-independent repressors or repressors which are activated in the absence of a metal such as iron.
Example 1
Iron Independent Activation of DtxR.
Materials and Methods
Bacterial Strains, Plasmids, Phages, and Medium.
The bacterial strains, plasmids and phages used in this study are described in Results and Table 2.
TABLE 2
Part A: Strains and Bacteriophage utilized in Examples 1 and 2
Source
Strains/Phage
Genotype
or Reference
Strains:
E. coli TOP 10
mcrA Δ(mrr-hsdRMS-mcrBC) φ8O
Invitrogen
Δlac ΔM 15 ΔlacX74 deoR recA 1 λ − endA1
E. coli DH5α
F-(φ8Od lacZ ΔM15) Δ(lacZYA-argF) recA1
BRL
endA gyrA thi1 hsdR17 (rk − , mk − ) supE44
relA1 U196
E. coli NK7049
F − λ − ΔlacX74 rspL galOP308
Simons et al.
(1987)
Corynebacterium
Boyd et al.
diphtheriae C7 (−)
(1990)
C. diphtheriae 484
Nakao et al.
(1996)
C. diphtheriae 880
Nakao et al.
(1996)
Brevibacterium ammoniagenes
ATCC
Bacteriophages:
λRS45
lacZ′ bla′
Simons et al
(1987)
λRS65
tetAPO-cat-lacZYA Cm R
Tao et al.
(1995)
λRS65T toxPO
toxPO − lacZ Kn R
Boyd et al.
(1990)
λRS65T
tetAPO-cat-lacZ′YA Cm R
Tao et al.
(1995)
TABLE 2
Part B: Plasmids utilized in Examples 1 and 2
Plasmid
Genotype
Source or Reference
Plasmids:
pRS551
lacZYA AP R Kn R
Simons et al. (1987)
pCM4
cat AP R
Pharmacia
pGPI-2
Kn R
Tabor and Richardson
(1987)
pWS129
pSC101 ori Kn R
Wang et al. (1991)
pRS551toxPO
toxPO AP R Kn R
Boyd et al. (1990)
pXT102C
dtxR AP R
Tao et al. (1993)
PCR/tetRT
tetR TL AP R Kn R
These Studies
pLS-1
dtxR AP R Kn R
These Studies
pLS-2
dtxR − AP R
These Studies
pRS65T
cat trpA TC AP R Kn R
These Studies
pSA20
AP R Kn R
These Studies
pSA18M1
pSC101 ori tetR mtP Kn R
These Studies
pSC6M1
pSC101 ori tetR toxPO Kn R
These Studies
pBR322
ColE1 ori AP R
New England Biolabs
pACYC184
p15A ori Cm R
Mew England Biolabs
pRDA
Co1E1 ori dtxR AP R
These Studies
PSC6
pSC101 ori toxpO-tetR Kn R
These Studies
pSDM2
pSC101 ori SAD2 Kn R
These Studies
pSDM3
pSC101 ori SAD3 Kn R
These Studies
pSDM11
pSC101 ori SAD11 Kn R
These Studies
pSDM5
pSC101 ori SAD5 Kn R
These Studies
pDM2
ColE1 ori SAD2 AP R
These Studies
pDM3
ColE1 ori SAD3 AP R
These Studies
pDM11
ColE1 ori SAD11 AP R
These Studies
pDM5
ColE1 ori SAD5 AP R
These Studies
pDM2A
p15A ori SAD2 Cm R
These Studies
pDM3A
p15A ori SAD3 Cm R
These Studies
Tabor, et al., Proc. Natl. Acad. Sci. USA 84:4767-4771 (1987); Wang, et al., Gene 100: 195-199 (1991). Complete citations of other publications refer to in table are set forth elsewhere in specification.
E. coli strains were grown in LB (10 g of tryptone, 10 g of NaCl, and 5 g of yeast extract per liter). LB broth and LB agar were supplemented with ampicillin (Ap; 100 μg/ml), kanamycin (Kn; 25 μg/ml), Cm (12.5 μg/ml), and 5-bromo-4-chloro-3-indolyl β-D-galactopyranoside (40 μg/ml) as indicated. The iron chelator DP was added to a final concentration of 200 μM to LB agar and as indicated to LB broth.
Nucleic Acids. DNA cloning, plasmid preparation, and DNA sequence analysis were performed according to standard methods (Ausubel, F. M., Brent, R., Kingston, R. E., Moore, D. D., Seidman, J. G., Smith, J. A. & Struhl, K. (1988) Current Protocols in Molecular Biology (Wiley, New York)., Sanger, F., Nicklen, S. & Coulsen, A. R. (1977) Proc. Natl. Acad. Sci. USA 74, 5463-5467). Restriction endonucleases, T4 polynucleotide kinase, and Klenow fragment of DNA polymerase (New England Biolabs) were used according to the manufacturer's specifications. PCR mutagenesis of DtxR was based on the method of Vartanian et al. (Vartanian, J.-P., Henry, S. & Wain-Hobson, S. (1996) Nucleic Acids Res. 24, 2627-2631). In brief, BglII-tagged primers 1515 (5′-ACCAGATCTGCCGAAAAACTTCGA-3′ (SEQ ID NO:9)) and 1516 (5′-ACCAGATCTCCGCCTT-TAGTATTTA-3′ (SEQ ID NO:10)) were used to PCR amplify dtxR from plasmid pRDA, which carries the wild-type dtxR operon. The products of the amplification then were digested with BglII and either were ligated into BglII-linearized pSC6M1 and were transformed into E. coli TOP10/λRS65T or were ligated into BamHl digested pBR322 and were transformed into E. coli TOP10/λRS65T/pSC6. Iron-independent mutants of DtxR then were selected on LB agar plates supplemented with chloramphenicol and 2,2′-dipyridyl.
β-Galactosidase Assay.
β-galactosidase activity was measured essentially as described by Miller (Miller, J. H. (1972) Experiments in Molecular Genetics (Cold Spring Harbor Lab. Press, Plainview, N-Y)). In brief, 0.5 ml of an overnight culture at A 600 of =1.0 were lysed by the addition of lysis mix (chloroform:10% SDS, 2:1), vortexing the mixture for 10 sec and transferring 200 μl to 800 μl lacZ buffer (60 mM Na 2 HP0 4 /40 mM NaH 2 PO 4 /10 mM KCl/1 mM MgSO 4 /50 mM β-mercaptoethanol). The reaction was initiated by adding 200 μl of o-nitrophenyl β-D-galactopyranoside (Sigma) (4 mg/ml). After incubation at room temperature (5 min-1hr), the reaction was stopped by the addition of 0.5 ml of 1M sodium carbonate. Absorbance was measured at 420 and 550 nm, and β-galactosidase units were calculated according to Miller, supra.
Results
Development of the PSDT System.
The PSDT system, which consists of a lysogenic E. coli TOP10 host strain carrying the reporter gene cat on an integrated λ phage, λRS65T, and a set of detector plasmids, is illustrated in FIG. 1 . Expression of cat on λRS65T is controlled by the tetA promoter/operator (tetAPO), and, in the absence of the tetracycline repressor (TetR), E. coli TOP10/λRS65T is resistant to chloramphenicol (Cm R ).
We next constructed the detector plasmid pSC6, which carries the tetR gene under the control of the diphtheria toxPO. When pSC6 is transformed into E. coli TOP10/λRS65T, the bacterial host strain becomes Cm-sensitive (Cm S ) by virtue of the constitutive expression of tetR, which recognizes and binds to the tetAO and represses cat gene expression. However, if a functional dtxR allele is introduced into the bacterial host on a second compatible plasmid, pRDA, the interaction between DtxR and the toxO will repress the expression of tetR, and the bacterial host, E. coli TOP10/λRS65T/pSC6/pRDA, then will regain its CMP phenotype. Furthermore, because the iron chelator 2,2′-dipyridyl (DP) is known to inactivate DtxR, the addition of DP to the growth medium results in a phenotypic conversion from Cm R to Cm S . As shown in Table 3, the addition of DP to the growth medium did result in the conversion to a 2,2′-dipyridyl Cm s phenotype.
Finally, to demonstrate the requirement for a functional dtxR in the PSDT system, pRDA was digested with EcoRV to delete a 713-bp fragment and thereby knock out the dtxR gene. The resulting plasmid, pLS-2, then was transformed into E. coli TOP10/λRS65T/pSC6. As anticipated, in the absence of a functional DtxR, the indicator strain becomes Cm s . Table 3 summarizes the antibiotic resistance phenotypes of derivatives of E. coli TOP10/λRS65T that carry one or more of the PSDT detector plasmids.
TABLE 3
Antibiotic Resistance Phenotype of Selected Strains and
Plasmids Central to Examples 1 and 2
Ap
Kn
Cm
Ap/Kn
Ap/Kn/Cm
Ap/Kn/DP
Ap/Kn/Cm/DP
TOP10/λRS65T
−
−
+ + +
−
−
−
−
pSC6
−
+ + +
−
−
−
−
−
pRDA
+ + +
−
+ + +
−
−
−
−
pSC6/pRDA
+ + +
+ + +
+ + +
+ + +
+ + +
−
−
pSC6/pLS-2
+ + +
+ + +
+ + +
+ + +
−
−
−
pLS-1/pSA18M1
+ + +
+ + +
−
+ + +
−
+ + +
−
pLS-1/pSA20
+ + +
+ + +
+ + +
+ + +
+ + +
+ + +
−
pLS-2/psA20
+ + +
+ + +
−
+ + +
−
+ + +
−
Isolation of Iron-Independent Self-Activating DtxR (SAD) Mutants.
The PSDT system initially was developed for the positive selection of dtxR alleles, homologues, and DtxR DNA target sites from genomic libraries. We have also used the PSDT system to isolate a unique class of iron-independent, constitutively active mutants of DtxR. For this purpose, we constructed the detector plasmid pSC6M1, in which the introduction of a unique BglII restriction endonuclease site allows the cloning of DtxR alleles in the same vector that carries the toxPO-tetR transcriptional fusion.
The overall scheme for the selection of SAD mutants is shown in FIG. 1 . The wild-type DtxR allele carried by pRDA was mutagenized by PCR amplification according to the method of Vartanian et al. (Vartanian, J.-P., Henry, S. & Wain-Hobson, S. (1996) Nucleic Acids Res. 24, 2627-2631) using BglII tagged primers 1515 and 1516. After PCR mutagenesis, the amplified DNA was digested with BglII and either was ligated into the BglII site of pSC6M1 and was transformed into TOP10/λRS65T or was ligated into the BamHl site of pBR322 and was transformed into TOP10/λRS65T/pSC6. Because wild-type DtxR is inactivated in the presence of the iron chelator DP, potential SAD mutants were selected on LB agar supplemented with both Cm and 200 μM DP. In a typical experiment, 10 5 colony forming units were plated on LB/Cm/DP agar plates, and after 24-hr incubation at 37° C., the colonies that developed were picked and colony purified, and their respective plasmids were analyzed.
In each instance, restriction endonuclease digestion analysis demonstrated that the plasmids had an insertion of the size anticipated for DtxR. Of the nine colonies that were isolated using the PSDT system, four clones subsequently were characterized fully. The plasmids named pSDM2, pSDM3, pSDMll and pSDM5 are derivatives of the detector plasmid pSCM61, and pSDM5 was derived from pBR322. The mutant DtxRs encoded by these plasmids were designated SAD2, SAD3, SADll, and SAD5, respectively.
To demonstrate that each isolate carried an active iron-independent mutant of dtxR, their respective dtxR alleles were recloned into the NcolBamHl sites of pRDA to replace the wild-type DtxR. The resulting plasmids were designated pDM2, pDM3, pDMll, and pDM5, respectively. The pDM series of plasmids then were transformed individually into E. coli DH5α/RS45toxPO. This reporter strain carries a transcriptional fusion in which the lacZ gene is under the control of the diphtheria toxPO, toxPO-lacZ, and, as a result, the synthesis of β-galactosidase is regulated by their respective dtxR gene products. Individual strains were grown in LB broth supplemented with appropriate antibiotics in either the absence or presence of increasing concentrations of DP. As shown in FIG. 2, β-galactosidase assays indicated that, in marked contrast to transformants that expressed wild-type DtxR, those strains that expressed either SAD2, SAD11, or SAD3 maintained complete repression of lacZ, even in the presence of 250 μM DP. In contrast, the transformant that expressed SAD5 displayed an intermediate iron-independent phenotype. These results are consistent with the observation that the growth of E. coli TOP10/λRS65T /pSC6/pSDM5 is inhibited partially by Cm in the presence of 200 μM DP. In comparison, E. coli TOP10/λRS65T strains that carry either pSDM2, pSDM3, or pDMll are completely Cm R .
To further demonstrate that SAD2 and SAD3 were iron-independent mutants of dtxR, each allele was knocked out by the deletion of a 713-bp EcoRV restriction endonuclease fragment that encompasses the promoter and N-terminal encoding portion of their structural genes. As anticipated, transformation of E. coli DH5α/λRS45toxPO with plasmids encoding defective SAD2 and SAD3 genes failed to confer detectable repression of lacZ (data not shown).
SUMMARY
The positive selection of iron-independent SAD mutants using the PSDT system is based on two sequential levels of gene regulation that lead to cat gene expression and the emergence of a Cm R phenotype in the E. coli indicator strain. In this system, cat gene expression is controlled by TetR, which in turn is regulated by a functional DtxR:toxO circuit. Wild-type DtxR must be activated by Fe(II), or other transition metal ions in vitro, to bind to the toxO. Therefore, the addition of the iron chelator DP to the growth medium results in the inactivation of the repressor. In the PSDT system, addition of DP to the growth medium results in the derepression of tetR and leads to a Cm s phenotype in the indicator strain. The power of the PSDT selection system is on the order of 10− 8 (data not shown). This system has been used to isolate a class of iron-independent mutants of DtxR that remain constitutively active even in the absence of iron.
The dtxR gene was randomly mutagenized by PCR amplification. After digestion of the amplified DNA with BglII and ligation into the BglII site of pSC6MI, E. coli TOP10/λRS65T was transformed and plated on LB agar supplemented with Cm and 200 μM DP. Alternatively, BglII digested amplified DNA was ligated into the BamHl site of pBR322, E. coli TOP10/λRS65T/pSC6 was transformed, and transformants were selected on LB agar supplemented with Cm and 200 μM DP. By using this system, a total of nine iron-independent SAD mutants were isolated, of which four were characterized extensively.
The independently isolated SAD2, SAD3, and SAD11 mutants were isolated from derivatives of pSC6M1 in the TOP10/λRS65T strain of E. coli. In each instance, the recombinant E. coli expressed one of several mutant iron independent DtxR proteins that demonstrate how alterations of DtxR protein structure can lead to a constant state of repression. These proof of concept experiments serve to support the validity of targeting the DtxR protein with small molecules to induce analogous changes in structure and thereby turn off virulence determinant expression.
Example 2
Example 2: Application of the PSDT Screen for rapid identification of functionally equivalent DtxR homologues and their cognate operator sequences in one step.
As discussed above, several repressors that exhibit considerable nucleotide and amino acid homology to DtxR have been identified and characterized in a number of pathogenic and non-pathogenic bacterial species (Doukhan, L. Predich, M., Nair, G., Dussurget, O., Mandic-Mulec, I., Cole. S.T. Smith, D.R., and Smith, I. (1995) Gene 165:67-70; Schmitt, M.P., Predich, M., Doukhan, L., Smith, I., and Holmes, R.K. (1995) Infect. Immun. 63:4284-4289.; Oguiza, I.A., Tao, X., Marcos, A.T., Martin, J.F., and Murphy, J.R. (1995) J. Bacteriol. 177:465-467; Gunter, K. Toupet, C., and Schupp, T. (1993) J Bacteriol. 175:3295-3302). These repressors have been implicated in the iron dependent gene regulation in their respective hosts of origin (Boyd, J., Oza, M., and Murphy, J.R. (1990) Proc. Natl. Acad. Sci. USA, 87:5968-5972; Schmitt, M.P., and Holmes, R.K. (1991) Infect Immun. 59:1899-1904: Schmitt, M.P., and Holmes, R.K. (1994) J. Bacteriol. 176:1141-1149; Schmitt, M.P., and Holmes, R.K. (1994) J. Bacteriol. 176:1141-1149., Schmitt, M.P. (1997) J. Bacteriol. 179:838-845). Furthermore, table 1 above has indicated an additional collection of bacterial species which have one or more identical copies of the toxO, operator sequence suggesting they may employ an analogous metal activated repressor dependent regulatory mechanism for state specific gene expression.
Given the potentially important role played by DtxR and DtxR homologues in pathogenesis, we have developed a positive genetic selection system for the rapid isolation of functionally equivalent dtxr alleles, dtxR homologues and DtxR-target DNA binding or “iron box” sites. The PSDT system as described above, is used in this example to demonstrate the cloning of dtxR alleles from chromosomal libraries of C. diphtheriae and Brevibacterium ammoniagenes in a single step using positive selection. We have recently isolated DtxR homologues from M. tuberculosis and M. avium . The use of the PSDT system in the cloning of DtxR binding sites from oligonucleotide libraries is also demonstrated. In each instance, only, those clones which carry a functional dtxR/DtxR target DNA binding site grow on medium supplemented with chloramphenicol. The utility of the PSDT system for these types of selection is not merely the rapid one step isolation of genes and operator sequences without the complication of PCR induced mutations but in the subsequent ability to modify the PSDT system such that it becomes more finely adjusted to characteristics of a given species specific repressor:operator circuits. This fine tuning can potentially augment the ability to identify compounds capable of activating a repressor in a given species of interest rather than rely upon activators of DtxR or a readily available homologue to serve as activators in the species of interest.
RESULTS AND DISCUSSION
Genetic Construction of the PSDT system
The PSDT system consists of a lysogenic E. coli host strain which carries the reporter gene cat on a derivative of coliphage X, E. coli TOP10/λRS65T, and a set of detector plasmids. The bacterial strains, plasmids. and coliphage X strains used in this work are listed in Table 2 above. The oligonucleotides encoding the tetracycline resistant determinant gene (tetA) promoter and operator sequence (tetAPO) with EcoRl and BamHl sticky ends.
5′-AATTCGTTGACACTCTATCATTGATAGAGTTATTTTAGGATCCA-3′ (SEQ ID NO:11);
5′-GATCTGGATCCTAAAATAACTCTATCAATGATAGAGTGTCAACG-3′ (SEQ ID NO:12) were synthesized in vitro, purified, annealed, and ligated into the EcoRl and BamHl sites of pRS551 to form pRS61. A promoterless cat gene derived from pCM4 was inserted into the BamHl site of pRS61 to construct pRS64. Plasmid pRS65T was made by eliminating the Kn gene of pRS64 by introducing a HpaI/FspI fragment from plasmid pGPl-2 into the SmaI site, and replacing the 624 bp HpaI fragment in the lacZ gene with a trpA transcription terminator (TC) (Simons, R.W., Houman, F., and Kleckner, N. (1987) Gene 53:85-96.). Plasmid p65T was then crossed with λRS45 in E. coli NK7049, and lysogens carrying the desired recombinant prophage. λRS65T, which formed a double crossover between the bla gene and lacZYA, were initially selected as Cm R colonies on LB/Cm agar, and further verified by their ampicillin sensitive phenotype.
Plasmid pLS-1 was constructed by inserting the entire dtxR operon from pXT102C into the EcoRl and Narl sites of pBR322. Plasmid pLS-2 was isogenic with pLS-1 except that the dtxR gene was knocked out by the deletion of an intragenic EcoRV fragment.
The promoterless tetracycline resistant determinant repressor (tetR) structural gene was obtained by PCR amplification of DNA from E. coli MM108 harboring TN10 using the following primers: HincII tagged forward primer: 5′-CGTGGTCAACAAAAATTAGG-3′ (SEQ ID NO:13). SacII-tagged backward primer:
5′-ATTCCGCGGTTATGCTGCTA-3′ (SEQ ID NO:14). The PCR product was cloned into the PCRII vector using the TA cloning kit. Several positive recombinants were subjected to DNA sequence analysis and one of the clones containing the correct tetR gene was named pCR/tetR. A derivative of pCR/tetR, pCR/tetRT, was constructed by insertion of a universal translation terminator (TL) was formed by annealing oligonucleotides (5′-GTTAACGCTTAATTAATTAAGC-3′ (SEQ ID NO:15); 5′-GCTTAATTAATTAAGCGTTAAC-3′ (SEQ ID NO:16)) and ligating them into the HincII site.
The construction of plasmid pSA18M1 is as follows: the parental plasmid, pRS551toxPO/dtxR was constructed by inserting the dtxR structural gene on a PvuII fragment of pHH2500 into the SmaI site of pRS551toxPO. The diphtheria tox minor (Boyd, J., Oza, M., and Murphy, J.R. (1990) Proc. Natl. Acad. Sci. USA, 87:5968-5972) promoter (mtP) plus a multiple cloning site (MCS) (5′-AATTCTGCAGGGCATTGATTCAGAGCACCCTTATAATAGATCTGAGCTCGGTACCCGGG-3′ (SEQ ID NO:17)) and its complementary strand (5′-GATCCCCGGGTACCGAGCTCAGATCTATTATAAGGGTGCTCTGAATCAATGCCCTGCAG-3′ (SEQ ID NO: 18)) were synthesized as two oligonucleotides with sticky EcoRI and BamHl ends. After annealing and phosphorylation, the double stranded oligonucleotides were ligated into the EcoRI and BamHl sites of pRS551toxPOIdtxR. The resulting plasmid was named pLS500. The tetR gene plus its upstream TL, carried on a HincII/SacII fragment, was excised from pCP/tetRT and ligated into the SmaI/SacII sites of pLS500 to construct pLS501. A transcription terminator (TC) (5′-GGCAGATAACCAACGCAACGACCCAGCTTCGGCTGGGTTTATCAG-3′ (SEQ ID NO: 19)) derived from the ant gene of the Salmonella phage P22 was inserted between the SacI and PvuII sites of pLS501, resulting in plasmid pLS502. Plasmid pLS502 was digested with HindIII and PvuII and the 2.2 kb tetR-bearing fragment was ligated with the 3.1 kb colE1 ori-bearing Hindll/Pvull fragment derived from pRS551, generating pLS503. Plasmid pLS503 was then digested with ScaI and PvuII and the 3.7 kb fragment containing the Kn gene, mtP, and tetR was purified and ligated with the 3.6 kb PvuII fragment from plasmid pWSK129 carrying the replication origin of pSC101 to construct plasmid pSA18. Plasmid pSA18M was created by inserting an EcoRl site at the MCS of pSA18.
Plasmid pSA20 is isogenic with pSA18M1, except that pSA20 has two copies of the dtxR operator sequence inserted upstream of the tetR gene. Plasmid pSC6M1 was constructed by replacing mtP in pSA18M1 with the wild type diphtheria tox promoter/operator sequence (toxPO) from pRS551toxPO and then inserting a 220 bp DNA fragment containing BamHI SmaI, and BqiII sites into the HincII site.
Development and Rationale of the PSDT system
The detector plasmids in the PSDT system that are used for the selection of DtxR binding sites are pSA18M1 and pLS-1 similar to pSC6M1. The overall principle underlying the PSDT system is shown in FIG. 3 . In order to determine whether the PSDT system would operate as designed, we synthesized a linker that encoded the wild type toxO and ligated it into the MCS of pSA18M1. The resultant plasmid. pSA20. when transformed into E. coli TOP10/ λRS65T/pLS-1, conferred a Cm R phenotype to the host. To examine whether Cm resistance was mediated by DtxR, the transformants were plated on LB agar supplemented with Ap/Kn, Ap/Kn/DP, Ap/Kn/Cm and Ap/Kn/Cm/DP. As shown in Table 3, in marked contrast to the growth observed on Ap/Kn, Ap/Kn/DP and Ap/Kn/Cm plates, E. coli TOP10/λRS65T/pLS-1/pSA20 failed to grow on Ap/Kn/Cm/DP. These results strongly suggested that a functional DtxR:toxO genetic switch was required to establish a Cm R phenotype. To further demonstrate that this was the case, the dtxR gene in pLS-1 was knocked out by an internal deletion of an EcoRV fragment to form pLS-2. As anticipated, in the absence of DtxR, E. coli TOP10/λRS65T/pLS-2/pSA20 is Cm S . Thus the PSDT system can be utilized to clone unique DtxR homologues or metal dependent regulatory proteins which recognize toxO, or employed to identify novel operator sequences that are functionally recognized by DtxR or DtxR homologues in vivo.
Screening random oligonucleotide libraries for DtxR target sites.
Having demonstrated the feasibility of the PSDT in a model system, we tested its general utility by applying it to the task of selecting DtxR targets from pools of random oligonucleotides generated by PCR. Tao and Murphy (Tao, X., and Murphy, J.R. (1994) Proc. Natl. Acad. Sci., USA. 91:9646-9650) have previously shown that DtxR-mediated affinity selection could be used in vitro to enrich families of oligonucleotides which contain the minimal essential sequence for DtxR recognition. Each of these libraries contains relatively low numbers of high affinity DtxR binding sites in a universe of greater than 10 10 sequences. Oligonucleotide families from round 8, 9 and 11 of in vitro selection were each re-amplified by PCR for an additional 30 cycles. These libraries are related to each other in a hierarchical way in both the abundance of potential DtxR binding sites and their relative affinity to bind DtxR. After purification and digestion with EcoRI and BamHI, the PCR products were then ligated into the MCS of pSA18M1. Ligation mixtures were then transformed into E. coli TOP10/λRS65T/pLS-1 and selected on Ap/Kn/Cm medium. Representative colonies that grew were then subjected to further analysis.
In order to determine whether the Cm R clones contained authentic DtxR binding sites, individual transformants were first examined for their sensitivity to 2,2′-dipyridyl. Representative colonies were replicate plated on LB agar supplemented with either Ap/Kn, Ap/Kn/DP, Ap/Kn/Cm, or Ap/Kn/Cm/DP, and their growth was carefully monitored. As anticipated, all colonies exhibited robust growth on AP/Kn, Ap/Kn/DP, and Ap/Kn/Cm plates. In contrast, the growth of all colonies was either severely retarded or completely inhibited on LB agar plates supplemented with Ap/Kn/Cm/DP. Subsequent DNA sequence analysis indicated that in general, the DtxR target sites selected from PCR rounds 8, 9 and 11, shared 67-77% (data not shown), 70-80% (data not shown ) and 85% (data not shown) identity with toxO respectively. Moreover, DNA sequence analysis demonstrated that all selected clones carried DtxR binding sites that possessed the minimal essential nucleotides required for DtxR binding. Most importantly, the PSDT system allowed for the direct selection of clones which carried functional DtxR sensitive operators from complex oligonucleotide libraries.
Positive selection of dtxR alleles and homologues from Corynebacterium diphtheriae and Brevibacterium amuioniagenes genomic libraries.
The PSDT system was then employed for the positive selection of dtxR alleles and homologues from genomic libraries. The detector plasmid used in this system is pSC6M1, a derivative of pSA18M1 that carries a single copy of toxPO which directs the expression of tetR. We first attempted to clone dtxR alleles from two different epidemic strains of C. diphtheriae recently isolated from Russia and Ukraine (Nakao, H., Pruckler, J.M., Mazurova, I.K., Narvskaia, O.V., Glushkevich, T., Marijevski, V.F., Kravetz, A.N., Fields, B.S., Wachsmuth, I.K., and Popovic, T. (1996) J. Clin. Microbiol. 34:1711-1716.,Nakao, H., Mazurova, I.K, Glushkevich, T., and Popovic, T. (1997) Res. Microbiol. 148:5-54.). Chromosomal DNA from each strain was isolated, digested partially with Sau3Al, and then ligated into the BglII site of pSC6M1 E. coli TOP10/λRS65T was transformed, and the transformants were selected on LB agar supplemented with Kn/Cm. Four to five colonies were readily obtained from each selection, and, as anticipated all were dtxR positive by both PCR analysis using dtxR specific primers and by DNA sequence analysis.
We then tested the cross-genus applicability of the PSDT system by attempting to clone the dtxR homologue from a genomic library of B. ammoniagenes . The molecular cloning and selection were conducted as described above. Each of the four Cm R colonies that grew on Cm supplemented medium carried a complete dtxR operon as demonstrated by DNA sequence analysis. The analysis showed that with the exception of a T to G transversion at 372, the structural gene of the DtxR homologue of B. ammoniogenes is identical to that of B. lactofermentum (Oguiza, I.A., Tao, X., Marcos, A.T., Martin, J.F., and Murphy, J.R. (1995) J. Bacteriol. 177:465-467).
Several techniques have been described previously which meet similar objectives as the PSDT system. For example, SELEX (systematic evolution of ligands by exponential enrichment) (Ochsner, U.A., and Vasil, M.L. (1996) Proc. Natl. Acad. Sci., USA. 93:4409-4414) and MuST (multiplex selection technique) (Nallur, G.N., Prakash, K., & Weissman, S.M. (1996) Proc. Natl. Acad. Sci., USA. 93:1184-1189.) are in vitro selection, procedures devised for the identification of regulatory protein target sites based on DNA-protein interaction. FURTA (Fur titration assay) (Stojiljkovic, L. Baumler, A.J., and Hantke, K. (1994) J. Mol. Biol. 236:531-545) is a genetic screen for the detection of Fur-binding activities based on the competition of a fur-box carried on a high-copy plasmid with the single-copy chromosomal Fur-box for Fur. Other methods relying on the activation of a promoterless lacZ gene and subsequent selection of the desired genes based on β-galactosidase/X-gal color reaction have also been developed (Schmitt, M.P., Predich, M., Doukhan, L., Smith, I., and Holmes, R.K. (1995) Infect. Immun. 63:4284-4289.). Although all of these systems have successfully identified numerous genes from both Gram positive and Gram negative organisms, their execution requires multiple selection steps, and, in some cases, the use of non-neutralizing monoclonal antibodies.
An ingenious strategy to select DNA-binding proteins involves the use of a challenge phage vector, P22 Kn9 arc-amHI605 which carries a substitution of a synthetic DNA-binding site for the Mnt operator (Benson, N., Sugiono, P., Bass, S., Mendelman, L.V.. and Youderian, P. (1986) Genetics 114:1-14). Occupancy of the DNA-binding site by the cognate protein will rescue the host from P22 phage lysis. This system relies upon sensitive strains of Salmonella as the host. The current state of the art in this technique involves the use of PCR to amplify a target gene using primers designed from conserved nucleotide sequences of the cloned members of the gene family.
In order to facilitate the cloning of both functional dtxR alleles/homologues and DtxR target sites, we developed the PSDT system. As described, we were readily able to select DtxR binding sites from three oligonucleotide libraries each representing a universe of greater than 10 10 sequences, and to clone and directly select dtxR alleles from genomic digests of C. diphtheriae and B. ammoniagenes in a single step. We expect, with little modification, the PSDT system can be used in the study of a variety of repressor/operator interactions.
While not intending to be bound by any particular theory of operation, Applicant believes that the self-activating properties exhibited by the DtxR mutants, e.g., SAD2, suggest an intramolecular process involving interaction between or among different domains of DtxR, and that peptides or other substances that mimic such activating effects will be candidates for new classes of antibiotics which phenotypically convert prokaryotic pathogens such as bacteria into non-pathogens. These antibiotics are expected to have medicinal value to both humans and animals.
All publications cited in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All these publications are herein incorporated by reference to the same extent as if each individual publication were specifically and individually indicated to be incorporated by reference.
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.
19
1
27
DNA
Corynebacterium diphtheriae
1
ataattagga tagctttacc taattat 27
2
19
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
2
gtaggttagg ctaacctat 19
3
25
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
3
ananttaggn tagnctannc tnnnn 25
4
19
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
4
twaggttags ctaacctwa 19
5
20
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
5
gataattgag aatcattttc 20
6
19
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
6
gatattgaga atcattttc 19
7
19
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
7
gatactgaga atcattttc 19
8
19
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
8
gatactgaga atcatgttc 19
9
24
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
9
accagatctg ccgaaaaact tcga 24
10
25
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
10
accagatctc cgcctttagt attta 25
11
44
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
11
aattcgttga cactctatca ttgatagagt tattttagga tcca 44
12
44
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
12
gatctggatc ctaaaataac tctatcaatg atagagtgtc aacg 44
13
20
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
13
cgtggtcaac aaaaattagg 20
14
20
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
14
attccgcggt tatgctgcta 20
15
22
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
15
gttaacgctt aattaattaa gc 22
16
22
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
16
gcttaattaa ttaagcgtta ac 22
17
59
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
17
aattctgcag ggcattgatt cagagcaccc ttataataga tctgagctcg gtacccggg 59
18
59
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
18
gatccccggg taccgagctc agatctatta taagggtgct ctgaatcaat gccctgcag 59
19
45
DNA
Unknown
Description of Unknown Organism
Oligonucleotide
19
ggcagataac caacgcaacg acccagcttc ggctgggttt atcag 45 | Disclosed is a method for identifying activators of a transition metal-dependent repressor of virulence gene expression in infectious prokaryotic pathogens. The method utilizes genetic circuitry that represents the response of a given prokaryote to nutritional stress and the expression of genes that contribute to the establishment of the infectious process. The exposure of recombinant cells or a cell-free system containing the genetic circuitry to a non-metal ion test substance that activates the repressor produces a detectable response. The method is applicable for any prokaryote employing metal ion-dependent repressors to regulate specific gene expression, specifically as it pertains to virulence determinant expression. | 2 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a cut sheet feeder for use with the image forming apparatus such as a copier or a printer, the feeder feeding the apparatus with cut sheets of recording paper.
Description of the Related Art
The image forming apparatus is most often used to record images on a large number of cut sheets of the same size which are fed continuously. But occasionally, it is desired to interrupt the ongoing process of image printing involving many cut sheets so as to insert image printing of a different kind typically on a smaller number of sheets. Some of the conventional cut sheet feeders for use with the image forming apparatus have mechanisms that meet the requirements for the on-demand inserted printing.
Such conventional cut sheet feeders have a plurality of sheet feed mechanisms positioned near the sheet feed table or sheet cassette assembly, each mechanism comprising its dedicated pick-up rollers, guide plates and other related parts. When the operator selects a desired sheet type, the corresponding sheet feed mechanism is activated. The activated mechanism picks up cut sheets one by one from the applicable sheet feed table or from the corresponding sheet cassette and feeds them into a position inside the image forming apparatus.
The conventional cut sheet feeder of the above-mentioned type has as many sheet feed mechanisms as the number of the sheet feed tables or the sheet cassettes that are mounted in advance of feed operation. The cut sheet feeder also has a plurality of sheet transport routes for guiding cut sheets from the multiple storage locations via rollers to a common feed position. These features combine to make the cut sheet feeder bulky, complex, and thus prone to feed-related troubles.
In view of these drawbacks of the prior art, the inventors of this invention came up with a cut sheet feeder having a single sheet feed mechanism to which any one of a plurality of sheet feed tables carrying many cut sheets or of sheet cassettes containing different sizes of cut sheets is positioned as desired.
But because the cut sheet feeder of the above type requires one of its sheet feed tables or sheet cassettes to be moved to a single sheet feed position, arrangements need to be made so that one table or cassette will not interfere during movement with any other table or cassette. In addition, this cut sheet feeder needs to be constructed so that cut sheets on the sheet feed table or in the sheet cassette selected and fed quickly, simply and smoothly to the sheet feed mechanism with the aid of appropriate electrical control means.
With the sheet cassettes made detachable, the procedure of on-demand inserted printing is made simpler, but there are still measures to be taken to ensure that the operator carries out operations correctly and that the whole system runs with safety and without malfunction.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a small, simply structured cut sheet feeder for use with an image forming apparatus, the feeder having a sheet feed unit and a sheet feed table positioned to the sheet feed position of a single sheet feed mechanism for selective switching between the sheet cassette-based and the sheet feed table-based feed operation, the switching between the two operations being carried out easily, safely and reliably.
In carrying out the invention and according to one aspect thereof, there is provided a cut sheet feeder for use with an image forming apparatus, comprising: a sheet feed mechanism 3 (see the accompanying drawings for reference numerals) for picking up stacked cut sheets 68 or 69 one at a time from a single sheet feed position P2 and for feeding each sheet to an image recording portion; a sheet feed unit 10 which is vertically movable relative to the sheet feed mechanism 3 and to which a cassette K containing cut sheets 69 may be attached in a detachable manner; a sheet feed table 50 which is vertically movable within the sheet feed unit 10 and which carries a large number of cut sheets 68; cassette presence detection means 114 and 100a for detecting the presence and absence of a cassette K on the sheet feed unit 10 and for outputting a signal indicating either the presence or the absence of the cassette K; a cover 67 swingingly furnished on the sheet feed unit 10 for covering the opening thereof through which cut sheets are loaded and unloaded and through which the cassette K may be attached and detached to and from the sheet feed unit 10; cover detection means 115 for outputting a detection signal indicating the swinging status of the cover 67; mode establishment means 100b for outputting a mode signal establishing one of two modes, i.e. a cassette feed mode involving the cassette K for sheet feed and a table feed mode involving the sheet feed table 50 carrying a large number of cut sheets; and mode control means 100f, when the cover detection means 115 issues a detection signal indicating the closed status of the cover 67, for controlling the up-down movement of at least one of the sheet feed unit 10 and the sheet feed table 50 relative to the sheet feed mechanism 3 in accordance with the detection signal from the cassette presence detection means 114 and 100a as well as with the mode signal from the mode establishment means 100b.
In a preferred structure according to the invention, the mode control means 100f lifts at least the sheet feed table 50 up to the sheet feed position P2 when, with the cassette presence detection means 114 and 100a outputting the signal indicating the absence of the cassette K, the cover detection means 115 outputs the detection signal indicating the close status of the cover 67.
In another preferred structure according to the invention, the mode control means 100f keeps stationary the sheet feed unit 10 and the sheet feed table 50 when the cover detection means 115 outputs the detection signal indicating the opened status of the cover 67.
In a further preferred structure according to the invention, the sheet feed unit 10 and the sheet feed table 50 are connected via clutches 9a and 9b to a motor 8 acting as a driving source, and the mode control means 100f controls the up-down movement of the sheet feed unit 10 and the sheet feed table 50 singly and in combination through the switching of the clutches 9a and 9b.
The invention when embodied works as follows: the cover 67 is attached swingingly to the sheet feed unit 10 so as to cover the opening thereof through which cut sheets are loaded and unloaded and through which the cassette K may be attached and detached to and from the sheet feed unit 10. The swinging status of the cover 67 is detected by the cover detection means 115 which outputs the detection signal reflecting the detected swinging status of the cover 67.
The presence or absence of the cassette K on the sheet feed unit 10 is detected by the cassette presence detection means 114 and 100a which output the detection signal reflecting the detected presence or absence of the cassette K.
The mode establishment means 100b outputs the mode signal indicating one of tow modes: a cassette feed mode involving the cassette K for sheet feed, and a table feed mode involving the sheet feed table 50 carrying a large number of cut sheets.
When the cover detection means 115 issues the detection signal indicating the closed status of the cover 67, the mode control means 100f controls the up-down movement of at least one of the sheet feed unit 10 and the sheet feed table 50 relative to the sheet feed mechanism 3 in accordance with the detection signal from the cassette presence detection means 114 and 100a as well as with the mode signal from the mode establishment means 100b.
Illustratively, when the mode signal designates the cassette feed mode, the vertically movable sheet feed unit 10 is positioned under the sheet feed mechanism 3. This allows the sheet feed mechanism 3 to feed cut sheets 69 from the cassette K into the image forming apparatus. When the mode signal designates the table feed mode with the cassette K detached, the sheet feed unit 10 is moved up so as to position a cassette sheet feed table 12 above the sheet feed mechanism 3. This allows the sheet feed mechanism 3 to feed cut sheets 68 from the sheet feet table 50 into the image forming apparatus. If the cassette K remains mounted on the sheet feed unit 10 despite the mode signal designating the feed table mode, the sheet feed unit 10 and the sheet feed table 50 are moved to a position low enough to let the cassette K be detached provided the cover detection means 115 outputs the detection signal indicating the closed status of the cover 67. When the cassette K is removed, the sheet feed unit 10 and the sheet feed table 50 are moved up to the sheet feed position P2.
Other objects, features and advantages of the present invention will become apparent in the following specification and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cut sheet feeder embodying the invention and for use with a printer;
FIG. 2 is a perspective view showing major driving mechanisms of the cut sheet feeder;
FIG. 3 is a front view indicating key structures of the cut sheet feeder;
FIG. 4 is a perspective view illustrating the driving source and related parts of the cut sheet feeder;
FIG. 5 is a perspective view depicting mechanisms for adjusting fences in the cut sheet feeder;
FIG. 6(a) is a view of the sheet feed status of the cut sheet feeder in the table feed mode;
FIG. 6(b) is a view of the sheet feed status of the cut sheet feeder in the cassette feed mode;
FIG. 7 is a block diagram of the electrical constitution of the cut sheet feeder;
FIG. 8 is a schematic view showing sensor positions in the cut sheet feeder;
FIG. 9 is a block diagram depicting the constitution of the feed-related control means in the cut sheet feeder;
FIG. 10 is a flowchart of steps showing the initial operation of the cut sheet feeder when it is powered;
FIG. 11(a) is a view of the status of the cut sheet feeder in the table feed mode prior to actual sheet feed;
FIG. 11(b) is a view of the status of the cut sheet feeder in the cassette feed mode prior to actual sheet feed;
FIG. 12 is a flowchart of steps in which the cut sheet feeder is switched from the cassette feed mode to the table feed mode;
FIGS. 13(a), 13(b) and 13(c) are views showing how cut sheets in the cut sheet feeder in the table feed mode change from insufficient to sufficient quantity for sheet feed;
FIGS. 14(a), 14(b) and 14(c) are views depicting how cut sheets in the cut sheet feeder in the table feed mode reach the upper limit of the sufficient quantity for sheet feed;
FIGS. 15(a) and 15(b) are views indicating how an excess amount of stacked cut sheets is detected in the cut sheet feeder in the table feed mode;
FIG. 16 is a flowchart of steps in which to remedy the status of the cut sheet feeder containing an excess amount of stacked cut sheets;
FIG. 17 is a flowchart of steps in which the cut sheet feeder is switched from the table feed mode to the cassette feed mode;
FIG. 18 is a flowchart of steps in which the cut sheet feeder in the table feed mode is remedied from sheet jamming and is replenished with cut sheets; and
FIG. 19 is a flowchart of steps in which the cut sheet feeder in the cassette feed mode is remedied from sheet jamming and is replenished with cut sheets.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A cut sheet feeder 1 shown in FIG. 1 is one preferred embodiment of the invention incorporated in a mimeograph printing machine 2. A sheet feed mechanism 3 furnished on the side of the printing machine 2 includes a pick-up roller 43 for taking in cut sheets from the cut sheet feeder 1. The cut sheet feeder 1 positions to the sheet feed mechanism 3 either a cassette containing cut sheets or a sheet feed table carrying cut sheets stacked thereon. The cassette or the sheet feed table is moved up and down before coming into a position to feed the printing machine 2 with necessary cut sheets.
As shown in FIGS. 2 and 3, the cut sheet feeder 1 has a substantially box-like frame 6 comprising a right-and a left-hand side plate 4 and a bottom plate 5. The top portions of the side plates 4 and 4 are interconnected fixedly by bars 7.
As depicted in FIG. 4, one side plate 4 has a motor 8 mounted on its outer surface near the bottom, the motor acting as a driving source of the cut sheet feeder 1. The motor 8 is coupled to the input shaft of a gear box 9. The gear box 9 comprises reduction gears that transmit the torque of the motor 8 to two clutches 9a and 9b. The clutches 9a and 9b are coupled respectively to two drive shafts A and B. The drive shafts A and B are in parallel and set apart from each other by a predetermined distance. The shafts A and B are furnished rotatably across the two side plates 4.
As indicate, in FIGS. 2 and 3, a substantially box-like sheet feed unit 10 is furnished in a vertically movable manner inside the frame 6. The sheet feed unit 10 has a bottom plate 11 and a top cassette plate 12, the latter plate 12 serving as a first sheet feed table. The two plates 11 and 12 are coupled by a pair of side plates 13. The top cassette plate 12 has a sheet-containing cassette K placed thereon (see FIG. 6(b)).
When a large number of cut sheets are to be printed continuously without the use of the cassette K, the cassette K is detached and the entire sheet feed unit 10 is set in an upward, appropriate position in a manner to be described later. At this point, the cassette plate 12 is kept from interfering with the pick-up roller 43 of the sheet feed mechanism 3. The interference is avoided by furnishing the cassette plate 12 with a cutout portion 14, as indicated in FIGS. 1 and 2.
FIG. 2 shows the frame 6 having vertically parallel guide grooves 15 and 16. A roller 70 attached rotatably to one edge of the bottom plate 11 moves freely up and down along one guide groove 15. Another roller 71 attached rotatably to one edge of the cassette plate 12 moves freely up and down along the other guide groove 16.
A take-up pulley 17 is mounted on the tip of the drive shaft A protruding from the side plate 4. An intermediate pulley 18 is furnished on the side plate 4 and above the guide groove 15. One end of a wire 19 is attached to the circumference of the take-up pulley 17. The wire 19 extends around the intermediate pulley 18, and has its other end connected to the roller 70.
As the motor 8 drives the drive shaft A to rotate the take-up pulley 17 to take up the wire 19, the wire 19 pulls the roller 70 upward. This causes the sheet feed unit 10 to move up along the guide grooves 15 and 16 inside the frame 6. When the drive shaft A is rotated in reverse, the wire 19 is unwound from the take-up pulley 17 to let the sheet feed unit 10 come down by its own weight. In this manner, the box-like sheet feed unit 10 is moved up and down inside the frame 6.
As shown in FIGS. 2 through 5, an adjusting shaft 20 is provided above the bottom plate 11 of the sheet feed unit 10 and in parallel with the drive shafts A and B. The adjusting shaft 20 spans rotatably the side plates 13 of the sheet feed unit 10. One end of the adjusting shaft 20 protrudes from a groove 21 provided vertically along one side plate 4 of the frame 6. The protruding end of the adjusting shaft 20 has a pulley 22 mounted thereon. A thread portion 23 is provided in the middle of the adjusting shaft 20.
Between the bottom plate 11 and the adjusting shaft 20 of the sheet feed unit 10 is a lower fence plate 24. The adjusting shaft 20 penetrates the edges 24a of the lower fence plate 24 with slide bushes 25 interposed between the shaft and the plate edges. The thread portion 23 of the adjusting shaft 20 engages with a thread receiver 27 fixed by fittings 26 to the top of the lower fence plate 24. In this setup, rotating the adjusting shaft 20 causes the lower fence plate 24 to move axially within the sheet feed unit 10.
The above-described mechanism for moving the lower fence plate 24 has its counterpart under the cassette plate 12 of the sheet feed unit 10, as shown in FIG. 3. In the latter mechanism, a thread portion 29 of an adjusting shaft 28 engages with a thread receiver 32 fixed by fittings 3It to an upper fence plate 30. As depicted in FIG. 2, the upper adjusting shaft 28 penetrates a groove 35 provided on the side plate 4. Reference numeral 33 stands for slide bushes, and 34 for a pulley. The pulley is fixed-to the adjusting shaft 28.
As shown in FIG. 3, the upper fence plate 30 and the lower fence plate 24 are coupled by guide shafts 40. A timing belt 41 is engaged around a pulley 34 of the upper fence plate 30 and around a pulley 22 of the lower fence plate 24. The adjusting shaft 28 of the upper fence plate 30 has a dial 42 for manual operation. The dial 42 when operated allows the adjusting shaft 28 to be rotated manually.
When the upper adjusting shaft 28 is rotated by manually turning the dial 42, the lower adjusting shaft 20 is rotated concurrently by way of the pulleys 34 and 22 and the timing belt 41. The upper and lower fence plates 30 and 24 coupled by the guide shafts 40, with their positions thus adjusted crosswise inside the sheet feed unit 10, constitute a mechanism for horizontally positioning a sheet feed table 50, to be described later with reference to FIG. 3.
As shown in FIG. 3, the sheet feed unit 10 incorporates the sheet feed table 50 under the cassette plate 12. The sheet feed table 50 is vertically movable and serves as a second sheet feed table. The sheet feed table 50 comprises an upper tray 51 on which a large number of cut sheets are stacked, and a lower tray 52 that movably supports the upper tray 51.
Guide members 54 are furnished on both sides of the upper tray 51. The guide shafts 40 penetrate the guide members 54. The upper tray 51 moves up and down along the guide shafts 40.
As shown in FIGS. 2 and 3, rollers 55 are provided at both ends of support shafts 53 fixed to the lower tray 52. As indicated in FIG. 2, the side plate 4 of the frame 6 has two vertical guide grooves 56 with which the rollers 55 of the support shafts 53 are movably engaged. A take-up pulley 57 is attached to the end of the drive shaft B protruding from the side plate 4. Intermediate pulleys 58 are provided on the side plate 4 above the guide grooves 56. One end of each of two wires 59 is attached to the circumference of the take-up pulley 57. The two wires 59 extend respectively around the two different intermediate pulleys 58, and have their other ends attached to the two rollers 55.
When the motor 8 drives the drive shaft B causing the take-up pulley 57 to take up the two wires 59, the wires 59 pull up the rollers 55 and thus lift the lower tray 52 along the guide shafts 40 within the sheet feed unit 10. When the drive shaft B is rotated in reverse, the wires 59 are unwound from the take-up pulley 57 to let the lower tray 52 come down by its own weight.
The side plate 4 opposite to the one shown in FIG. 2 has another identical mechanism for driving the sheet feed unit 10 and the sheet feed table 50 by use of the drive shafts A and B and of the wire and pulley arrangement. This mechanism is omitted in FIG. 4.
As shown in FIG. 3, a plurality of bearings 60 is provided on top of the lower tray 52. These bearings 60 carry the upper tray 51 in a freely movable manner. The upper tray 51 is movable vertically along the guide shafts 40 and horizontally along the support shafts 53. When the dial 42 is manipulated to move the upper and lower fence plates 30 and 24 horizontally, the upper tray 51 of the sheet feed table 50 moves along the support shafts 53.
As shown in FIGS. 3 through 5, two fences 61 are furnished in a horizontally movable manner between the upper and lower fence plates 30 and 24. As depicted in FIG. 5, sliders 73 are mounted slidingly on two parallel guide shafts 62 fixed to the lower fence plate 24. The lower portions of the fences 61 are fixed to the sliders 73 so that the fences 61 may be moved together with the sliders 73 along the guide shafts 62. Although not shown, the same mechanism is provided between the upper fence plate 30 and the fences 61. Fittings, also not shown, are provided to secure the fences 61 in position.
Comparing FIG. 1 with FIG. 2 reveals that the mechanisms outside the side plates 4 are covered with outer frames 63a and 63b. At the front of the cut sheet feeder 1 is the cover 67 installed swingingly, as shown in FIG. 1. Arrangements are made so that if the cover 67 is left open, the moving parts will not be driven or moved up or down. This ensures the operator's safety upon operation.
With the above setup, suppose that a large number of cut sheets are desired to be printed continuously (in the table feed mode, to be described later in more detail). In that case, without the cassette K mounted on the cassette plate 12, the sheet feed unit 10 and the sheet feed table 50 are moved up in cooperation. The cassette plate 12 is positioned above the sheet feed mechanism 3, as shown in FIG. 6(a). At this point, with the clutches 9a and 9b engaged, driving the motor 8 in the forward direction causes the drive shafts A and B to lift the sheet feed unit 10 and the sheet feed table 50.
While the sheet feed unit 10 and the sheet feed table 50 are being lifted, the cutout portion 14 of the cassette plate 12 allows the entire sheet feed unit 10 including the plate 12 to go up without interference with the sheet feed mechanism 3. The sheet feed unit 10 is then positioned so that the pick-up roller 43 of the sheet feed mechanism 3 will come into contact, at a predetermined contact pressure, with the top of the cut sheets 68 stacked on the sheet feed table 50. After printing is started, the sheet feed table 50 alone goes up as the stacked cut sheets 68 are being exhausted. The sheet feed table 50 is lifted by having only the drive shaft B rotate in the forward direction with the clutch 9b alone engaged.
In the table feed mode, the printing position relative to the cut sheets 68 is fine-adjusted by use of the dial 42. That is, the upper and lower fence plates 30 and 24 as well as the upper tray 51 of the sheet feed table 50 are adjusted crosswise in position by manipulating the dial 42.
Suppose that cut sheets are desired to be fed from the cassette (in the cassette feed mode, to be described later in more detail). In that case, the sheet feed unit 10 and the sheet feed table 50 are moved down in cooperation, as shown in FIG. 6(b). The cassette plate 12 is positioned under the sheet feed mechanism 3. At this point, with the clutches 9a and 9b engaged, driving the motor 8 in reverse causes the drive shafts A and B to lower the sheet feed unit 10 and the sheet feed table 50. At this time, too, the sheet feed mechanism 3 goes through the cutout portion 14 without interference with the cassette plate 12. As depicted in FIG. 6(b), the cassette K containing cut sheets 69 is mounted on the cassette plate 12. When a print start button 82 on the side of the printing machine 2 is pushed, the sheet feed unit 10 goes up and comes into contact, at a predetermined contact pressure, with the pick-up roller 43. The sheet feed mechanism 3 then starts feeding the sheets.
The electrical constitution of the cut sheet feeder 1 described above will now be explained with reference to the block diagram of FIG. 7. The printing machine 2 is controlled in printing by print control means 80. The print control means 80, in turn, is set and activated by use of the print start button 82 and other controls on a control panel 81.
Sheet feed control means 100 on the side of the cut sheet feeder 1 is electrically connected to the print control means of the printing machine 2 for sheet feed control during printing. On a control panel 101 of the cut sheet feeder 1 there are a table/cassette changeover button (called the T/K changeover button) 102, a table/cassette descent button (T/K descent button) 103, and a display unit 104 acting as indication means. The sheet feed control means 100 controls the driving of the motor 8 and the engagement of the clutches 9a and 9b on the basis of an operation signal from the control panel 101 (to be described later) and of the detection signal from any of the sensors acting as detection means. The sheet feed unit 10 and the sheet feed table 50 go up and come down under control of the sheet feed control means 100.
The T/K changeover button 102 is set to one of the two modes: the table feed mode (T mode) in which a large number of cut sheets 68 stacked on the sheet feed table 50 are fed and printed continuously, and the cassette feed mode (K mode) in which the cut sheets 69 in the cassette K (FIG. 6(b)) are fed and printed. The T/K descent button 103 is used in the T or K mode to lower either the sheet feed unit 10 or the sheet feed table for recovery from jamming or for sheet replenishment. The display unit 104 displays the operation status during sheet feed operation.
As shown in FIG. 8, various sensors for sending detection signals to the sheet feed control means 100 are located fixedly where appropriate such as on the side plates 4 in the vertical direction of the sheet feed unit 10. A T-K home sensor 110 is positioned at the highest stop position of the sheet feed unit 10. The sensor 110 outputs an ON signal only when the cassette table 12 of the sheet feed unit 10 is in a T-K home position P1; otherwise the sensor 110 outputs an OFF signal.
A sheet feed upper limit sensor 111 is attached to the pick-up roller 43 or to a position close thereto. The sensor 111 outputs an ON signal when the sheet feed unit 10 or the sheet feed table 50 as it rises causes the cut sheets 68 or 69 to contact the pick-up roller 43 and to lift then up to the sheet feed position P2; otherwise the sheet feed upper limit sensor 111 outputs an OFF signal. When the sheet feed upper limit sensor 111 is turned on, the cut sheets 68 or 69 may be fed by the pick-up roller 43.
A T--T lower limit sensor 112 is located in a T--T lower limit position P3 a little lower than the middle of the sheet feed unit 10. The sensor 112 outputs an ON signal when the sheet feed table 50 reaches the T--T lower limit position P3. The T--T lower limit sensor 112 outputs an OFF signal when the sheet feed table 50 is above the T--T lower limit position P3.
A K--K lower limit sensor 113 is attached to a K--K lower limit position at the bottom of the sheet feed unit 10. The sensor 113 outputs an ON signal only when the sheet feed unit 10 is in the K--K lower limit position P4; otherwise the sensor 113 outputs an OFF signal.
A cassette sensor 114 is attached to the cassette plate 12. The cassette sensor 114 outputs an ON signal when the cassette K is mounted on the cassette plate 12; otherwise the sensor 114 outputs an OFF signal. The cassette sensor 114 may illustratively be constituted by a magnet on the cassette K and by a reed switch in that position of the cassette plate 12 which comes opposite to the magnet of the cassette K when the latter is mounted.
The position of the magnet on the cassette K may be altered according to the size of the cut sheets 69 contained in the cassette, and the relocated magnet may be detected by the combination of a plurality of reed switches. This arrangement makes it possible automatically to recognize the size of the cut sheets 69 through, say, four-bit value combinations whenever the cassette K is mounted on the cassette plate 12.
A cover sensor 115 detects the swinging status of the cover 67 and is composed illustratively of a microswitch. A power switch 116 is used to turn on and off the main power of the cut sheet feeder 1.
A table sheet presence sensor 117 is attached to the sheet feed table 50. The sensor 117 detects the presence and absence of the cut sheets 68 stacked on the sheet feed table 50. The table sheet presence sensor 117 outputs an ON signal when the cut sheets 68 are present; otherwise the sensor 117 outputs an OFF signal. A cassette sheet presence sensor 118 is attached to the cassette K. The sensor 118 detects the presence and absence of the cut sheets 69 contained in the cassette K. The cassette sheet presence sensor 118 outputs an ON signal when the cut sheets 69 are contained in the cassette K; otherwise the sensor 118 outputs an OFF signal.
A jam detection means 119 detects the occurrence of jam during sheet feed operation. The jam detection means 119 outputs an ON signal illustratively when the pick-up roller 43 fail to feed a cut sheet 68 or 69 all the way into the printing machine 2, i.e., the sheet jammed halfway through the sheet transport route.
The sheet feed control means 100 controls the motor 8 and the clutches 9a and 9b so as to lift and lower the sheet feed unit 10 and the sheet feed table 50 singly or in combination. In the T mode, the T-K home position P1 in which the T-K home sensor 110 is turned on is taken as the reference sheet feed position for the sheet feed unit 10. Between the sheet feed position P2 and the T--T lower limit position P3 (see FIG. 8), the sheet feed table 50 is lifted and lowered under control of the sheet feed control means 100.
In the K mode, the K--K lower limit position P4 in which the K--K lower limit sensor 113 is turned on is taken as the reference cassette feed position for the sheet feed unit 10. The sheet feed unit 10 is lifted and lowered under control of the sheet feed control means 100 between the K--K lower limit position P4 on one hand, and the position where the topmost cut sheet 69 in the cassette K contacts the sheet feed upper limit sensor 111 and activates it, on the other hand. It should be noted that the sheet feed table 50 is lifted and lowered within the sheet feed unit 10.
The constitution of the sheet feed control means 100 will be described further with reference to the function block diagram of FIG. 9. The sheet feed control means 100 comprises cassette presence detection means 100a, mode establishment means 100b, input changeover means 100c, sheet overload detection means 100d, print inhibit signal output means 100e, mode control means 100f, motor driving means 100g, and clutch switching means 100h.
The cassette presence detection means 100a checks to see if the cassette K is mounted on the cassette plate 12 in accordance with the detection signal from the cassette sensor 114. The ON or OFF signal from the cassette sensor 114 determines the presence or absence of the cassette K. A determination signal S1 reflecting the result of the detection is output to the mode establishment means 100b, the mode control means 100f and the print inhibit signal output means 100e. The cassette sensor 114 and cassette presence detection means 100a constitute the generic cassette presence detection means.
The mode establishment means 100b establishes either the T mode in which cut sheets are fed from the sheet feed table 50, or the K mode in which cut sheets are fed from the cassette K, on the basis of the determination signal S1 from the cassette presence detection means 100a and of the ON/OFF signal from the power switch 116. Pushing the T/K changeover button 102 switches the current; operation mode to the other mode. With either the T mode or the K mode established, the mode establishment means 100b outputs a mode establishment signal S2 designating the established mode to the input changeover means 100c and the mode control means 100f.
Upon receipt of the mode establishment signal S2 from the mode establishment means 100b, the input changeover means 100c selectively switches the detection signals from the buttons 102 and 103 as well as from the sensors 110 through 115. The selected detection signal is output to the mode control means 100f.
The sheet overload detection means 100d checks the cut sheets 68 on the sheet feed table 50 for sheet overload on the basis of the detection signals from the T-K home sensor 110, from the sheet feed upper limit sensor 111 and from the T--T lower limit sensor 112. A determination signal S3 reflecting the result of the check is output by the means 100d to the mode control means 100f. If a sheet overload condition is detected, that condition is displayed on the display unit 104, announced by voice, or indicated by other suitable means.
The print inhibit signal output means 100e outputs a print inhibit signal S4 when the T/K changeover button 102 or T/K descent button 103 is pushed on the control panel 101. The print inhibit signal S4 when output disables the operation of the print start button 82 and thus inhibits the print control means 80 of the printing machine 2 from starting print operation. The print inhibit signal output means 100e further receives the determination signal S1 from the cassette presence detection means 100a. As will be described later, the print inhibit signal output means 100e also outputs the print inhibit signal S4 when the determination signal S1 reflecting the presence of the cassette is input upon changeover from the K mode to the T mode.
The mode control means 100f comprises T mode control means 100fA and K mode control means 100fB. The T mode control means 100fA controls the operation of the T mode, to be described later in more detail, upon receipt of the mode establishment signal S2 designating the T mode from the mode establishment means 100b. The T mode control means 100fA also receives the signals from the buttons 102 and 103 and the detection signals from the sensors 110 through 119. In turn, the T mode control means 100fA supplies the motor driving means 100g with a pulse signal S5 for rotating the motor 8 in the forward or reverse direction.
On receiving the determination signal S1 from the cassette presence detection means 100a, the determination signal S3 from the sheet overload detection means 100d, or the print inhibit, signal S4 from the print inhibit signal output means 100e, the T mode control means 100fA controls the motor 8 accordingly. In lifting or lowering the sheet feed unit 10 and the sheet feed table 50, the T mode control means 100fA outputs to the clutch switching means 100h a control signal S7 for switching the clutches 9a and 9b in the T mode.
The K mode control means 100fB controls the operation of the K mode upon receipt of the mode establishment signal S2 designating the K mode from the mode establishment means 100b. On further receiving the input signals from the buttons 102 and 103 and the detection signals from the sensors 110 through 119 via the input changeover means 100c, the K mode control means 100fB supplies the motor driving means 100g with a pulse signal S6 for rotating the motor 8 in the forward or reverse direction.
Upon input of the determination signal S1 from the cassette presence detection means 100a, the determination signal S3 from the sheet overload detection means 100d or the print inhibit signal S4 from the print inhibit signal output means 100e, the K mode control means 100fB controls the motor 8 accordingly. In lifting or lowering the sheet feed unit 10 and the sheet feed table 50, the T mode control means 100fA outputs to the clutch switching means 100h a control signal S8 for switching the clutches 9a and 9b in the K mode.
The motor driving means 100g receives the pulse signal S5 from the T mode control means 100fA or the pulse signal S6 from the K mode control means 100fB. Depending on the pulse signal received, the motor driving means 100g causes the motor 8 to rotate in the forward or reverse direction.
With the motor 8 controlled in rotation, the clutch switching means 100h switches the clutches 9a and 9b in the operation mode designated by the control signal S7 or S8 from the T mode control means 100fA or from the K mode control means 100fB. The setup above provides control over three kinds of up-down movement: the movement of the sheet feed unit 10 between the T-K home position P1 and the K--K lower limit position P4 in the T mode, the movement of the sheet feed table 50 within the sheet feed unit 10, and the movement of the cassette K between the sheet feed upper limit sensor 111 and the K--K lower limit position P4 in the K mode.
The control operation of the sheet feed control means 100 will now be described with reference to the flowchart of FIG. 10 and other accompanying drawings. FIG. 10 shows the steps constituting the initial operation of the cut sheet feeder when it is powered. When the power switch 116 is turned on (step 10-1), a check is made to see if the cassette K is mounted on the cassette plate 12. The check is made in accordance with the determination signal S1 from the cassette presence detection means 100a based on the detection signal from the cassette sensor 114 (step 10-2).
If the cassette K is not mounted on the cassette plate 12 and the cassette sensor 114 outputs an OFF signal (NO in step 10-2), the mode establishment means 100b establishes the T mode automatically (step 10-3). If, with the power switch 116 turned on, the cassette K is mounted on the cassette plate 12 and the cassette sensor 114 outputs an ON signal (YES in step 10-2), then the mode establishment means 100b establishes the K mode automatically based on the determination signal S1 (step 10-4).
When the T mode is established automatically, the mode establishment signal S2 from the mode establishment means 100b activates the T mode control means 100fA. In the T mode, the T mode control means 100fA brings the top surface of the cut sheets 68 into contact with the pickup roller 43 based on the detection signals from the T-K home sensor 110 and from the sheet feed upper limit sensor 111. This allow the pick-up rollers 43 to feed the cut sheets 68 from the sheet feed table 50. The control operations involved are as follows:
When the sheet feed unit 10 is set to the T-K home position P1, i..e., the reference table sheet feed position in the T mode shown in FIG. 6(a), a check is made to see if the T-K home sensor 110 outputs an ON signal. If the T-K home sensor 110 is found to be on (YES in step 10-5), the print start button 82 of the printing machine 2 is pushed (step 10-6). This executes another check to see if the sheet feed upper limit sensor 111 outputs an ON signal. If the sensor 111 is found to be on (YES in step 10-7), the top surface of the stacked cut sheets 68 is in contact with the pick-up roller 43. Then the cut sheet feeder 1 starts feeding the cut sheets 68 into the printing machine 2 (step 10-8).
In the T mode, if the sheet feed unit 10 is not in the reference table sheet feed position and is below the pick-up roller 43 as shown in FIG. 11(a), the cut sheets 68 are not in contact with the pick-up roller 43 and sheet feed operation cannot be executed. In that case, the T-K home sensor 110 outputs an OFF signal (NO in step 10-5). Then with the two clutches 9a and 9b engaged, the motor 8 is rotated in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 10-9).
As the sheet feed unit 10 rises and reaches the reference table sheet feed position as shown in FIG. 6(a), the T-K home sensor 110 outputs an ON signal (YES in step 10-5). When the print start button 82 of the printing machine 2 is pushed (step 10-6) and the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 10-7), the cut sheet feeder 1 starts feeding the cut sheets 68 into the printing machine 2 (step 10-8).
At this point, a check is made to see if the sheet feed upper limit sensor 111 outputs an OFF signal. If the sensor 111 does output the OFF signal (NO in step 10-7), the sheet feed table 50 alone is raised until the sheet feed upper limit sensor 111 outputs an ON signal (step 10--10).
When the K mode is automatically established, the mode establishment signal S2 from the mode establishment means 100b activates the K mode control means 100fB. In the K mode, the K mode control means 100fB brings the top surface of the cut sheets 69 in the cassette K into contact with the pick-up rollers 43 based on the detection signal from the sheet feed upper limit sensor 111. This allows the pick-up rollers 43 to feed the cut sheets 69 from the cassette K. The control operations involved are as follows:
When the K mode is automatically established, the print start button 82 of the printing machine 2 may be pushed (step 10-11). If the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 10-12) in the state shown in FIG. 6(b), the top surface of the cut sheets 69 is in contact with the pick-up rollers 43. At this point, the sheet feed unit 10 and the sheet feed table 50 are stationary (step 10-13). The cut sheet feeder 1 then starts feeding the cut sheets 69 into the printing machine 2 (step 10-8).
By contrast, as shown in FIG. 11(b), it may happen that the cassette K is positioned lower than the pick-up roller 43. This means no contact between the cut sheets 69 and the pick-up roller 43, and sheet feed operation cannot be performed. In that case, with the print start button 82 of the printing machine pushed (step 10-11), the sheet feed upper limit sensor 111 outputs an OFF signal (NO in step 10-12). With the clutches 9a and 9b engaged, the OFF signal from the sensor 111 causes the motor to rotate in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 10-14).
As the sheet feed unit 10 rises and reaches the position shown in FIG. 6(b) where the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 10-12), the lifting of the sheet feed unit 10 and sheet feed table 50 is stopped (step 10-13). The cut sheet feeder 1 then starts feeding the cut sheets 69 into the printing machine 2 (step 10-8).
What follows is a description of how to change the currently established operation mode. If the current operation mode is the T mode, pushing the T/K changeover button 102 causes the mode establishment means 100b to output the mode establishment signal S2 designating the K mode. The K mode control means 100fB then carries out necessary processing. If the current operation mode is the K mode, pushing the T/K changeover button 102 triggers the output of the mode establishment signal S2 designating the T mode. Thereafter, the T mode control means 100fA performs necessary processing.
The changeover from the K mode as the current operation mode to the T mode, effected by pushing the T/K changeover button 102, will now be described in more detail with reference to the flowchart of FIG. 12. Since the current operation mode is the K mode (step 12-1), the T/K changeover button 102 is pushed (step 12-2). This executes a check to see if the cassette sensor 114 outputs an ON signal indicating the presence of the cassette K on the cassette plate 12. If the cassette sensor 114 does output the ON signal (YES in step 12-3), steps are taken to remove the cassette K from the cassette plate 12. If the cassette K is not mounted on the cassette plate 12, the steps for cassette removal are skipped and step 12-10 is reached.
When the cassette sensor 114 outputs the ON signal, the cassette presence detection means 100a outputs the determination signal S1 indicating the presence of the cassette K. This causes the print inhibit signal output means 100e to output the print inhibit signal S4 to the print control means 80. The print inhibit signal S4 disables the operation of the print start button 82 of the printing machine 2 and thereby inhibits print operation.
When the cassette K is left mounted on the cassette plate 12, with the ON signal output by the cassette sensor 114, pushing the T/K changeover switch 102 (step 12-2) executes a check to see if the sensor 114 keeps outputting the ON signal. While the cassette sensor 114 remains on (YES in step 12-3), the motor 8 is rotated in reverse by engaging the clutches 9a and 9b so that the sheet feed unit 10 and the sheet feed table 50 will be lowered together by the same amount (step 12-4).
The sheet feed unit 10 and the sheet feed table 50 are allowed to descend until the K--K lower limit sensor 113 outputs an ON signal (YES in step 12-5). The unit 10 and the table 50 are then stopped (step 12-6). With the sheet feed unit 10 in its lower limit position, the presence of the cassette K on the cassette plate 12 is displayed on the display unit 104, announced by voice, or indicated by other suitable means. In this state, the cover 67 is opened and the cassette K is removed from the cassette plate 12 (step 12-7). The cassette sensor 114 then outputs an OFF signal.
When the cover 67 is closed (step 12-8) and the cover sensor 115 outputs an ON signal (YES in step 12-9), the sheet feed unit 10 and the sheet feed table 50 are now ready to be lifted according to the selected mode. The lift operation takes place as follows:
Depending on the amount of the cut sheets 68 on 25 the sheet feed table 50, one of the processes illustrated in FIGS. 13 through 15 is selectively executed. When the amount of the cut sheets 68 is within a range H1 (the appropriate range), the process depicted in FIGS. 13(a)-13(c) are carried out. Suppose that, with the T/K changeover button 102 pushed, the sheet feed unit 10 is not in the reference table sheet feed position, that the T-K home sensor 110 outputs an OFF signal (NO in step 12-11), and that the sheet feed upper limit sensor 111 outputs an OFF signal (NO in step 12--12), as depicted in FIG. 13(a). In that case, with the clutches 9a and 9b engaged, the motor 8 is rotated in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 12-10).
As shown in FIG. 13(b), the sheet feed unit 10 then reaches the reference table sheet feed position and the T-K home sensor 110 outputs an ON signal (YES in step 12-11). After this, pushing the print start button 82 of the printing machine 2 (step 12-13) disengages the clutch 9a alone and allows only the sheet feed table 50 to rise (step 12-14) until the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 12-15). When the cut sheets 68 come into contact with the pick-up roller 43 as shown in FIG. 13(C), the sheet feed upper limit sensor 111 outputs the ON signal that stops the sheet feed table 50 (step 12-16). Sheet feed operation thus starts in the T mode (step 12-17).
The case where the amount of the cut sheets 68 is at the maximum allowable height H2 as illustrated in FIGS. 14(a)-14(c) will now be described. Suppose that, with the T/K changeover button 102 pushed, the sheet feed unit 10 is not in the reference table sheet feed position, that the T-K home sensor 110 outputs an OFF signal (NO in step 12-11), and that the sheet feed upper limit sensor 111 outputs an OFF signal (NO in step 12-12), as depicted in FIG. 14(a). In that case, with the clutches 9a and 9b engaged, the motor 8 is rotated in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 12-10).
As shown in FIG. 14(b), before the sheet feed unit 10 reaches the reference table sheet feed position, the T-K home sensor 110 keeps outputting an OFF signal (NO in step 12-11). In this state, the top surface of the cut sheets 68 on the sheet feed table 50 comes into contact with the pick-up roller 43. This turns on the sheet feed upper limit sensor 111 (YES in step 12--12) and leaves the T--T lower limit sensor 112 turned off (NO in step 12-18). The clutch 9b alone is then disengaged and only the sheet feed unit 10 is allowed to rise (step 12-19).
When the sheet feed unit 10 has reached its upper limit position and the T-K home sensor 110 outputs an ON signal (YES in step 12-20) as illustrated in FIG. 14(C), the lifting of the sheet feed unit 10 stops (step 12-21). The print start button 82 of the printing machine 2 is then pushed (step 12-13), and subsequent steps are carried out.
The case where the amount of the cut sheets 68 is at a height H3 exceeding the maximum allowable height, as illustrated in FIGS. 15(a) and 15(b), will now be described. In that case, with the T/K changeover button 102 pushed, the sheet feed unit 10 and the sheet feed table 50 may be positioned as shown in FIG. 15(a). That is, the sheet feed unit 10 is not in the reference table sheet feed position, the T-K home sensor 110 outputs an OFF signal (NO in step 12-11), and the sheet feed upper limit sensor 111 also outputs an OFF signal (NO in step 12--12). Then with the clutches 9a and 9b engaged, the motor 8 is rotated in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 12-10).
Thereafter, the state of FIG. 15(b) may occur. That is, with the sheet feed unit 10 yet to reach the reference table sheet feed position, i.e., with the OFF signal coming from the T-K home sensor 110 (NO in step 12-11), the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 12--12) and the T--T lower limit sensor 112 also outputs an ON signal (YES in step 12-18). This state involves an excess amount of cut sheets 68 stacked on the sheet feed table 50. Under the excess amount of its cut sheets, the sheet feed table 50 is impeding the sheet feed unit 10 from being lifted up to the reference table sheet feed position. In that case, the sheet overload detection means 100d recognizes a sheet overload condition based on the detection signals from the sensors involved, and the process of recovery from sheet overload is carried out (starting from step 12-22).
The sheet overload recover process will now be described with reference to the flowchart of FIG. 16. The sheet feed unit 10 and the sheet feed table 50 are first lowered together by the same amount (step 16-1).
The sheet feed unit 10 stops in the K--K lower limit position P4 (step 16-3). The sheet overload condition is indicated visually, by voice, or by other suitable means (step 16-4). In this state, the cover 67 is opened and the excess cut sheets 68 are removed from the sheet feed table 50 (step 16-5). Closing the cover 67 completes the sheet overload recovery process (step 12-21). After this, the sheet feed operation in the T mode outlined in FIG. 12 is resumed (by going to step 12-10).
Alternatively, the sheet feed unit 10 and the sheet feed table 50 need not be lowered to the K--K lower limit position P4. Instead, the sheet feed table 50 may be positioned just low enough for the top surface of the cut sheets 68 to leave a sufficient clearance against the pick-up roller 43 whereby the excess cut sheets 68 may be removed.
The operations involved when the T/K changeover button 102 is pushed for changeover to the K mode will now be described with reference to the flowchart of FIG. 17. Since the current operation mode is the T mode (step 17-1), the sheet feed unit 10 is in the state of FIG. (C) (or in the state of FIG. 14(C), which is the same state). That is, the sheet feed unit 10 is in the reference table sheet feed position, i.e., the T-K home position P1; the sheet feed table 50 is positioned between the sheet feed upper limit position P2 and the T--T lower limit position P3. To select the K mode requires lowering the sheet feed unit 10 and the sheet feed table 50 and placing the cassette K on the cassette plate 12 so that the top surface of the cut sheets 69 will contact the pick-up rollers 43.
When the T/K changeover button 102 is pushed (step 17-2), the clutches 9a and 9b are engaged and the motor 8 is rotated in reverse so that the sheet feed unit 10 and the sheet feed table 50 will be lowered together by the same amount (step 17-3). When the K--K lower limit sensor 113 outputs an ON signal (YES in step 17-4), the descent of the sheet feed unit 10 and sheet feed table 50 is stopped (step 17-5).
In this state, the cover 67 is opened and the cassette K is mounted on the cassette plate 12 (step 17-6). After the cassette sensor 114 outputs an ON signal (step 17-67), closing the cover (step 17-7) causes the cover sensor 115 to output an ON signal (YES in step 17-8). When the print start button 82 of the printing machine 2 is pushed (step 17-9), the clutches 9a and 9b are engaged and the motor 8 is rotated in the forward direction so that the sheet feed unit 10 and the sheet feed table 50 will be lifted together by the same amount (step 17-10).
When the sheet feed upper limit sensor 111 outputs an ON signal (YES in step 17-11), the lifting of the sheet feed unit 10 and sheet feed table 50 stops (step 17-12). The cut sheet feeder 1 then starts feeding the cut sheets 69 into the printing machine 2 in the K mode (step 17-13).
During sheet feed operation, jamming may occur or it may become necessary to replenish cut sheets or to replace the currently set cut sheets with those of a different size. In such cases, pushing the T/K descent button 103 causes the T mode control means 100fA or the K mode control means 100fB, whichever is in effect depending on the current operation mode, to control the lowering of the sheet feed unit 10 and the sheet feed table 50.
How jamming is remedied or cut sheets are replenished in the T mode will now be described with reference to the flowchart of FIG. 18. If a jam is detected by the jam detection means 119 during sheet feed operation in the T mode (YES in step 18-1), the jammed condition is indicated on the display unit 104 and the sheet feed operation stops automatically (step 18-2).
Then pushing the T/K descent button 103 (step 18-3) causes the motor 8 to rotate in reverse with only the clutch 9b engaged. The sheet feed table 50 alone is lowered (step 18-4) until the T--T lower limit sensor 112 outputs an ON signal (YES in step 18-5). In this state, the cover 67 is opened and the jammed sheet is removed (step 18-6).
With the jammed condition remedied and the cover 67 closed (step 18-7), the cover sensor 115 outputs an ON signal (YES in step 18-8). When the print start button 82 of the printing machine 2 is pushed, the sheet feed operation of the T mode is resumed as described above (by going to step 12-13 of FIG. 12).
During sheet feed operation in the T mode, it may become necessary to replenish the sheet feed table 50 with more cut sheets 68 or to replace the currently set cut sheets 68 with those of a different size (YES in step 18-10). In that case, the print operation including the feeding of cut sheets to the printing machine 2 is stopped for the moment by pushing a print stop button, not shown, of the printing machine 2. Then pushing the T/K descent button 103 (step 18-11) rotates the motor 8 in reverse with only the clutch 9b engaged. This lowers the sheet feed table 50 alone (step 18-12) until the T--T lower limit sensor 112 outputs an ON signal (YES in step 18-13).
In this state, the cover 67 is opened, an appropriate amount of cut sheets 68 is added or the sheets of a necessary size are placed on the sheet feed table 50 (step 18-14), and the width of the fences 61 is adjusted as needed. With the cut sheets 68 supplied and in place, the cover 67 is closed (step 18-7). The cover sensor 115 outputs an ON signal (YES in step 18-8). Pushing the print start button 82 of the printing machine 2 resumes the sheet feed operation of the T mode as described above (step 12-13 is reached).
If the table sheet presence sensor 117 indicates that the cut sheets have been exhausted (YES in step 18-15) during sheet feed operation of the T mode, only the clutch 9b is engaged and the motor 8 is rotated in reverse. The sheet feed table 50 alone is thus lowered (step 18-16) until the T--T lower limit sensor 112 outputs an ON signal (YES in step 18-17). In this state, the cover 67 is opened, an appropriate amount of cut sheets 68 is placed on the sheet feed table 50 (step 18--18), and the cover 67 is closed (step 18-7). When the cover sensor 115 outputs an ON signal (YES in step 18-8), pushing the print start button 82 of the printing machine 2 resumes the sheet feed operation of the T mode as described above (step 12-13 is reached).
How jamming is remedied or cut sheets are replenished in the K mode will now be described with reference to the flowchart of FIG. 19. If a jam is detected by the jam detection means 119 during sheet feed operation in the K mode (YES in step 19-1) as in the case of the T mode, the jammed condition is indicated on the display unit 104 and the sheet feed operation stops automatically (step 19-2).
Then pushing the T/K descent button 103 (step 19-3) causes the motor 8 to rotate in reverse with the clutches 9a and 9b engaged. This lowers the sheet feed unit 10 and the sheet feed table 50 together by the same amount (step 19-4) until the K--K lower limit sensor 113 outputs an ON signal (YES in step 19-5).
In this state, the cover 67 is opened and the jammed sheet is removed (step 19-6). With the jammed condition remedied and the cover 67 closed (step 19-7), the cover sensor 115 outputs an ON signal (YES in step 19-8). When the print start button 82 of the printing machine 2 is pushed, the sheet feed operation of the K mode is resumed as described above (by going to step 17-9).
During sheet feed operation in the K mode, it may become necessary to replenish the cassette K with more cut sheets 69 (YES in step 19-9). In that case, the print operation including the feeding of cut sheets to the printing machine 2 is stopped for the moment by pushing the print stop button, not shown, of the printing machine 2. Then pushing the T/K descent button 103 (step 19-10) rotates the motor 8 in reverse with the clutches 9a and 9b engaged. The sheet feed unit 10 and the sheet feed table 50 are thus lowered together by the same amount (YES in step 19-11) until the K--K lower limit sensor 113 outputs an ON signal (YES in step 19-12).
In this state, the cover 67 is opened, and the cassette K is replenished with an appropriate amount of cut sheets 69 (step 19-13). With the cut sheets 69 supplied and in place, the cover 67 is closed (step 19-7). The cover sensor 115 outputs an ON signal (YES in step 19-8). Pushing the print start button 82 of the printing machine 2 resumes the sheet feed operation of the K mode as described above (step 17-9 is reached). For the sheet feed operation to be resumed, the sheet feed unit 10 and the sheet feed table 50 are lifted together until the sheet feed upper limit sensor 111 outputs an ON signal.
If the cassette sheet presence sensor 118 indicates that the cut sheets have been exhausted (YES in step 19-14) during sheet feed operation of the K mode, the clutches 9a and 9h are engaged and the motor 8 is rotated in reverse. The sheet feed unit 10 and the sheet feed table 50 are thus lowered together by the same amount (step 19-15) until the K--K lower limit sensor 113 outputs an ON signal. (YES in step 19-16). In this state, the cover 67 is opened, an appropriate amount of cut sheets 69 is set in the cassette K (step 19-17), and the cover 67 is closed (step 19-7). When the cover sensor 115 outputs an ON signal (YES in step 19-8), pushing the print start button 82 of the printing machine 2 resumes the sheet feed operation of the K mode as described above (step 17-9 is reached).
In any of the operations of the above-described embodiments, the sheet feed unit 10 and the sheet feed table 50 remain stationary whenever the cover 67 is opened and the cover sensor 115 outputs an OFF signal.
As described, the cut sheet feeder of the invention comprises the sheet feed unit and the sheet feed table. The sheet feed unit accommodates a sheet cassette, and the sheet feed table moves up and down inside the sheet feed unit and has cut sheets stacked thereon. The sheet feed unit and the sheet feed table are lifted selectively up to a single sheet feed mechanism for sheet feed operation. This setup allows the sheet feed mechanism to pick up cut sheets selectively from the cassette or from the sheet feed table and to feed them into the image recording portion of the image forming apparatus.
Because the single sheet feed mechanism feeds cut sheets selectively from the cassette or from the sheet feed table into the image recording portion, the sheet transport route remains unchanged from the sheet feed mechanism to the image recording portion. The sheet feed timing is thus kept constant, which eliminates the need for adjustments to keep constant the timing of feeding cut sheets to the image forming portion. This is particularly effective in improving the print quality of mimeograph printing machines wherein a slight deviation in sheet feed timing results in the longitudinal misalignment of printed contents.
The fact that the single sheet feed mechanism feeds cut sheets selectively from the cassette or from the sheet feed table into the image recording portion offers another benefit. That is, the structure of the sheet transport route is simplified and this route is easier to maintain than conventional sheet transport routes. With the simply structured sheet transport route taking up less space, the cut sheet feeder as a whole may be manufactured smaller than ever before.
According to the invention, the sheet feed unit has a swingingly installed cover that covers the opening of the unit through which cut sheets are loaded and unloaded and through which the cassette K may be attached and detached to and from the sheet feed unit. The swinging status of the cover is detected by the cover detection means. Only when the cover detection means outputs a detection signal indicating the closed status of the cover, the sheet feed unit and the sheet feed table can be moved vertically relative to the sheet feed mechanism. The vertical movement of the components is carried out based on the detection signal from the cassette presence detection means (indicating the presence or absence of the cassette) and on the mode signal from the mode establishment means (indicating either the table feed mode or the cassette feed mode is in effect). If the cassette is left inadvertently loaded in the cut sheet feeder, the above arrangements prevent the sheet feed unit or the sheet feed table from going up and colliding with the sheet feed mechanism. The sheet feed unit and the sheet feed table are thus moved safely and smoothly according to the current operation mode. The sheet feed unit or the sheet feed table is not allowed to run unless and until the cover is securely closed. This protects the operator from injuries caused by having any part of his body get caught by the movable components of the cut sheet feeder.
As many apparently different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the appended claims. | A cut sheet feeder for an image forming apparatus is basically formed of one sheet feed mechanism for picking up stacked cut sheets at a single sheet feed position, a sheet feed unit vertically movable relative to the sheet feed mechanism, a cassette detachably attached to the sheet feed unit and containing the cut sheets, and a sheet feed table vertically movably situated inside said sheet feed unit and carrying a large number of the cut sheets.. The feeder further includes a cassette presence detection device for detecting presence or absence of the cassette on the sheet feed unit, a cover detection device for indicating an opening status of a cover for the sheet feed unit, a mode establishment device for establishing a cassette feed mode or a table feed mode, and a mode control device for controlling the sheet feed unit. The mode control device lowers the sheet feed unit to a predetermined position in case the cassette feed mode is changed to the table feed mode by the mode establishment device while the cover detection device outputs a detection signal indicating a closed status of the cover and the cassette presence detection device outputs a signal indicating the presence of the cassette. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION DATA
This application claims the benefit of the earlier filed Japanese Patent Application No. 2006-337006 having a filing date of Dec. 14, 2006.
FIELD OF THE INVENTION
The present invention relates to a terminal insertion apparatus.
BACKGROUND
The terminal insertion apparatus described in Prior Art FIG. 5 (see JP10-112229A), for example, is a terminal insertion apparatus which inserts a terminal attached to an electrical wire into a terminal insertion hole of a connector housing during the production of a wire harness.
Prior Art FIG. 5 is a side view of a terminal insertion apparatus according to JP10-112229A. Prior Art FIG. 6 is a side view showing a terminal insertion head provided in the terminal insertion apparatus shown in Prior Art FIG. 5 .
The terminal insertion apparatus 50 shown in Prior Art FIG. 5 comprises a pair of X-axis beams 52 installed on frames 51 , a Y-axis beam 53 supported on the respective X-axis beams 52 in a movable manner, a terminal insertion head 54 capable of moving along the Y-axis beam 53 , and a connector gripping unit 55 similarly capable of moving along the Y-axis beam 53 .
As is shown in Prior Art FIG. 5 , the terminal insertion head 54 is attached to the rail 57 of the Y-axis beam 53 in a movable manner via a linear motion guide (LM guide) 56 .
As is shown in Prior Art FIGS. 5 and 6 , the terminal insertion head 54 comprises a frame 58 fastened to the linear motion guide 56 , a first base plate part 60 attached to the frame 58 via a ball screw unit 59 so as to be freely raised and lowered, and a second base plate part 62 attached to the first base plate part 60 via a vertical cylinder 61 so as to be freely raised and lowered.
An electrical wire separation unit 63 is installed at the front end of the first base plate part 60 . Furthermore, a terminal gripping unit 64 is installed on the second base plate part 62 .
The electrical wire separation unit 63 comprises a pair of electrical wire separation claws 65 capable of opening and closing in the left-right direction (depth direction in Prior Art FIGS. 5 and 6 ), and a chuck cylinder 66 that causes the electrical wire separation claws 65 to open and close.
The terminal gripping unit 64 comprises a pair of front-side electrical wire gripping hands 68 , a pair of rear-side electrical wire gripping hands 69 , a first chuck cylinder 70 that causes the front-side electrical wire gripping hands 68 to open and close in the left -right direction, and a second chuck cylinder 71 that causes the rear-side electrical wire gripping hands 69 to open and close in the left-right direction. Moreover, the terminal gripping unit 64 comprises a first horizontal cylinder 72 that causes the entire terminal gripping unit 64 to advance and retract, and a second horizontal cylinder 73 that causes only the rear-side electrical wire gripping hands 69 to advance and retract.
When the terminal C attached to each electrical wire W is to be inserted into a terminal insertion hole of a connector housing 67 by means of the terminal insertion apparatus 50 , the ball screw unit 59 first lowers the terminal insertion head 54 , and the vertical cylinder 61 lowers the two sets of electrical wire gripping hands 68 and 69 . Then, the two sets of electrical wire gripping hands 68 and 69 grip the terminal of an electrical wire W that is set in an electrical wire clip 74 .
Next, the ball screw unit 59 raises the entire terminal insertion head 54 , and the vertical cylinder 61 raises the two sets of electrical wire gripping hands 68 and 69 . Then, the terminal insertion head 54 moves along the Y-axis beam 53 so as to be above the connector housing 67 that is gripped by the connector gripping unit 55 .
Furthermore, the ball screw unit 59 again lowers the terminal insertion head 54 , thus causing the electrical wire separation claws 65 of the electrical wire separation unit 63 to be inserted between lead electrical wires (not shown in the figures) that are led out from the connector housing 67 . Moreover, the chuck cylinder 66 opens the electrical wire separation claws 65 , so that a state is created in which the lead electrical wires are separated.
Afterward, the first horizontal cylinder 72 on the upper side causes the two sets of electrical wire gripping hands 68 and 69 to advance integrally with the second base plate part 62 . As a result, the terminal C is temporarily inserted into a terminal insertion hole of the connector housing 67 .
Then, the front-side electrical wire gripping hands 68 are opened, the second horizontal cylinder 73 is extended, and the electrical wire W is pushed only by the rear-side electrical wire gripping hands 69 . As a result, the terminal C is completely inserted into the terminal insertion hole of the connector housing 67 .
Because lead electrical wires of terminals C that have already been inserted into terminal insertion holes of the connector housing 67 can be separated using such a terminal insertion apparatus 50 , it is possible to reliably perform the insertion of each terminal C into a terminal insertion hole of the connector housing 67 .
However, in the terminal insertion apparatus 50 shown in Prior Art FIGS. 5 and 6 , it is necessary to perform the insertion of terminals C attached to electrical wires W into terminal insertion holes of the connector housing 67 for one terminal at a time for each electrical wire W during the production of a wire harness. Accordingly, it is difficult to increase the wire harness production efficiency.
SUMMARY
The present invention, in one embodiment, relates to a terminal insertion apparatus having a wire holding unit holding two wires, each wire having a terminal, a connector holding unit holding a connector housing having at least two holes for receiving terminals, and a terminal insertion head. The terminal insertion head has a wire gripping unit having a first holder and a second holder. The first holder and second holder are movable in a vertical direction toward and away from the wire holding unit and are movable in a horizontal direction toward and away from the connector holding unit. The first holder has an outer grip and an inner grip that together hold one of the two wires while the second holder has an outer grip and an inner grip that together hold the remaining of the two wires.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique schematic view of the essential parts of a terminal insertion apparatus according to an embodiment of the present invention;
FIG. 2 is an orthogonal front view of the terminal insertion apparatus of FIG. 1 ;
FIG. 3 is an orthogonal side view of the terminal insertion apparatus of FIG. 1 ;
FIG. 4 is an oblique schematic view of a chuck of the terminal insertion apparatus of FIG. 1 ;
Prior Art FIG. 5 is an orthogonal side view of a terminal insertion apparatus of JP10-112229A; and
Prior Art FIG. 6 is an orthogonal side view of a terminal insertion head of the terminal insertion apparatus of Prior Art FIG. 5 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
A terminal insertion apparatus of an embodiment of the present invention will be described below with reference to the figures. For the convenience of description, the terminal guides and the like are omitted in FIG. 1 .
The terminal insertion apparatus 1 shown in FIG. 1 is used to insert terminals C attached to one end of electrical wires W into terminal insertion holes F of a connector housing H during wire harness production.
As is shown in FIGS. 1 through 3 , the terminal insertion apparatus 1 comprises an electrical wire supporting unit 2 arranged on the surface of a base (not shown in the figures), a connector holding unit 3 similarly arranged on the surface of the base, and a terminal insertion head 4 attached to a side wall B that is vertically installed on the base.
The electrical wire supporting unit 2 comprises a clamp 6 for holding electrical wires W, and a carrier 7 for carrying terminals C that are attached to the electrical wires W.
The clamp 6 can hold a plurality of electrical wires W (two electrical wires in the present embodiment) at a specified wire separation distance α (approximately 8 mm in the present embodiment, for example). Furthermore, in cases where the specified wire separation distance α of the electrical wires W held by the clamp 6 is set at 8 mm, this wire separation distance α is a relatively narrow distance for clamp provided in automated apparatuses of this type.
The connector holding unit 3 comprises a baseplate 9 on which the connector housing H is carried, and a lock 10 for locking the connector housing H carried on the baseplate 9 .
The terminal insertion head 4 comprises a vertical mount 13 attached to the side wall B via a vertical actuator 12 so as to be freely raised and lowered, a horizontal mount 15 attached to the vertical mount 13 via a horizontal actuator 14 so as to be freely moved horizontally, and an electrical wire gripping unit 16 attached to the horizontal mount 15 . In this embodiment, the vertical actuator 12 and horizontal actuator 14 each comprise an air cylinder or are otherwise pneumatic. However, in alternative embodiments of the present invention, any other suitable actuation device may be substituted for the air cylinders.
The electrical wire gripping unit 16 comprises a pair of first and second outer claws 21 a , 21 b opened and closed by an outer chuck 18 and a pair of first and second inner claws 22 a , 22 b opened and closed by an inner chuck 19 . The outer chuck 18 and inner chuck 19 are attached to the horizontal mount 15 .
As is shown in FIG. 4 , each of the first and second outer claws 21 a , 21 b is formed substantially in the shape of the letter “L” as seen from the left-right direction (left-right direction in FIGS. 1 and 4 ). Outer grips 23 that protrude downward in the vertical direction (vertical direction in FIGS. 1 and 4 ) are respectively provided at the tip end portions of the first and second outer claws 21 a , 21 b.
Each of the first and second inner claws 22 a , 22 b is formed substantially in the shape of the letter “L” as seen from the left-right direction as shown in FIG. 4 . Inner grips 24 that protrude downward in the vertical direction are respectively provided at the tip end portions of the first and second inner claws 22 a , 22 b.
In the electrical wire gripping unit 16 , the inner grips 24 of the first and second inner claws 22 a , 22 b are arranged between the outer grips 23 of the first and second outer claws 21 a , 21 b . In the electrical wire gripping unit 16 , furthermore, the first and second inner claws 22 a , 22 b and first and second outer claws 21 a , 21 b are arranged so that the inner grips 24 of the first and second inner claws 22 a , 22 b and the outer grips 23 of the first and second outer claws 21 a , 21 b overlap as seen from the left-right direction. Moreover, in the initial state of the electrical wire gripping unit 16 , the first and second inner claws 22 a , 22 b are arranged with a specified distance in the left-right direction as shown in FIGS. 1 and 4 so as to allow the gripping of the two electrical wires W arranged at the specified wire separation distance α.
Furthermore, the first outer claw 21 a and first inner claw 22 a (together on the same side) make up a first holder 26 a . The first holder 26 a grips one of the electrical wires W with the inner surface of the outer grips 23 of the first outer claw 21 a and the outer surface of the inner grips 24 of the first inner claw 22 a.
Moreover, the second outer claw 21 b and the second inner claw 22 b (together on an opposite side) make up a second holder 26 b . The second holder 26 b grips the other electrical wire W with the inner surface of the outer grips 23 of the second outer claw 21 b and the outer surface of the inner grips 24 of the second inner claw 22 b.
With regard to the first holder 26 a and second holder 26 b , the outer chuck 18 causes the first and second outer claws 21 a , 21 b to move outward, and the inner chuck 19 causes the first and second inner claws 22 a , 22 b to move inward, so that the sets of outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b are placed in an open state.
With regard to the first holder 26 a and second holder 26 b , furthermore, the outer chuck 18 causes the first and second outer claws 21 a , 21 b to move inward, and the inner chuck 19 causes the first and second inner claws 22 a , 22 b to move outward, so that the sets of outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b are placed in a closed state.
Thus, the electrical wire gripping unit 16 makes it possible to grip or release the electrical wires W between the sets of outer and inner grips 23 , 24 of the respective holders 26 a , 26 b by opening or closing the sets of outer and inner grips 23 , 24 of the respective holders 26 a , 26 b.
In the first and second holders 26 a , 26 b that are in a state in which the outer and inner grips 23 , 24 are closed, the outer chuck 18 causes the first and second outer claws 21 a , 21 b to move further inward, so that the first and second outer claws 21 a , 21 b press the first and second inner claws 22 a , 22 b inward, thus reducing the distance between the first and second inner claws 22 a , 22 b . As a result, it is possible to move the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b inward in the direction of arrangement of the first and second holders 26 a , 26 b (left-right direction in FIG. 1 ). Consequently, the electrical wire gripping unit 16 can change the wire separation distance α of the two electrical wires W gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b to a smaller distance.
In the first and second holders 26 a , 26 b that are in a state in which the outer and inner grips 23 , 24 are closed, the inner chuck 19 causes the first and second inner claws 22 a , 22 b to move further outward, so that the first and second inner claws 22 a , 22 b press the first and second outer claws 21 a , 21 b outward, thus increasing the distance between the first and second inner claws 22 a , 22 b . As a result, it is possible to move the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b outward in the direction of arrangement of the first and second holders 26 a , 26 b . Consequently, the electrical wire gripping unit 16 can change the wire separation distance α of the two electrical wires W gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b to a larger distance.
Thus, the first holder 26 a and second holder 26 b can change the wire separation distance α of the two electrical wires W gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b from the specified wire separation distance α, at which these electrical wires W have been held by the clamp 6 to an terminal hole separation distance β at which the terminals C attached to the electrical wires W that are gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b can be simultaneously inserted into specified terminal insertion holes F of the connector housing H.
In this case, by causing the inner surface of the first inner claw 22 a of the first holder 26 a and the inner surface of the second inner claw 22 b of the second holder 26 b to contact each other as shown in FIG. 2 , the wire separation distance of the two electrical wires W gripped by the outer and inner grips 23 , 24 of these first and second holders 26 a , 26 b is set at the terminal hole separation distance β (3 mm in the present embodiment, for example), which allows the simultaneous insertion of the terminals C attached to the electrical wires W that are gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b into specified terminal insertion holes F of the connector housing H.
Furthermore, in the first and second holders 26 a , 26 b that are in a state in which the first and second inner claws 22 a , 22 b contact each other, the distance between the first and second inner claws 22 a , 22 b is returned to the specified distance described above by the outer chuck 18 causing the first and second outer claws 21 a , 21 b to move outward.
Moreover, as is shown in FIGS. 2 and 3 , the electrical wire gripping unit 16 is provided with a pair of terminal guides 29 that are opened and closed by a terminal guide actuator 28 . The terminal guide actuator 28 is attached to the horizontal mount 15 . In this embodiment, the terminal guide actuator comprises an air cylinder or is otherwise pneumatic. However, in alternative embodiments, any suitable actuator may be substituted for the air cylinder.
Recesses 30 that can support the terminals C attached to the electrical wires W are respectively formed on the inside of the lower end portions of these terminal guides 29 . The recesses 30 of the respective terminal guides 29 support the outside of the respective terminals C carried on the carrier 7 .
Next, actions that are taken when the terminals C attached to the electrical wires W are inserted into terminal insertion holes F of the connector housing H by the terminal insertion apparatus 1 will be described.
When the terminals C attached to the electrical wires W are to be inserted into terminal insertion holes F of the connector housing H by means of the terminal insertion apparatus 1 , the two electrical wires W to which the terminals C have been crimped beforehand in a previous step are first set in the electrical wire supporting unit 2 . In this case, the respective electrical wires W are held by the clamp 6 , and the terminals C attached to the respective electrical wires W are placed on the carrier 7 . Here, the wire separation distance α of the two electrical wires W held by the clamp 6 is set at 8 mm.
Furthermore, the connector housing H is set in the connector holding unit 3 . In this case, the connector housing H is carried on the baseplate 9 , and the connector housing H carried on the baseplate 9 is locked by the lock 10 .
Here, in the electrical wire gripping unit 16 that is in the initial state, the first and second outer claws 21 a , 21 b are arranged in a state in which these outer claws are moved outward, and the first and second inner claws 22 a , 22 b are arranged in a state in which these inner claws are moved inward, so that the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b are placed in a mutually open state.
Moreover, in the electrical wire gripping unit 16 that is in the initial state, the first and second inner claws 22 a , 22 b assume a state in which these inner claws are arranged with a specified distance in the left-right direction so that these inner claws can grip the two electrical wires W that are arranged at the specified wire separation distance α.
In addition, in the electrical wire gripping unit 16 that is in the initial state, the two terminal guides 29 are in a mutually open state by being arranged in a state in which these terminal guides are moved outward.
Then, the vertical actuator 12 lowers the electrical wire gripping unit 16 that is in the initial state. As a result, the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b are respectively disposed on the outside and on the inside of the individual electrical wires W that are held by the clamp 6 . At the same time, furthermore, the respective terminal guides 29 are disposed on the outside of the respective terminals C that are carried on the carrier 7 .
Next, the outer chuck 18 causes the first and second outer claws 21 a , 21 b to move inward, and the inner chuck 19 causes the first and second inner claws 22 a , 22 b to move outward. As a result, the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b grip the respective electrical wires W.
Moreover, the terminal guide actuator 28 causes the two terminal guides 29 to move inward. Consequently, the recesses 30 of the respective terminal guides 29 support the terminals C attached to the respective electrical wires W.
Next, the vertical actuator 12 raises the electrical wire gripping unit 16 . As a result, positioning in the vertical direction is performed between the terminals C attached to the electrical wires W that are gripped by the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b and specified terminal insertion holes F of the connector housing H disposed in the connector holding unit 3 . In this case, the wire separation distance of the electrical wires W that are gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b of the electrical wire gripping unit 16 is still the wire separation distance α, at which these two electrical wires W have been held by the clamp 6 .
Then, the chuck 18 causes the first and second outer claws 21 a , 21 b to move further inward, thus causing the inner surface of the first inner claw 22 a of the first holder 26 a and the inner surface of the second inner claw 22 b of the second holder 26 b to contact each other. This changes the wire separation distance of the two electrical wires W that are gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a , 26 b to 3 mm, which is the terminal hole separation distance β for allowing the simultaneous insertion of the terminals C attached to these two electrical wires W into specified terminal insertion holes F of the connector housing H. In this case, in synchronization with the change in the wire separation distance of the electrical wires W gripped by the outer and inner grips 23 , 24 of the first and second holders 26 a and 26 b , the terminal guide actuator 28 causes the two terminal guides 29 to move further inward, thus causing these terminal guides 29 to continue to support the terminals C attached to the respective electrical wires W.
Furthermore, the horizontal actuator 14 causes the electrical wire gripping unit 16 to advance toward the connector housing H that is disposed in the connector holding unit 3 . As a result, the terminals C attached to the two electrical wires W that are gripped by the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b are simultaneously inserted into specified terminal insertion holes F of the connector housing H in a temporary manner.
Following the temporary insertion of the terminals C into the terminal insertion holes F, the terminal guide actuator 28 causes the two terminal guides 29 to move outward. This releases the support of the terminals C attached to the respective electrical wires W by means of the respective terminal guides 29 .
Then, the horizontal cylinder 14 causes the electrical wire gripping unit 16 to advance further toward the connector housing H. As a result, the terminals C attached to the respective electrical wires W are completely inserted into the specified terminal insertion holes F of the connector housing H.
Furthermore, following the insertion of the terminals C attached to the respective electrical wires W into the specified terminal insertion holes F of the connector housing H, the gripping of the electrical wires W by the outer and inner grips 23 , 24 of the respective first and second holders 26 a , 26 b is released.
Moreover, the electrical wire gripping unit 16 is returned to the initial state and prepared for insertion of subsequent electrical wires W.
Thus, during wire harness production, the terminal insertion apparatus 1 enables the insertion of the terminals C attached to electrical wires W into terminal insertion holes F of the connector housing H for two electrical wires W at the same time.
Here, when gripping two electrical wires W and changing the wire separation distance of these two gripped electrical wires W, it is ordinarily necessary to use a total of three drive systems, i.e., drive systems that respectively drive two gripping means for gripping the individual electrical wires W and a drive system that moves these two gripping means. However, in the electrical wire gripping unit 16 of the terminal insertion apparatus 1 , the first chuck 18 and second chuck 19 perform the gripping of two electrical wires W by means of the respective first and second holders 26 a , 26 b and the changing of the wire separation distance of these two electrical wires W. That is, the terminal insertion apparatus 1 makes it possible to grip two electrical wires and to change the wire separation distance of the two gripped electrical wires by using only two sets of drive systems.
In addition, with the terminal insertion apparatus 1 , as a result of the recesses 30 of the respective terminal guides 29 supporting the terminals C attached to the respective electrical wires W, it is possible to prevent the occurrence of positional deviation between the terminals C and terminal insertion holes F when the terminals C attached to the electrical wires W are inserted into the terminal insertion holes F of the connector housing H.
The present invention performs the insertion of terminals C attached to electrical wires W into terminal insertion holes F of the connector housing H for two electrical wires at the same time during wire harness production. The present invention also provides that the gripping of two electrical wires W and the changing of the wire separation distance α of the two electrical wires W can be performed using two sets of drive systems. Further, because the terminal guides 29 that support the terminals C attached to the electrical wires W are provided, the present invention makes it is possible to prevent the occurrence of positional deviation between the terminals C and terminal insertion holes F when the terminals C attached to the electrical wires W are inserted into the terminal insertion holes F of the connector housing H. | A terminal insertion apparatus having a wire holding unit holding two wires, each wire having a terminal, a connector holding unit holding a connector housing having at least two holes for receiving terminals, and a terminal insertion head is disclosed. The terminal insertion head has a wire gripping unit having a first holder and a second holder. The first holder and second holder are movable in a vertical direction toward and away from the wire holding unit and are movable in a horizontal direction toward and away from the connector holding unit. The first holder has an outer grip and an inner grip that together hold one of the two wires while the second holder has an outer grip and an inner grip that together hold the remaining of the two wires. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a method of tempering a glass sheet for use, for example, as an automobile side or rear window by heating the glass sheet to a temperature above the strain point and quenching the heated glass sheet by directing cooling air jets onto both surfaces of the glass sheet.
The quenching of the glass sheet produces a center-to-surface temperature gradient through the thickness of the glass sheet and results in that permanent compressive stresses are produced in the surface layers of the glass sheet, with compensating tensile stresses in the center of the glass thickness. The tempered glass sheet is expected to break up into small and not very dangerous particles of glass when it is fractured by accident.
As to tempered glass sheets for use as automobile side or rear windows, there are official regulations which specify the manner of fragmentation of the tempered glass sheets. Such regulations commonly require that fracture of a tempered glass sheet should not produce dangerously large or elongated particles of glass. For example, British and European Economic Community (EEC) standards basically prohibit the presence of particles longer than 60 mm in which the length is not less than four times the width. Such particles are referred to as "splines". Besides, the same standards specify that the number of particles included in any 50 mm×50 mm square traced on the glass sheet (except in specified marginal areas and a specified circular area around the point of impact) should be within a limited range, such as from 60 to 400, and further specify a maximum permissible area of each particle, such as 300 mm 2 .
In the recent automobile industry a matter of important concern is reducing the vehicle weight. Accordingly there is a growing demand for tempered glass sheets of reduced thickness for use as side and rear windows. However, glass sheets less than about 3 mm in thickness are difficult to temper by the conventional air quenching method as so to comply with the aforementioned standards, primarily because of difficulty in creating and maintaining a suitable gradient of temperature in the thickness direction of the thin glass sheets during the quenching process.
With a view to satisfactorily tempering relatively thin glass sheets less than about 3 mm in thickness by air quenching, some proposals have been made for enhancement of the cooling efficiency. U.S. Pat. No. 4,578,102 proposes directing jets of a mixture of air and atomized water onto the heated glass surfaces by means of Laval nozzles. Air is supplied to the Laval nozzles at such a pressure that the jet velocity at the exit of each nozzle becomes at least sonic, while water is introduced from a radial direction into the constricted throat section of each nozzle to accomplish atomization of water and mixing of the atomized water with air within the divergent cone section of the nozzle. The mixture of air and atomized water has a higher specific heat than air alone. It is intended to rapidly extract heat from the glass sheet surfaces by using such high-velocity and high-specific heat two-phase jets. However, from a practical point of view this method is rather inconvenient and has some disadvantages. First, the necessity of using water besides air offers complicacy. Besides, very high precision of the equipment is required for complete atomization of water into a fine mist by using Laval nozzles and for thorough mixing of the atomized water with air during the transfer of the two fluids from the nozzle throat to the nozzle exit. Naturally a heavy cost is entailed. Furthermore, the relative pressure of air supplied to the nozzles must be at least 0.91 bar (about 0.93 kg/cm 2 ) in order to enable the jet velocity at the exit of the nozzles to be sonic. Despite the complicacy of the equipment and operation, still it is difficult to eliminate the possibility of relatively large droplets of water hitting the heated glass sheet to cause the glass to break.
Japanese patent application primary publication No. 60-145921 relates to tempering of a glass sheet by directing jets of air from quenching nozzles onto the heated glass sheet surfaces, and proposes to determine the air pressure and the nozzle configuration such that the maximum drop of the cooling air pressure takes place at the exit of each nozzle whereby the air jet velocity at the nozzle exit becomes sonic. The quenching nozzles used in this method are straight nozzles narrowed at the exit so as to form a small orifice, and the pressure of cooling air supplied to the nozzles is at least 0.9 bar (about 0.92 kg/cm 2 ) by gauge pressure. A disadvantage of this method is that fluctuations of the air supply pressure in the quenching equipment are liable to be transmitted to the glass sheet surfaces so that the heated glass sheet under quenching is liable to be distorted, particularly when the glass thickness is less than 3 mm. Besides, in this method it will be necessary to give very careful consideration to the arrangement of the quenching nozzles on a plane parallel to the glass sheet.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved method of tempering a glass sheet, which may be for use as an automobile side or rear window and may be as thin as about 1.5-3 mm, by quenching with air jets ejected from simple nozzles.
This invention provides a method of tempering a glass sheet, which has the steps of heating the glass sheet to a temperature above the strain point of the glass and quenching the heated glass sheet by directing jets of cooling air onto both surfaces of the heated glass sheet from two sets of nozzles protruding from oppositely disposed two air chambers, respectively. According to the invention, at the start of the quenching step each air chamber is suddenly allowed to communicate with a source of compressed air maintained at a predetermined first pressure, which is in the range from 2 to 8 kg/cm 2 by gauge pressure, such that a rapid drop in pressure from the first pressure to a predetermined second pressure in the range from 0.05 to 0.5 kg/cm 2 by gauge pressure takes place as the compressed air expands into the air chamber and such that substantially the whole length of each air chamber and the nozzles protruding therefrom serves as a sort of shock wave tube.
The quenching by this method can be accomplished by using simple nozzles such as, for example, substantially straight nozzles. Each of the air chambers used in this method has a capacity sufficient to maintain therein the predetermined second pressure almost unchanged at least for a predetermined length of time, which is not less than 3 sec and may be 5 to 15 sec.
As the compressed air rapidly expands into each air chamber with a sudden drop in pressure, a shock wave is formed at a section close to the entrance to the air chamber and propagates through the air chamber and the nozzles. By virtue of the propagated shock wave, the jets of air directed to the glass sheet by the nozzles have high kinetic energy at the initial stage of impingement on the glass sheet surfaces. Therefore, a heat transfer suppressive laminar film that exists on each surface of the heated glass sheet is immediately broken up or diminished in thickness, and heat is rapidly and efficiently dissipated or extracted from both surfaces of the glass sheet. Thus, the initial cooling power of the air jets is remarkably enhanced without greatly increasing the nozzle pressure.
Glass sheets of various thicknesses can be well tempered by the method according to the invention. Even thin glass sheets with thickness ranging from about 3 mm to about 1.5 mm can be tempered by this method so as to meet the current regulations on tempered glass sheets for use as automobile side or rear windows. Furthermore, this tempering method is applicable to the production of tempered glass sheets for various uses such as train or other vehicle window panes, building window panes and electronic device substrates.
It is also an important merit of the method according to the invention that distortion or deformation of the quenched glass sheet and probability of break of the quenched glass sheet greatly reduce because pulsation of the pressure of air supplied to the nozzles is small so that the glass sheet under quenching is scarcely swayed. This is particularly valuable in the cases of tempering thin glass sheets since, in general, liability of glass sheet to deformation or distortion augments approximately inversely proportional to the square of thickness.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a schematic presentation of a quenching apparatus used in a glass sheet tempering method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In tempering a glass sheet by a method according to the invention the first step is uniformly heating the glass sheet to a temperature above the strain point of the glass and slightly below the glass softening temperature, e.g. to 600°-700° C. This is similar to the heating treatment in the conventional glass sheet tempering methods. Uniformity in thickness of the glass sheet is important for achievement of desired tempering, and the importance of uniform thickness augments when tempering glass sheets thinner than about 2.5 mm. The heated glass sheet is soon carried into the quenching station.
To ensure that the glass sheet has an appropriately elevated temperature at the start of quenching with air jets, it is desirable to reheat a central region of the already uniformly heated glass sheet for a short period of time by using a suitable heating means such as a press heater. The area of the central region to be reheated is about 40-70% of the entire area of the glass sheet. The favorable effect of such reheating on the degree of tempering of the glass sheet augments as the thickness of the glass sheet reduces.
The FIGURE shows the outline of an example of quenching apparatus for use in the present invention. Numeral 10 indicates a glass sheet to be tempered, which is already heated as mentioned above. The glass sheet 10 is carried vertically by tongs 12 suspended from hoist means (not indicated) and is held in position for equenching. Since it is intended to direct jets of cooling air onto both surfaces of the heated glass sheet 10 the quenching apparatus has oppositely arranged two identical sets of air jetting systems, though the FIGURE shows only one air jetting system arranged on the right-hand side of the glass sheet 10. The glass sheet 10 is positioned between and in the center of the two air jetting systems.
On each side of the glass sheet 10 there is a blasthead 14 which defines therein an air chamber 16 and has a faceplate 18 opposite and parallel to the glass sheet 10. In the case of tempering a curved glass sheet the faceplate 18 too is curved. A number of nozzles 20 protrude from the faceplate 18 perpendicularly toward the glass sheet 10. These nozzles 20 communicate with the air chamber 16. In plan view the nozzles 20 are arranged on the faceplate 18 in a suitable pattern such as, for example, a lattice pattern or a concentrically circumferential pattern. The distance between adjacent two nozzles is usually 20-50 mm. The nozzles 20 used in this invention are simple in configuration, such as substantially straight nozzles or slightly tapering nozzles with the minimum diameter at the exit. It is unsuitable to use nozzles constricted at an intermediate section. The nozzles 20 have a relatively small diameter, usually several millimeters, so that the total area of the nozzles 20 is not more than 1/3 of the surface area of the faceplate 18. The distance between the glass sheet 10 and the end of the nozzles 20 is usually several centimeters.
A gas passage 22 connects the air chamber 16 to a compressor 24, and there is an air tank 26 which is also connected to the compressor 24 and can communicate with the air chamber 16 via the passage 22. At a section between the air tank 26 and the air chamber 16 and close to the inlet to the air chamber 16, the passage 22 is provided with a throttle means 28 which can completely block up the passage 22 to separate the air chamber 16 from the compressor 24 and the air tank 26 and can quickly open the passage 22 to any degree. The throttle means 28 may be either a manually operatable means or an automatic means, though it is preferable to employ an automatic throttle means which opens the passage 22 in response to setting of the heated glass sheet 10 in the predetermined position between the two blastheads 14.
Throughout the following description every value of air pressure refers to gauge pressure.
Before carrying the heated glass sheet 10 into the quenching station the compressor 24 is operated to accumulate pressurized air in the air tank 26 in each air jetting system, while the throttle means 28 is kept closed to leave the air chamber 16 in each blasthead 14 substantially at the atmospheric pressure. The air pressure in each air tank 26 is controlled to a predetermined first pressure which is in the range from 2 to 8 kg/cm 2 .
When the heated glass sheet 10 is set in position between the two blastheads the throttle means 28 is opened to suddenly release the pressurized air in each air tank 26 from confinement. Then the pressurized air rushes into the air chamber 16 in each blasthead 14 and undergoes a sudden and considerable reduction in pressure at the entrance to the air chamber 16, while the atmospheric air existing in the air chamber 16 is rapidly compressed. Consequently a shock wave is generated at a section close to the entrance to the air chamber 16, and the shock wave propagates through the air chamber 16 and the nozzles 20. The capacities of the air tank 26 and the air chamber 16 and the degree of opening of the throttle means 28 are such that the expansion of the pressurized air into the air chamber 16 results in a rapid drop in air pressure to a predetermined second pressure which is in the range from 0.05 to 0.5 kg/cm 2 . Soon air begins to jet out from the nozzles 20 of each blasthead 14 to collide against the heated glass sheet 10. At the initial stage the air jets arrive at the glass surfaces with high kinetic energy which is attributed to the propagation of the shock wave through the air chamber 16 and the nozzles 20. Accordingly the air jets are effective in quickly breaking a heat transfer suppressive laminar film that exists on each surface of the heated glass sheet 10 and thereby promoting dissipation of heat from the glass sheet 10 into the atmosphere. That is, air jets directed to the glass sheet at the initial stage of this quenching method are very high in the heat extracting or cooling capability. The delivery of cooling air onto the glass sheet surfaces continue for several seconds though the kinetic energy of the air jets soon lowers from the initial high level. As mentioned hereinbefore, the capacity of each air chamber 16 is sufficient to maintain the reduced air pressure, in the range from 0.05 to 0.5 kg/cm 2 , almost unchanged at least for 3 sec and preferably for 5-15 sec. In another aspect, it is suitable that the volume of each air chamber 16 is at least 10 times the total volume of the nozzles 20 on each nozzles 20 on each blasthead 14.
During this quenching operation each blasthead 14 is oscillated parallel to the glass sheet 10 usually vertically or horizontally and sometimes arcuately, as is often done in the conventional air quenching methods. This is for the purpose of macroscopically uniformly quenching the glass sheet 10. The amplitude of the oscillation is usually slightly greater than the distance between adjacent two nozzles 20 on the faceplate 18.
In the quenching method according to the invention the reduced pressure of air in each air chamber 16 is limited within the range from 0.05 to 0.5 kg/cm 2 . If this air pressure is lower than 0.05 kg/cm 2 it is difficult to accomplish sufficient tempering of the glass sheet. On the other hand, if this air pressure is higher than 0.5 kg/cm 2 the quenching operation is liable to result in either fracture of the glass sheet, which may be thinner than 3 mm and is in a heated and fragile state, or deterioration of the optical characteristics of the tempered glass sheet. A preferred range of the reduced air pressure in each air chamber 16 is from 0.1 to 0.4 kg/cm 2 . The primary air pressure in each air tank 26 is limited within the range from 2 to 8 kg/cm 2 . If this air pressure is lower than 2 kg/cm 2 it is impossible to realize a sudden drop of a sufficient magnitude in air pressure, and therefore it is impossible to enhance the initial cooling power of air jets directed from the nozzles 20 onto the heated glass sheet. It is unnecessary and uneconomical to raise the primary pressure in the air tank 26 beyond 8 kg/cm 2 . The primary air pressure and the magnitude of the sudden drop in air pressure are selectively determined according to the thickness of the glass sheet and the desired degree of toughening of the glass sheet.
Desired tempering of the glass sheet 10 is accomplished by the above described quenching operation even when the glass sheet is as thin as about 1.5 mm. At the quenching operation the glass sheet is not necessarily held vertically, and may alternatively be held horizontally. Optionally the above described quenching operation according to the invention may be followed by a known quenching operation in which supplemental air is supplied to each air chamber 16 from a blower (not shown) after blocking the communication between the air chamber 16 and the air tank 26.
EXAMPLES 1-6
In every example a 500 mm×300 mm wide rectangular sheet of glass was tempered by a method according to the invention. The thickness of the glass sheet was variable: 1.5 mm in Examples 1 and 4, 2.3 mm in Examples 2 and 5, 2.5 mm in Example 6, and 2.9 mm in Example 3.
In the quenching apparatus used in these examples, the blastheads were generally of the shape shown in the FIGURE. The nozzles 20 were substantially straight nozzles having an inner diameter of about 3.5 mm. On the faceplate 18 of each blasthead the nozzles were arranged in a lattice pattern. The distance between adjacent two nozzles was about 30 mm in the horizontal direction and about 25 mm in the vertical direction. The faceplate 18 was about 700 mm×500 mm in widths. Referring to the FIGURE, length L 1 of the straight section of the air chamber 16 was about 300 mm and length L 2 of the tapered section was about 600 mm.
In every example the glass sheet was carried into the quenching station soon after heating in a furnace so as to accomplish quenching while the glass sheet has a temperature of 670-°700° C. The glass sheet was held vertically between the two blastheads. In advance, compressed air was accumulated in the air tank 26 for each blasthead 14. As shown in the following table the primary air pressure in the air tanks 26 was controlled to 8 kg/cm 2 , 7 kg/cm 2 or 2 kg/cm 2 . At the start of quenching operation the throttle means 28 for each blasthead was opened such that the pressurized air rapidly expanded into the air chamber 16 with rapid drop in pressure to 0.5, 0.3 or 0.05 kg/cm 2 . Delivery of cooling air jets from the nozzles 20 continued for more than 10 sec. During an initial period of about 5 sec the pressure in each air chamber 16 remained almost unchanged from the initially produced pressure, viz. 0.5, 0.3 or 0.05 kg/cm 2 . In 10 sec the pressure in each air chamber 16 reduced to about 1/2 of the initially produced pressure. During the quenching operation each blasthead 14 was oscillated upward and downward at a rate of 50-80 cycles/min. The amplitude of oscillation was about 40 mm.
The tempered glass sheets obtained in Examples 1-6 were subjected to a fragmentation test as described hereinafter.
COMPARATIVE EXAMPLES 1-4
The glass sheets tempered in these comparative examples were identical with the one used in Example 6. The tempering method and the quenching apparatus were as described in Examples 1-6 except that the primary pressure of air in the air tanks 26 and/or the reduced pressure of air in the air chambers 16 were varied as shown in the table. The tempered glass sheets obtained in Comparative Examples 1-4 too were subjected to the fragmentation test.
COMPARATIVE EXAMPLES 5-7
The glass sheets tempered in these comparative examples were identical with either the one used in Example 3 or the one used in Example 6, as shown in the table. In these experiments the quenching apparatus was modified by connecting each air chamber 16 to a blower without using the compressor 24 and the air tank 26. At the quenching operation, air was continuously supplied from each blower to the nozzles 20 substantially at a constant pressure, which was 0.3 or 0.25 kg/cm 2 as shown in the table. The tempered glass sheets obtained in Comparative Examples 5-7 too were subjected to the fragmentation test.
FRAGMENTATION TEST
The test procedure was generally in accoredance with British Standard BS 5282. The point of impact on each sample of the tempered glass sheets was at the approximate center of the rectangular glass sheet ("A" in the following table) or at a distance of 100 mm from the middle point of a longer side of the glass sheet toward the center ("B" in the table). The fragmentation was checked by counting the number of particles included in each of many arbitrarily traced 50 mm×50 mm square areas of the tested glass sheet and the total number of elongated particles (splines) which were longer than 60 mm and in which the length was at least four times the width. However, fragmentation was not checked in a strip 20 mm wide all round the edge of the glass sheet, and within a radius of 75 mm around the point of impact. The test results were as shown in the following table.
__________________________________________________________________________ Fragmentation Test Result Particle Count Primary Air Pressure of Air Fed Glass Sheet Point of (in 50 mm × 50 mm Number of Pressure (kg/cm.sup.2) to Nozzles (kg/cm.sup.2) Thickness (mm) Impact Max. Min. Elongated__________________________________________________________________________ ParticlesEx. 1 8 0.5 1.5 A 221 63 0Ex. 2 7 0.3 2.3 A 260 83 0Ex. 3 2 0.05 2.9 A 203 66 0Ex. 4 8 0.5 1.5 B 188 87 0Ex. 5 7 0.3 2.3 B 199 81 0Ex. 6 7 0.3 2.5 A 330 168 0Comp. Ex. 1 1 0.2 2.5 A 4 1 0Comp. Ex. 2 1 0.2 2.5 B 4 1 0Comp. Ex. 3 7 0.03 2.5 A 3 1 0Comp. Ex. 4 7 0.03 2.5 B 3 1 0Comp. Ex. 5 0.3 0.3 2.5 A 30 2 1Comp. Ex. 6 0.25 0.25 2.9 A 240 53 5Comp. Ex. 7 0.25 0.25 2.9 B 166 67 1__________________________________________________________________________
The fragmentation of the tempered glass sheets obtained in the foregoing examples and comparative examples was further tested by the test methods specified in Japanese Industrial Standard JIS R 3212 and in the EEC Standard. The results of these supplementary tests were nearly equivalent to the test results shown in the above table. | The invention relates to a method of tempering a glass sheet by first suitably heating the glass sheet and quenching the heated glass sheet by directing jets of air onto both surfaces of the glass sheet from two sets of nozzles respectively protruding from oppositely disposed two air chambers. At the start of quenching, each air chamber is suddenly allowed to communicate with a source of compressed air kept at a predetermined first pressure in the range from 2 to 8 kg/cm 2 (gauge pressure) such that a rapid drop from the first pressure to a predetermined second pressure in the range from 0.05 to 0.5 kg/cm 2 (gauge pressure) takes place as the compressed air expands into the air chamber and such that substantially the whole length of the air chamber and the nozzles serves as a sort of shock wave tube. Consequently, the air jets arriving at the glass sheet surfaces at the initial stage of quenching are very high in kinetic energy and heat dissipating power. By this method even glass sheets thinner than 3 mm can be tempered so as to meet the current regulations on tempered glass sheets for use as automobile side or rear windows. | 2 |
BACKGROUND OF THE INVENTION
Fabrics made from high performance polymer fibers may utilized in a variety of commercial and private end-uses ranging from composites and aircraft to body armor and armored vehicles. Performance textiles are also used across the market to provide fabrics and designs that can withstand heat, abrasions, stains, discolorations, and other environmental assaults. Antiballistic articles or fabrics woven for life protection are used to repel and trap ammunition, shrapnel, or hand driven sharp objects such as knives, awls, shanks and the like. These antiballistic fabrics are typically layered, cut, and stitched in a pattern to construct protective soft armor such as vests, or may be used in the construction of armored vehicles and helmets.
High performance fabrics may be woven in patterns such as plains, twills, baskets, and satins. The warp and fill yarn interlace at right angles, are typically light weight, and preferably have floats extending over multiple yarns. Patterns such as twill and satins have shown improved ballistic performance due in part to the longer floats of a looser weave. For instance, when a projectile hits a protective vest or other article of protective material, the resulting back face deformation is typically reduced in a looser weave than when compared to a plain weave. The main goal of protective armor is to prevent fatalities and minimize damage, injury and blunt force trauma to the person(s) being protected; therefore, it is most desirable utilize a fabric that results in less back face deformation. However, using these type of weaves represents a challenge to armor manufacturers during layering and cutting patterns due to looseness of the fabric structure, fraying, and distortion that causes yarn interlacing to deviate from right angle interlacing. The yarns of these fabrics are not secured as well within the fabric layer and therefore tend to fray and fall apart along the cut edges more easily. For these reasons, these weaving patterns are not widely used in the high performance fabric industry. Although the performance characteristics of the fabric may be enhanced by these particular weaves, the difficulty in handling poses a large problem.
When using a tighter weave, such as a plain weave, the handleablility during fabric construction may be improved over that of a looser weave; however, the performance characteristics may not be up to par for a particular end-use. Furthermore, high performance fabrics constructed from a plain weave or a tight construction may not conform as easily to a particular shape or curvature. When designing vests or other clothing, this characteristic translates to clothing that does not conform as well to a person's body and tends to be very uncomfortable to wear. When military personnel and law enforcement wear antiballistic clothing, maintaining maneuverability is essential; these articles should provide protection, not distraction. Therefore, it would be beneficial to design a high performance fabric of a lower weight and improved comfort that can bend and conform more easily to accommodate both men and women of varying body types and sizes, as well as maintaining the high quality performance characteristics required of these articles.
Given the problems and disadvantages associated with the current art, it would be advantageous to provide a weaving pattern and process that results in a fabric having the handleablility of a tighter weave with the performance characteristics of a looser weave. This fabric would maintain shape and construction during the manufacturing of an end-use product, yet still possess the advantages resulting from the longer float of a looser weave. A further advantage would be improved tightness and stabilization of the fabric, particularly when the fabric is cut and sewn together to form a desired system, yet the fabric may still conform easily to a variety of shapes and curvatures. The weave pattern and process of the present invention provides stability of fabric structure without compromising the quality and performance characteristics of the end-use product.
BRIEF SUMMARY OF THE INVENTION
The present invention consists of a weave pattern and method that provides stability to high performance fabrics, such as fabrics used for life protection (i.e. antiballistic) and composite use. This weave pattern and method is not restricted to high performance fabrics, however, and may be applied to the construction of any type of fabric where improved handleablilty is desired. This invention consists of adding an additional set of yarn in the warp direction, such that there are two sets of warp yarns per fill yarn alternating throughout the structure of the fabric. Set one may consist of any known weave pattern such as plain, twill, basket, satin, or another pattern. Set two is preferably a plain weave in the warp direction, alternating over and under each fill yarn, but may be any weave variation provided it is inserted in the fabric such that it interrupts the pattern of set one.
This introduction of a second set of warp yarn locks the fill yarns in place, subsequently interlocking and stabilizing the fabric pattern. This stabilization increases tensile strength, tightness, stiffness, and also improves the handling and cutting of the fabric by resulting in decreased fraying and fiber loss during product construction. Also, the fabric maintains proper shape and form due to the 90 degree interlacing of warp and fill yarns. This interlacing is maintained and does not suffer from the distortion that may be found in looser weaves with a longer float. In this way, the fabric may have the enhanced performance characteristics of a looser weave in combination with the enhanced handleability of a tighter weave.
DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1A illustrates a traditional plain weave with a single set of warp yarn.
FIG. 1B illustrates a weave chart showing one embodiment of the present invention, whereby a plain weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 1C illustrates a plain weave of one embodiment of the present invention whereby a plain weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 2A illustrates a traditional 2/2 basket weave with a single set of warp yarn.
FIG. 2B illustrates a weave chart showing one embodiment of the present invention, whereby a 2/2 basket weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 2C illustrates a 2/2 basket weave of one embodiment of the present invention, whereby a 2/2 basket weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 3A illustrates a traditional four harness satin weave with a single set of warp yarn.
FIG. 3B illustrates a weave chart showing one embodiment of the present invention, whereby a four harness satin weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 3C illustrates a four harness satin weave of one embodiment of the present invention, whereby a four harness satin weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 4A illustrates a traditional 2/2 twill weave with a single set warp yarn.
FIG. 4B illustrates a weave chart showing one embodiment of the present invention, whereby a 2/2 twill weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 4C illustrates a 2/2 twill weave of one embodiment of the present invention, whereby a 2/2 twill weave set one warp yarn is interrupted with an alternating plain weave set two warp yarn.
FIG. 5A is a chart showing the pattern, warp denier, tex, and ends per inch used to calculate fabric cover factor and calculate tightness factor of fabrics with and without warp set two.
FIG. 5B is a continuation of the chart of FIG. 5 a chart showing the calculated fabric cover factor and calculated tightness factor of fabrics with and without warp set two, as well as the values used to calculate each factor.
FIG. 6 is a chart showing experimental values of fabric tensile strength and fabric stiffness of fabric with warp set two.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A, 2A, 3A, and 4A represent traditional weave patterns with a single set of warp yarn. FIGS. 1B, 2B, 3B, and 4B are weave charts representing these same weave patterns interrupted and interlocked with a second set of warp yarn in a plain weave pattern. Columns 1 - 6 of these “B” group figures represent a warp yarn, while each row represents a fill yarn. The “X” denotes where the warp yarn is passing over the fill yarn. FIGS. 1C, 2C, 3C, and 4C represent weave patterns of the present invention derived from the weave charts of FIGS. 1B, 2B, 3B, and 4B .
The ratio range of warp set one to warp set two is preferably 2:1 to 5:1, more preferably 2:1 to 3:1, most preferably 2:1. For example: in a 2:1 ratio, there would be two yarns of warp set one, followed by one yarn of warp set two, followed by two yarns of warp set one, followed by one yarn of warp set two, and so on. In a 3:1 ratio, there would be three yarns of warp set one, followed by one yarn of warp set two, followed by three yarns of warp set one, followed by one yarn of warp set two, and so on. If a ratio below 2:1 is used, the resulting fabric weave would most likely mimic the qualities of a typical plain weave without the added advantages of a loose weave. Similarly, if a ratio greater than 5:1 is used, the handelablility of the resulting fabric may decrease beyond an advantageous extent, thus negating the favorable construction qualities obtained through the introduction of warp set two.
A preferred ratio of 2:1 is illustrated in FIGS. 1B, 2B, 3B, and 4B . Also in these same figures, the yarns of the plain weave pattern of set two are shown alternating with respect to the same fill yarn. For example, in FIG. 1B , column 3 , the yarn of set two is shown in an under-over-under-over pattern with respect to the fill yarn; whereas in FIG. 1B column 6 , the yarn of set two is shown in an over-under-over-under pattern with respect to the same fill yarn. The pattern of set two within the same fabric may vary or alternate as desired, as shown in the figures, or the pattern may stay the same throughout the fabric. For example, in a fabric with a 2:1 ratio of set one to set two, the yarns of warp set two (represented in figure columns 3 , 6 , and so on) may all be over-under-over-under with respect to the same fill yarn. Or, the yarns of warp set two may vary, whereby some are over-under and others are under-over with respect to the same fill yarn.
FIG. 1A shows a traditional plain weave with a single set of warp yarn. The pattern is such that each warp and fill yarn pass in an over-under-over-under pattern. FIGS. 1B and 1C show the addition of set two, also in a plain weave, whereby the introduction of set two disrupts the normal pattern of the traditional, single warp plain weave. In this embodiment, the warp sets are present in a 2:1 ratio of warp set one to warp set two.
FIG. 2A shows a traditional 2/2 basket weave with a single set of warp yarn, whereby each warp yarn passes over two fill yarns, then passes under two fill yarns. The longer float of the basket weave results in a looser weave when compared to a plain weave. The longer float is preferred for high performance fabrics, such as fabrics made for life protection; however, the looser construction results in fraying and separation of the yarns when cutting and handling the fabric.
FIGS. 2B and 2C show the addition of set two into a basket weave, also in a 2:1 ratio, whereby set two is weaving in a plain weave pattern. The plain weave of set two disrupts the basket weave pattern of set one and locks the fill yarns in place. In this manner, the fabric may still maintain the enhanced performance characteristics found in a looser weave with a longer float; yet, the fabric has better handleability and will not fray, fall apart, or suffer from distortion during cutting and construction.
FIG. 3A shows a traditional four harness satin weave with a single set of warp yarn. This weave is very loose with a long float, meaning it provides better ballistic protection but is very difficult to handle. FIGS. 3B and 3C show an embodiment of the present invention whereby a set two is introduced in a plain weave pattern, also in a 2:1 ratio of set one to set two.
FIG. 4A shows a traditional 2/2 twill weave with a single set of warp yarn. FIGS. 4B and 4C again show the introduction of a second set of warp yarn in a plain weave pattern that disrupts the two by two twill weave pattern, thus locking the fill yarns and the weave pattern in place.
Warp set one, warp set two, and the fill yarn may consist of the same or different materials, sizes, and numbers of fibers. For example, the fill yarn and warp set one may be made from fibers of a first material such as an aramid, while warp set two may be made from fibers of a second material such as ultra high molecular weight polyethylene (UHMWPE); the resulting fabric being composed of both aramid and UHMWPE fibers. Alternatively, the fill yarn and both sets of warp yarn may all be fibers of a first material; the resulting fabric being composed of all aramid fibers or all UHMWPE, for example.
Preferred fibers include, but are not limited to, high tenacity polymer fibers, such as various aramid fibers, high performance polyethylene fibers, and the like. Due to their remarkably high tensile strength-to-weight ratio, such fibers have many applications such as body armor. Specific high tenacity fibers suitable for the composite material of the present invention include but are not limited to Kevlar®, a para-aramid synthetic fiber; Twaron, another para-aramid fiber with roughly the same chemical structure; terephthaloyl chloride (TCI), an aramid fiber closely related to para-aramids; and ultra high molecular weight polyethylene (UHMWPE) such as commercially known Dyneema® and Spectra®. Other suitable materials include polybenzobisoxazole fibers (PBO), glass, quartz, heat resistant aramid fiber products such as Nomex® and Protera® fabrics, fiberizable inorganic ceramic materials such as silicon carbide, carbon, graphite, mullite, aluminum oxide and piezoelectric ceramic materials. Non-limiting examples of suitable fiberizable organic materials include cotton, cellulose, natural rubber, flax, ramie, hemp, sisal and wool. Non-limiting examples of suitable fiberizable organic polymeric materials include those formed from polyamides (such as nylon and aramids), thermoplastic polyesters (such as polyethylene terephthalate and polybutylene terephthalate), acrylics (such as polyacrylonitriles), polyolefins, polyurethanes and vinyl polymers (such as polyvinyl alcohol).
Warp set one and warp set two may be the same denier, although it is preferred that set two be a smaller denier than set one. In a typical woven fabric, the weave is balanced because the weight of the warp yarn and fill yarn are the same; however, by introducing a second set of warp yarn into the fabric, the weave may become slightly unbalanced due to having more warp yarns than fill yarns. This unbalance could be remedied by adding more fill yarns; however this additional fill yarn may increase in the weight of the fabric. One goal in manufacturing high performance fabrics is to keep the fabric weight as low as possible; therefore, a lower weight fabric is desirable. For this reason, it is preferred to use a smaller denier for the second warp set to minimize any additional weight of the resulting fabric. By using a smaller denier for warp set two, this second set can serve to interlock the fill yarns and stabilize the pattern of set one without adding much additional weight to the final fabric itself.
A preferred practical denier range for warp set one is 400-1500 denier. The denier of warp set two depends on the denier of set one, although a preferred practical denier range for set two is 100-400 denier. The fill yarn denier is typically the same as the denier of warp set one, however it may be a different denier if so desired. The fabric weight depends on the denier of set one and set two and the number of yarns per inch. Additionally, the fabric weight of ounces per square yard is based on warp set one, warp set two, and fill yarn construction; typically, the added fabric weight due to the addition of set two preferably will not increase by 20% of the weight of warp set two.
Warp set one determines the weave pattern of the overall fabric, while warp set two interlocks the weave of the fill yarn with warp set one. For example, if the fill yarn and warp set one are woven in a 2/2 basket weave, but warp set two is woven with the fill yarn as plain weave, the overall pattern of the fabric remains 2/2 basket, with the plain weave of set two interrupting the 2/2 basket weave and interlocking the basket pattern. Warp set two is preferably woven into the fabric as a plain weave, although it may be any other desired weave useful for a particular application. Plain weave is preferred for set two due to the over-under-over-under pattern that results in more interlocking of the fill yarn, and a plain weave can typically be cut without unraveling or loss of construction.
Although specific fibers, combinations of fibers, weave patterns, combinations of weave patterns, and specific denier ranges, etc. are discussed herein, it is to be understood that these examples do not limit the present invention to just the described embodiments. It is noted that any person skilled in the art of high performance fabrics would know what types of fibers, weaves, weights, deniers, etc. may be suitable for a particular product and would be capable of making the appropriate substitutions and combinations thereof.
FIGS. 5A and 5B charts calculated cover factors and tightness factors of various weave patterns using an aramid yarn to construct hypothetical Fabric A and Fabric B. The charts compare these calculated factor for fabrics with and without a warp set two. The tightness factor represents the tightness and entanglement of the yarns of the fabric. The more entangled the yarns, the greater the tightness factor. This entanglement can be illustrated by the amount of “knuckles” or crimping of yarns in the fabric if the fabric were to be unraveled or unwoven. For example, a plain weave typically has a tightness factor greater than a satin weave due to the over-under-over-under pattern of a plain weave. The satin weave is a looser weave with a longer float, so if you were to unravel a satin weave, it will have less crimping in the fibers than an unraveled plain weave. The cover factor indicates the extent to which the area of a fabric is covered by yarns and isn't necessarily related to any particular weave pattern. Rather, the cover factor is related to how closely the yarns are woven or placed together in any given weave pattern. For example, in FIG. 5 b it can be seen that the cover factor of all four different weaves, without the inclusion of warp set two, is the same value of 0.54 for Fabric A and 0.50 for Fabric B.
These calculated factors shown in FIGS. 5A and 5B are based on the values calculated and listed in the chart for fabric weight (ounces per square yard), warp denier, tex, ends per inch, warp cover (Kw), fill denier, fill tex, fill per inch, and fill cover (Kf). Anyone skilled in the art would know what these values represent, as well as how to calculate them. These values may be calculated as follows:
Yarn diameter inch=1.86×10 3 ×(Tex/Density) 0.5 Aramid density=1.44 g/cm 3
Tex=yarn linear density in gm/1000 m
Warp cover ( Kw )=ends/inch×(1/warp diameter (measured in inches))
Fill cover ( Kf )=picks/inch×(1/fill diameter (measured in inches))
Fabric cover factor= Kw+Kf −( Kw×Kf )
Fabric tightness factor=cover factor/weave factor
Weave factor for plain weave=0.75 Weave factor for 2/2 twill, 2/2 basket, and 4H satin=0.889
FIG. 5B shows the additional tightness values and fabric cover values that may be achieved by adding warp set two. When looking at FIG. 5B , the values listed under the column “Tightness Factor” or “Fabric Cover Factor” for the rows that include the addition of warp set two, it should be noted that the values do not represent total tightness factor, rather the values represent what may be added to the existing tightness factor of the same fabric without the addition of warp set two. For example, under Fabric A in FIGS. 5A and 5B : If there are 28 ends per inch in a twill weave with only set one, adding set two in a plain weave with a 2:1 ratio adds 14 additional ends per inch (28 ends divided by 2). The denier of warp set two is preferably lower than the denier of warp set one, in this example 200 denier versus 500 denier. Since set two is added in a warp direction only, all of the fill values may remain the same. In this particular example (a twill weave with the addition of set two in a plain weave at a 2:1 ratio), the fabric cover factor may be increased by a value of 0.39; and, the tightness factor may increase by a value of 0.52.
FIG. 6 charts experimental values of fabric tensile strength, fabric stiffness (warp and fill directions), and fabric king stiffness of various weave patterns for actual Fabric A and Fabric B with the addition of set two in a plain weave at a 2:1 ratio of set one to set two. The fabric tensile strength in FIG. 6 is tested (reference to ASTM D-5035), and the fabric stiffness tested (reference to ASTM D-4032 and ASTM D-1388).
The following tables show the results of ballistic testing of a fabric of the present invention. These tests were performed according to the testing specifications for the National Institute of Justice (NIJ) Standard-0101.06. This standard and other detailed technical information can be found in the NIJ Standard -0101.06, Ballistic Resistance of Body Armor (July 2008) which specifies the minimum performance requirements that equipment must meet to satisfy the requirements of criminal justice agencies and the methods that shall be used to test such performance; this document is herein incorporated by reference in its entirety.
TABLE 1
Average V50
Test specification- NIJ-0101.06, pack size 15 × 15 (inch)
Pack
NIJ Threat
Bullet
V50
Fabric Type
(psf)
Type
Type
(ft/s)
Fabric “A” 2/2 Twill
0.76
II
9
mm
1594
(Greige)
0.76
II
.357
Mag
1565
0.76
IIIA
.44
Mag
1459
Fabric “B” 2/2 Twill
0.76
II
9
mm
1554
(Greige)
0.76
II
.357
Mag
1567
0.76
IIIA
.44
Mag
1495
Conventional Ballistic Fabric
0.77
II
9
mm
1543
(Greige)
Fabric “A” 2/2 Twill
0.76
II
9
mm
1511
(Water repellant treated)
Conventional Ballistic Fabric
0.77
II
9
mm
1452
(Water repellant treated)
Table 1 shows ballistic performance test results from certified test labs. Fabric “A” and fabric “B” are both a 2/2 twill weave of the present invention (comprising a warp set 1 and warp set 2, described herein) tested against a conventional aramid ballistic fabric (comprising only one warp set). Fabric “A” and “B” are a 0.76 psf panel (corner stitched), and the conventional fabric is a 0.77 psf panel. Tests are performed according to the NIJ Standard-0101.06 for level type II and IIIA, and the V50 performance in both greige and water repellant treated fabric is compared. Fabric A of the present invention shows an improvement in V50 values due to the structure of Fabric A, which consists of warp set 1 and warp set 2, as described herein. This inclusion of warp set 2 not only increases the stability and handleablility of Fabric A, but also reduces the number of fabric plies needed in a pack as compared to conventional ballistic fabric. Typically, water repellent treatment reduces the ballistic performance; however, the V50 shown for water repellant-treated fabric “A” remains superior to that of the conventional fabric.
TABLE 2
Ballistic performance of hybrid design
Test specification NIJ-0101.06, pack size 15 × 15 (inch)
Threat level type IIIA, caliber tested: .44 Magnum
Shot number
4
5
(30°
(45°
1
2
3
angle)
angle)
6
Hybrid Design: Fabric “A” 2/2 Twill (40% by wt) and UD-1 (60% by wt)
Pack areal weight (psf) 1.26
Velocity
1404
1421
1419
1437
1426
1416
(ft/s)
BFS (mm)
37.43
37.10
37.46
29.29
34.03
37.81
Hybrid Design: Fabric “A” 2/2 Twill (40% by wt) and UD-2 (60% by wt)
Pack areal weight (psf) 1.25
Velocity
1417
1441
1425
1414
1437
1411
(ft/s)
BFS (mm)
36.17
36.76
38.57
33.92
30.16
34.76
Table 2 shows hybrid pack ballistic performance as tested in certified test labs. Ballistic testing of these packages is carried out according to NIJ Standard-0101.06, V0 level IIIA protocol, and the backface signature (BFS) is measured. The maximum allowable BFS for law enforcement applications is 44 mm. Fabric “A” is a 2/2 twill of the present invention (comprising a warp set 1 and warp set 2, as described herein) tested in a hybrid design with two different unidirectional fiber-based composite laminate products (UD-1 and UD-2) at areal density of 1.26 psf and 1.248 psf respectively. In this hybrid design, Fabric “A” is 40% fabric weight of total pack weight, and the UD products consist of 60% fabric weight of the total pack weight. Fabric “A” shows a good back face signature (BFS) due to observed high engagement of bullets with fabric. Results are shown in table 2, with 44 mm being the maximum allowable BFS. The projectile stopped within the fabric plies, meaning the fabric successfully “engaged” the bullet. This testing demonstrates the fabric performance for law enforcement applications.
The present invention as described hereinafter may be embodied in many different forms and should not be construed as limited to the embodiments set forth. Rather, these embodiments are provided so that this disclosure will be operative, enabling, and complete. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention. One skilled in the art is capable of knowing, for example, which weave patterns, yarn materials, and deniers are preferred for specific high performance fabric uses, composites, etc., as well as what types of substitutions may be appropriate or suitable. Moreover, many embodiments, such as adaptations, variations, modifications, and equivalent arrangements, will be implicitly disclosed by the embodiments described herein and fall within the scope of the present invention.
Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad ordinary and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one”, “single”, or similar language is used. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list.
For exemplary methods or processes of the invention, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be described as being in a sequence or temporal arrangement, the steps of any such processes or methods are not limited to being carried out in any particular sequence or arrangement, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and arrangements while still falling within the scope of the present invention. | A weave pattern and method for weaving that provides stability to high performance fabrics, such as fabrics used for life protection and composite use, is provided. An additional set of yarn may be added in the warp direction, such that there are two sets of warp yarns per fill yarn alternating throughout the structure of the fabric. This second set of warp yarn locks the fill yarns in place, subsequently interlocking and stabilizing the fabric pattern. This stabilization increases tensile strength, tightness, stiffness, and also improves the handling and cutting of the fabric by resulting in decreased fraying and fiber loss during product construction. Also, the fabric maintains proper shape and form due to the 90 degree interlacing of warp and fill yarns. In this way, the fabric may have the enhanced performance characteristics of a looser weave in combination with the enhanced handleability of a tighter weave. | 3 |
BACKGROUND OF THE INVENTION
The invention relates in general to piston vibrators employed to cause ordinarily non-flowing granular materials to move and more particularly to a pneumatic piston vibrator of the impact type combining great force with low decibel noise level during operation.
Not all materials flow unaided through troughs, chutes, bins or hoppers with the speed desired. It has long been recognized that pneumatic piston vibrators fixed to one of the above enumerated retainers along which the material is meant to flow will accelerate the materials' movement by relaying the force of impact of a reciprocating piston housed inside a vibrator piston chamber, through the vibrator housing mounted on the retainer surface to the material itself.
Pneumatic piston vibrators are of various generic types classed by the mode of cushioning of the piston in the vibrator piston chamber. Impact pneumatic piston vibrators allow the piston to strike the chamber extremity at one end of the stroke while preventing impact at the other end of the stroke by means of a cushion of pressurized air. The silent pneumatic piston vibrator introduces a cushion of pressurized air at each end of the piston stroke, preventing piston impact at either end of the piston chamber.
Some of the problems and requisites that should be considered in designing a pneumatic piston vibrator are as follows:
The vibrator housing transmits force to the material sought to be moved. The piston generates that force. The greater the force, the greater the material influencing efficiency of the vibrator. The impact type piston strikes the piston chamber extremity directly and thereby generates force in the area of 107 lbs. The silent type piston never strikes either chamber extremity. The pressurized air cushion reduces the force generated to the area of 100-1000 lbs.
The Occupational Safety and Health Administration has promulgated regulations on the noise level in decibels acceptable in industrial occupational settings. That decibel limit is currently approximately 90 dba. An impact vibrator will produce noise in the area of 105-110 dba. A silent type vibrator will produce approximately 40-65 dba.
Both types of pneumatic piston vibrators offer problems. By allowing the piston to strike a chamber extremity, the impact type generates more impact force and a more efficient material influencing vibrator but the decibel level is high and unacceptable. The silent type pneumatic piston vibrator has significantly lower decibel level but the cushioning effect of the pressurized air produces a correspondingly low force of impact to be transmitted to the material.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a pneumatic piston vibrator which will produce the maximum usable impact force at a decibel level acceptable to the the Occupational Safety and Health Standards and safe and comfortable to the user.
Other objects and a fuller understanding of the invention may be had by referring to the following description and claims taken in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the invention.
FIG. 2 is a cross-sectional view taken along section 2--2 of FIG. 1.
FIG. 3 is similar to FIG. 2 showing another embodiment of the invention, as is FIG. 4.
DETAILED DESCRIPTION
With reference to the drawings, FIGS. 1 and 2, the invention comprises an impact pneumatic piston vibrator having a vibrator housing 15 with a base at one end and defining an open piston cylinder chamber 23 at the other. A cylinder head 11 attaches to the vibrator housing and seals the piston cylinder 23 at the open end. The base end of the piston cylinder takes the impact of a cylindrical piston 12 which slidably reciprocates in the piston cylinder 23 through the introduction of air under pressure. The air reaches the cylinder 23 by means of an entry fitting and channel 16 penetrating the housing 15 side and communicating to a peripheral air passage 17 grooved around the circumference of the interior cylinder wall at its longitudinal midpoint. To direct the pressurized air in the cylinder the piston 12 defines a pair of air conduits, 13 and 20 each with an inlet port 19 and 21 at the piston side and an exit port 18 and 22 at an oppositely disposed piston end. Each air conduit 13 and 20 has its inlet port 19 and 21 positioned along the piston side beyond the midpoint and opposite that piston end on which its exit port 18 and 22 is located. An elastomer 14 prevents the piston end from directly striking the impact end of the piston chamber.
In operation, pressurized air flows through the air entry fitting 16 into the peripheral air passage 17 and engages one of the two air directional conduit inlet ports 19 and 21 on the piston 12. (For this explanation, conduit 13 will be used, but it must be understood that the same sequence applies equally to both conduits 13 and 20.) The pressurized air passes through the conduit 13 in the piston 12 to its exit port 18, rapidly filling the space between piston end and cylinder end, thereby building up pressure necessary to thrust piston 12 along the cylinder in the opposite direction. The piston's 12 movement disengages the peripheral air passage 17 and inlet port 19 cutting off entry of pressurized air to the conduit 13 and the piston cylinder. The thrust carries the piston 12 until the peripheral air passage 17 engages the second inlet port 21. Pressurized air flows through the conduit 20 to its exit port 22 at the leading end of the moving piston 12 filling the space between the piston end and cylinder end thereby slowing, stopping and reversing the piston 12. The reverse movement disengages the peripheral air passage 17 from the second inlet port 21 and delivers the piston 12 to impact, aligning the peripheral air passage 17 with the first inlet port 19 and completing the piston cycle.
The length of the piston stroke is determined by the placement of the inlet ports 19 and 21 relative to each other along the piston sides. The pneumatic vibrator illustrated is an impact type. The piston 12 travels and strikes one end of the piston cylinder before the first side inlet port is engaged. At the other end of the piston stroke, however, the second inlet port is engaged before the piston strikes the cylinder end, thereby delivering pressurized air into the space between piston and cylinder end, effectively slowing, stopping and then thrusting the piston away before impact.
In addition to the cushion of pressurized air, the invention introduces an elastomer at the impact end of the piston stroke. Such an elastomer allows the piston impact to be carried with minimum dissipation directly to the vibrator housing thence to the material to be influenced, while reducing the decibel level of noise created on impact. The elastomer may be on either impact surface, attached to the piston (See FIG. 2 at 14) or the piston cylinder end (See FIG. 4 at 40). The piston itself may be wholly constructed of the elastomer (See FIG. 3 at 30) or various configurations of plugs or pads may be employed. Anti-friction material along the sides of piston or cylinder may be introduced to improve efficiency. Whatever configuration is ultimately employed, the impact will generate a noise decibel level lower than if the elastomer were absent and one acceptable to the Occupational Safety and Health Administration and industry. | A reciprocating pneumatic piston vibrator for flowing granular materials is cushioned at an impact and by an elastomer and at the other end by air for reducing the decibel level while transmitting sufficient impact force to begin and maintain granular material flow. | 1 |
This application is a continuation of our application Ser. No. 06/928,916, filed Nov. 7,1986, now abandoned.
Reference is made pursuant to the provisions of 35 U. S. C. § 120 to copending patent applications Ser. No. 915,023, filed Oct. 3, 1986 now abandoned, and entitled "Mobile Restaurant System And Network Controller Therefor," and Ser. No. 907,496, filed Sept. 15, 1986 and entitled "In-Store Multiple Device Communications Unit And Centralized Data System Utilizing Same," now U.S. Pat. No. 4,972,463.
The disclosures including drawings of these copending applications are hereby incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Multiple channel network controllers have many uses, several of which being described in the referenced copending applications.
In accordance with one embodiment of the present invention, it is conceived that a personal computer system such as that known as the PC/AT should be adaptable by means of its expansion slots so as to provide a multichannel communications capability, with a plug-in communications board providing interrupt vectors to the processor of the personal computer mother board. It is conceived that a distribution configuration for the communications channels should not enlarge the footprint of the system or detract from its appearance. Ideally as many as eight channels should be connectable with the distribution configuration in a neat and orderly fashion.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a novel network controller system adaptable to multiple communications channels.
A further object is to provide a novel multiple channel communications board capable of being applied to a conventional personal computer system such as the PC/AT, and to provide a novel distribution configuration therefor suited to as many as eight communications channels without disturbing the basic compactness and neatness of the conventional computer layout.
A preferred embodiment of eight channel communications board and distribution configuration has been found to meet high standards of reliability. The basic communications controller system has also been successfully implemented in a wall mounted AT type computer system where communications controllers and distribution boards are housed in a common wall box with the AT type processor.
Other objects, features and advantages of the present invention will be apparent from the following detailed disclosure taken in connection with the accompanying drawings, and from the relationships and individual features of the respective claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat diagrammatic partial front elevational view of a PC/AT computer console and monitor to which a multiple channel communications system and a packaging configuration in accordance with the present invention have been applied;
FIG. 2 is a somewhat diagrammatic top plan view of the arrangement of FIG. 1 for illustrating details of the packaging configuration for a preferred communications system;
FIG. 3 is a somewhat diagrammatic partial rear elevational view of the arrangement of FIG. 1 showing further details of the packaging configuration for a preferred communications system;
FIGS. 4A through 4G show a preferred electric circuit for a multiple channel communications board which may be inserted into a PC/AT computer console as shown in FIG. 1 and which may be employed as a part of a preferred communications system in accordance with the present invention; FIG. 4B being a continuation of FIG. 4A to the right and a continuation of an upper part of FIG. 4D to the right; FIG. 4C being a continuation of FIG. 4B to the right; FIG. 4D being a continuation of FIG. 4A in a downward direction; FIG. 4E being a continuation of FIG. 4B in a downward direction and being a continuation of FIG. 4D to the right; FIG. 4F being a continuation of FIG. 4E to the right; and FIG. 4G showing a network of bypass capacitors for the power supply lines of FIGS. 4A through 4F; and
FIGS. 5A through 5D are waveform diagrams with a common time axis, FIG. 5A showing the interrupt signal (INT) supplied by the communications board of FIGS. 4A through 4G; FIG. 5B showing a pseudo interrupt acknowledge signal (INTA) generated by a pseudo interrupt acknowledge circuit means of FIG. 4D in response to selected address and control signals which can be supplied by a conventional PC type bus; FIG. 5C illustrating a read signal (RD) to be generated by the pseudo interrupt acknowledge circuit means of FIG. 4D; and FIG. 5D illustrating the relative timing of the transmission of an interrupt vector from the communications circuit of FIGS. 4A through FIG. 4G to the PC systems board.
DETAILED DESCRIPTION
FIG. 1 shows a computer console 10 of the type having a conventional PC bus, for example a type PC/AT. One or more disk drives may be accessible at a frontal region 12 of the console. In the illustrated version, a disk loading slot of a disk drive is shown at 14, and a plate 16 covers a lower unused disk drive location. A keyboard (not shown) is conventionally coupled with the console, e.g. via a connector at 18, FIG. 3, at the rear of the console.
A video monitor 20 is shown as being located above the console 10 and is coupled with a system board of the console unit 10 (indicated at 22, FIG. 3), for example via a conventional plug-in type of graphics board (indicated at 24, FIG. 3) arranged vertically in one of the expansion slots of the console 10. A system board such as indicated at 22, FIG. 3, may be termed a mother board while the auxiliary boards such as graphics board 24, FIG. 3, may be termed daughter boards.
In a PC type computer configuration, the system board 22 may be provided with an array of input/output connectors, respective connectors such as indicated at 26 and 28, FIG. 3, being disposed in alignment with respective expansion slots so that respective auxiliary boards such as 24 can be inserted downwardly into the respective expansion slots and plugged into the respective input/output connectors.
A PC bus configuration has provision for receiving interrupt request signals from the respective expansion slots. The system board's I/O channel signals may include twenty address signals SA0 through SA19, seven unlatched signals LA17 through LA23 used to address memory and I/O devices, data signals SD0 through SD15, and interrupt request signals IRQ3 through IRQ7, IRQ9 through IRQ12, IRQ14 and IRQ15. The interrupt request lines of the PC bus are used to signal the microprocessor of the system board 22 that an I/O device needs attention. The interrupt request line must be held high until the microprocessor acknowledges the interrupt request via an Interrupt Service routine in the conventional arrangement.
The PC bus configuration also provides I/O Read (IOR) and I/O Write (IOW) signals which respectively may instruct an I/O device to drive its data onto the data bus, and instruct an I/O device to read the data on the data bus.
An address enable signal (AEN) is used to degate the microprocessor and other devices from the I/O channel to allow DMA transfers to take place.
In FIG. 1, a distribution board assembly 30 is shown stacked between the console 10 and the monitor 20. The width of distribution board enclosure 31 of the distribution board assembly is such as to essentially fit within a space defined by the vertical extension of lateral margins 10a and 10b of the console 10. For example, the enclosure 31 may have a maximum width dimension equal to or slightly less than the width of console 10 as measured between its lateral margins 10a and 10b. The purpose of the distribution board assembly 30 is to coact with other components of a multichannel communications system in accordance with the present invention so that a single expansion location of the console 10 such as indicated at 32 in FIGS. 2 and 3 can service a substantial number of communications channels.
In an embodiment which has been successfully built and tested, a distribution board assembly such as 30 had eight communications ports located along a rear edge thereof, in side-by-side relationship, generally as indicated by dash lines 41-48 in the top plan view of FIG. 2.
As shown in FIG. 3, the communications ports 41 through 48 of FIG. 2 may receive respective plug connectors 51 through 58, with respective cables 61 through 68. For the purposes of a simplified diagrammatic illustration, only connector 52 and its associated cable 62 are shown in FIG. 2.
In FIGS. 2 and 3, a multichannel communications board 80 in accordance with the present invention is indicated as having connector means 81, FIG. 3, plugged into connector 28, FIG. 3, of the expansion location 32. The board 80 may have connector means such as indicated at 91, FIG. 3, which is exposed at a rear panel 93 of the console. Ribbon cable means 94 is indicated as having mating connector means 96 engaged with connector means 91, and as having connector means 98 engaged with mating connector means 9 at the rear edge of the distribution board assembly 30, FIGS. 2 and 3. The positions of boards 24 and 80 shown in FIG. 2 is for convenience of diagrammatic illustration only, and actual expansion slot locations are shown more nearly accurately in FIG. 3.
A typical daughter board for the PC/AT is shown in the sixth figure of Chapter One (FIGS. 1-6) of an IBM PC AT User's Reference Manual by Gilbert Held, Hayden Book Company, 1985, and the general appearance of the communications board 80 with associated connectors 81 and 91 may be essentially similar.
Exemplary connections provided by the communications board assembly 30 between connector 99, FIGS. 2 and 3, and the respective connectors 41-48 at the communications ports of assembly 30 are given in the following table.
______________________________________Table Showing Connections ProvidedBy Distribution Board Assembly 30Connections Between CommunicationsBoard Connector 99 (J1 and J2) andCommunications Port Connectors 41-48(JA1, JB1, through JA8, JB8)Pin No. (J1) Label Connector Pin No.______________________________________ 1 GND JA1- 7 2 ##STR1## JA1 2 3 RTSA JA1 4 4 ##STR2## JA1 3 5 CTSA JA1 5 6 TXCA JB1 2 7 DTRA JB1 7 8 RXCA JB1 4 9 DSRA JA1 6 10 ##STR3## JA2 211 RTSB JA2 4 12 ##STR4## JA2 313 CTSB JA2 514 TXCB JB2 215 DTRB JB2 716 RXCB JB2 417 DSRB JA2 6 GND JA2 7 18 ##STR5## JA3 219 RTSC JA3 4 20 ##STR6## JA3 321 CTSC JA3 522 TXCC JB3 223 DTRC JB3 724 RXCC JB3 425 DSRC JA3 6 GND JA3 7 26 ##STR7## JA4 227 RTSD JA4 4 28 ##STR8## JA4 329 CTSD JA4 530 TXCD JB4 231 DTRD JB4 732 RXCD JB4 433 DSRD JA4 634 GND JA4 7______________________________________
______________________________________Pin No. (J2) Label Connector Pin No.______________________________________ 1 GND JA5 7 2 ##STR9## JA5 2 3 RTSE JA5 4 4 ##STR10## JA5 3 5 CTSE JA5 5 6 TXCE JB5 2 7 DTRE JB5 7 8 RXCE JB5 4 9 DSRE JA5 6 10 ##STR11## JA6 211 RTSF JA6 4 12 ##STR12## JA6 313 CTSF JA6 514 TXCF JB6 215 DTRF JB6 716 RXCF JB6 417 DSRF JA6 6 18 ##STR13## JA7 219 RTSG JA7 4 20 ##STR14## JA7 321 CTSG JA7 522 TXCG JB7 223 DTRG JB7 724 RXCG JB7 425 DSRG JA7 6 GND JA7 7 26 ##STR15## JA8 227 RTSH JA8 4 28 ##STR16## JA8 329 CTSH JA8 530 TXCH JB8 231 DTRH JB8 732 RXCH JB8 433 DSRH JA8 634 GND JA8 7______________________________________
In FIGS. 4A through 4G a preferred form of multichannel communications circuit is illustrated for incorporation in the multichannel communications board 80. The connector means 81, FIG. 3, which is located at a lower edge of the board is electrically represented in FIGS. 4A and 4D as comprising a thirty-two pin connector component J1 designated "JACK A" and a thirty-two pin connector component J3 referred to as "JACK B". The PC/AT type of host computer system has a system board (such as indicated at 22, FIG. 3) which may include input/output connector means (such as indicated at 26 and 28, FIG. 3) with thirty-two pins at an A side and thirty-two pins at a B side. The pins at the A side include the following pin numbers and signal designations pins two through nine, designated as SD7 through SD0; a pin eleven, AEN; and pins sixteen through thirty-one, SA15 through SA0. The pins at the B side include the following: a pin one, GND (ground); a pin two, RESET DRV; a pin three, +5 vdc; a pin seven -12 vdc; a pin nine, +12 vdc; a pin ten, GND (ground); a pin twenty-four, IRQ4, a pin twenty-five, IRQ3; a pin twenty-nine, +5 vdc; and a pin thirty-one, GND (ground). The mating pins of connector components J1 and J3, which mate with the foregoing PC/AT pins have respective similar designations so that the input/output signals associated with the PC type bus in FIGS. 4A et seq. will generally be apparent. The lines SD7 through SD0 in FIG. 4 may be considered data lines, and the lines A15 through A2, SA1 and SA0 may be regarded as address lines.
Where the communications board 80, FIG. 3, is at input/output port number two of the system board 22, the interrupt signal (INT) should be supplied to pin 25 of the I/O channel B side connector to provide the interrupt request signal IRQ3 to the PC bus. Thus selector SEL5, FIG. 4D, is shown with a jumper link at 110. Pins 1 and 2 of selector SEL5 would be connected instead where board 80 were to be inserted at input/output port number one of the system board 22.
The communications chips U17 and U25, FIG. 4B, and U7 and U12, FIG. 4E, are each capable of supplying an interrupt vector (a byte of information regarding the source or cause of an interrupt in the chip), and such interrupt vectors for the four chips are programmed to be distinct from each other. However, the chips require an interrupt acknowledge signal (INTA or INTACK).
The information concerning an interrupt which is supplied by each communications chip may be such as to identify one of a pair of communications channels for each chip, designated channel A and channel B. The binary patterns of signal lines DB1, DB2 and DB3 from the chips for various status conditions are as follows:
______________________________________Channel A Status VectorsFor Communications Chips U17, U25, U7, & U12DB3 DB2 DB1______________________________________0 0 0 Transmit Buffer Empty0 0 1 External/Status Change0 1 0 Receive Character Available0 1 1 Special Receive Condition______________________________________Channel B Status VectorsFor Communications Chips U17, U15, U7, & U12DB3 DB2 DB1______________________________________1 0 0 Transmit Buffer Empty1 0 1 External/Status Change1 1 0 Receive Character Available1 1 1 Special Receive Condition______________________________________
The bit positions DB4 and DB5 of the interrupt vector identify the particular chip involved, e.g., DB5=0, DB4=0, for chip U17; DB5=0, DB4=1, for chip U25; DB5=1, DB4=0, for chip U7; and DB5=1, DB4=1, for chip U12. By way of example a vector with DB5 through DB1 all zeros may be termed "Vector 0" and a vector with DB5 through DB1 all ones may be termed ∓Vector 63", and so on.
Thus the interrupt vector contains information identifying which chip and which channel of a chip causes an interrupt, and contains at least three additional items of information concerning what activity on a particular channel caused the interrupt. Accordingly, transmission of the interrupt vector to the system board is highly advantageous in enabling the host processor to immediately jump to a particular appropriate subroutine servicing the particular interrupt for the specifically identified one of eight communications channels.
Simply for the sake of example, respective service routines for exemplary interrupt conditions on the communications board 80 may be stored at addresses in the host system as follows:
TABLE A______________________________________EXEMPLARY RELATIVE STARTING ADDRESSESFOR INTERRUPT VECTOR SUBROUTINESADDRESSHexadecimal Decimal CODE SPACE______________________________________0000 1,032,192 Service Routine for Vector Zero (VO)0040 1,032,256 Service Routine for Vector One (V1)0100 1,036,544 Service Routine for Vector Twenty-Eight (V28)0600 1,037,824 Service Routine for Vector Sixty-Three (V63)______________________________________
The relative addresses for the interrupt service subroutines may be stored respectively in an interrupt vector jump table as shown below:
______________________________________JUMP TABLE SHOWINGEXEMPLARY RELATIVE ADDRESSESAT WHICH SERVICE ROUTINESFOR INTERRUPT VECTORS MAYBE STORED Interrupt AddressRelative Vector of correspondingAddress Number Service Routine(Decimal) (Decimal) (Hexadecimal)______________________________________ 0 V0 0000 2 V1 0040. . .. . .. . . 56 V28 0100. . .. . .. . .126 V63 0600______________________________________
It will be observed that the relative address for each vector servicing subroutine may be obtained by using the vector value as an offset in the jump table. The basis for determining vector values is illustrated by the examples of Tables C and D.
TABLE C______________________________________Conversion Of Interrupt Vector One (V1)to a Corresponding Vector ValueSignal on Data Bus (DBO = 0) Corresponding VectorVector DB5 DB4 DB3 DB2 DB1 Value (Decimal)______________________________________V1 0 0 0 0 1 2______________________________________
By referring to a relative address of two in Table B, one obtains 0040 (hexadecimal), the desired starting relative address as shown in Table A for the subroutines for processing interrupt vector one (VI).
______________________________________Conversion Of Interrupt VectorTwenty-Eight (V28)to a Corresponding Vector ValueSignal on Data Bus (DBO = 0) CorrespondingVector DB5 DB4 DB3 DB2 DB1 Decimal Value______________________________________V28 1 1 1 0 0 56______________________________________
By referring to a relative address of 56 (decimal) in Table B, one obtains 0100 (hexadecimal), the desired relative starting address.
In accordance with the present invention, a pseudo interrupt acknowledge circuit 220, FIG. 4D, is provided, comprised of components U26, UlA and UlB, for effecting the transmission of the interrupt vectors from communications chips U17, U25, U7, and U12 to the host processor.
The input side of component U26 is connected to address lines A13, A12, A11, A10 and A2 of component J1, via an address bus 230 on the communications board 80, and is also connected with various control lines of a control bus 240. A data bus 250 supplies the interrupt vectors to data lines SD7 through SD0 of component J1 via a component U14, FIG. 4A, and a controlled data bus ("CON DATA BUS") designated by reference numeral 260 in FIG. 4A.
The operation of component U26 is illustrated by the waveforms of FIGS. 5A through 5D. FIG. 5A shows the occurrence of an interrupt signal on an interrupt line 270, FIG. 4E, during a time interval as indicated at 271. This signal is inverted at component U2, FIG. 4D, and is supplied to the host processor via jumper 110 and a signal line IRQ3 of connector component J3.
The host processor, e.g., a PC/AT processor such as the 80286 is programmed to respond to the interrupt signal IRQ3 with the signals, e.g., at A3 through A8, A14 and A15 required to actuate component U21, FIG. 4A, so as to produce the board enable output signed BDEN at output line 290 from component U21, FIG. 4A. This board enable signal is supplied via control bus 240 to the input IN1 of component U26. The host processor provides the following signals on address lines A13, A12, A11, A10, A2: 1, 1, 1, 0, 1; and deactivates the address enable line (AEN). Other processors commonly used with a PC bus configuration include the 8088 microprocessor family.
When the host processor supplies the input/output write signal (IOWR), the output (OUT 7) of component U26 goes low, triggering component UlB to supply the interrupt acknowledge signal (INTA) on line 292, FIG. 4D, for supply via interrupt bus 280 to the communications chips. This action is indicated at 293, FIG. 5B. While the interrupt acknowledge signal is active as shown in FIG. 5B, the host processor activates the input/output read line (IORD) of connector component J3, FIG. 4D, to trigger the read signal (RD) at output OUT 6 of component U26, as indicated at 294, FIG. 5C. The read signal is transmitted via control bus 240, to the respective chips. At the same time the read signal is applied to component U14, FIG. 4A, to effect readout of the interrupt vector to the host processor as indicated at 295, FIG. 5D.
It is found that for reliable operation of the illustrated embodiment the host processor should be programmed to introduce a delay between signal 293, FIG. 5B, and 294, FIG. 5C, to increase the interval between actuations of the communication chips. In one interrupt service routine, the interrupt acknowledge signal was generated via an output command, and this was followed by an output command which had no effect on the communications board. A "NOP" command would be equally suitable to introduce the desired interval between the interrupt acknowledge signal (INTA) and the read signal (RD).
The following are the logic equations describing the operation of component U26 forming part of the pseudo interrupt acknowledge circuit means for the case of an eight channel communications board for plug-in connection with a PC/AT type host computer system.
Logic Equations for
Component U26, FIG. 4D
Input Signals (IN1 through IN12): BDEN, A13, A12, A11, A10, A2, IOWR, IORD, AEN, RST, RST2I, NC (i.e. IN12 not connected); (Input pin 12, not shown, is connected to GND).
Output Signals (OUT 1 through OUT 10): CS0, CS1, CS2, CS3, WR, RD, INTAWR, INTARD, DATAEN, RST2; (Pin 24, not shown, is connected to VCC).
Logic Equations For Active Chip
Select Signals (at OUT 1 through
OUT 4) During Input/Output Write
CS0=BDEN*AEN*A13*A12*A11*A10*A2*IOWR
CS1=BDEN*AEN*A13*A12*A11*A10*A2*IOWR
CS2=BDEN*AEN*A13*A12*A11*A10*A2*IOWR
CS3=BDEN*AEN*A13*A12*ALL*A10*A2*IOWR
Logic Equations for Active Chip Select
Signals (at OUT 1 through OUT 4) During
Input/Output Read Operation
CS0=BDEN*AEN*A13*A12*A11*A10*A2*IORD
CS1=BDEN*AEN*A13*A12*A11*A10*A2*IORD
CS2=BDEN*AEN*A13*A12*A11*A10*A2*IORD
CS3=BDEN*AEN*A13*A12*A11*A10*A2*IORD
Logic Equations for Active Write and
Read Signals (At Outputs OUT 5 and OUT 6)
WR=BDEN*IOWR*A11*A10*A2+(OR:)RST2I
RD=BDEN*IORD*A11*A10+(OR:)RST2I
Logic Equations for Active Signals
at Further Outputs (OUT 7 through OUT 10)
INTAWR=BDEN*IOWR*AEN*A13*A12*A11*A10*A2
INTARD=BDEN*IOWR*AEN*A13*A12*A11*A10*A2
DATAEN=BDEN*AEN*A11*A10 ##STR17##
From the programming standpoint, the address lines SA0, SA1, A2 and A3 may represent a lowest order hexadecimal digit, i.e. HEX DIGIT 0. Address lines A4, A5, A6 and A7 may represent a next hexadecimal digit, HEX DIGIT 1; lines A8, A9, A10 and All may represent a HEX DIGIT 2; and lines A12, A13, A14 and A15 may be considered as HEX DIGIT 3. From this programming point of view, the logic equations for the logic circuitry of FIGS. 4A through 4G may be represented as corresponding addresses. In the following tabulation of such addresses, it is assumed that two communications boards such as 80 are present, a COM1 board at expansion port one of the host processor and a COM2 board at expansion port two. (More than two boards would be feasible, e.g. four.) For one of the communications boards, its first communications chip (e.g. like chip U17) may be designated as "chip 0" and the A and B communications channels of such chip zero may be called channels one and two ("ch 1 & 2"), while the A and B communications channels of the corresponding chip zero of the other communications board may be designated as "chan 9 & 10", and similarly for the other chips of the two boards. The tabulation of exemplary communications board addresses may be presented as follows:
__________________________________________________________________________HEX DIGITS 3, 2 & 1:3 2 10 A F COM2 Board chip O chan 1 & 21 A F COM2 Board chip 1 chan 3 & 42 A F COM2 Board chip 2 chan 5 & 63 A F COM2 Board chip 3 chan 7 & 80 B F COM1 Board chip 0 chan 9 & 101 B F COM1 Board chip 1 chan 11 & 122 B F COM1 Board chip 2 chan 13 & 143 B F COM1 Board chip 3 chan 15 & 16HEX DIGIT 0:8 Chip chan. B CMD9 Chip chan. B DATAA Chip chan. A CMDB Chip chan. A DATSPECIAL ADDRESSES:3 2 1 03 A F C Board INTA WR/RD for COM2 Board3 B F C Board INTA WR/RD for COM1 Board0 E F 8 "SOFT" HARDWARE RESET (WR) for COM2 Board0 F F 8 "SOFT" HARDWARE RESET (WR) for COM1 Board__________________________________________________________________________
EXAMPLE
To send data on chan 3 (with other parameters set), write the data to address IAFB
In order to insure the reliability of the illustrated communications system, a test program was written which may be outlined as shown on the following Table I, (the abbreviation "INT." being used for INTERRUPT, "COM." for COMMUNICATIONS, "CHAN" for CHANNEL, KYBD for KEYBOARD, and "SRVC" for SERVICE):
TABLE I__________________________________________________________________________Outline of a TestProgram for theIllustrated ExemplaryEmbodiment__________________________________________________________________________MAIN CODESET UP COMMUNICATION CHIP REGISTERSSET UP PC INTERRUPT VECTOR TO INT. SERVICE ROUTINE save current PC vector install int. routine vectorVERIFY ACCESS TO COM. CHIPS REGISTERS read interrupt vector register of all com. chipsWAIT FOR KEYBOARD DEPRESSION TO CONTINUELOOP WAITING FOR CHAN NUMBER OR "END"T0 BE ENTERED FROM KYBD If "E", goto end of programIf number, send a pre-defined character for that channel over that channel Wait for trasmit buffer empty Send character over desired channel Repeat loop Else (if any other key), repeat loopEXIT THE PROGRAMINTERRUPT SERVICE ROUTINE "COM.sub.-- INT.sub.-- SRVC"GET INTERRUPT VECTOR OF HIGHEST PRIORITY INTERRUPTING COM CHIPDISPLAY THE INTERRUPT VECTOR T0 THE SCREENCHECK THE INTERRUPT VECTOR FOR ERRORSUSE INTERRUPT VECT0R TO JUMP T0 PROPER ENTRY POINT ENTRY POINT Messages to screen Channel of interrupt Type of interrupt If Rx Char available, jump to READ CHARACTER Else, jump to EXIT INTERRUPT READ RECEIVED CHARACTER FROM INTERRUPTING DEVICE DISPLAY CHARACTER RECEIVEDEXIT INTERRUPT SERVICE ROUTINE RESET HIGHEST IUS BIT IN INTERRUPTING DEVICE SEND EOI (end of interrupt) TO PC INTERRUPT CONTROLLER RETURN FROM INTERRUPT__________________________________________________________________________
An exemplary symbolic programming sequence for effecting the step of obtaining the interrupt vector, i.e. the first step under "INTERRUPT SERVICE ROUTINE" in the outline of TABLE I is given in the following TABLE II, (the step
TABLE II__________________________________________________________________________Exemplary SymbolicProgramming Sequencefor Obtaining anInterrupt Vectorfor the IllustratedEmbodimentCOM.sub.-- INT.sub.-- SRVC: PUSH AX PUSH DX PUSH BX PUSH DI PUSH ES MOV AL,OFFH MOV DX,COM2.sub.-- INTA.sub.-- ADDR CLI OUT DX,AL ;SEND INTERRUPT ACKNOWLEDGE OUT MATH.sub.-- CHIP.sub.-- ADDR,AL IN Al,DX ;RED INTERRUPT VECTOR REG. OUT MATH.sub.-- CHIP.sub.-- ADDR,AL STI AND AX,OOFFH ;mask off unwanted MOV ES,AX ;SAVE VECTOR__________________________________________________________________________
being inserted to provide a delay between the signals of FIGS. 5B and 5C as previously described):
TABLE II__________________________________________________________________________Exemplary SymbolicProgramming Sequencefor Obtaining anInterrupt Vectorfor the IllustratedEmbodimentCOM.sub.-- INT.sub.-- SRVC: PUSH AX PUSH DX PUSH BX PUSH DI PUSH ES MOV AL,OFFH MOV DX,COM2.sub.-- INTA.sub.-- ADDR CLI OUT DX,AL ;SEND INTERRUPT ACKNOWLEDGE OUT MATH.sub.-- CHIP.sub.-- ADDR,AL IN Al,DX ;RED INTERRUPT VECTOR REG. OUT MATH.sub.-- CHIP.sub.-- ADDR,AL STI AND AX,OOFFH ;mask off unwanted MOV ES,AX ;SAVE VECTOR__________________________________________________________________________
With a system such as illustrated, interrupts from eight different communications channels for each communications board can be handled very rapidly by the host processor. Thus relatively higher communications rates are feasible, for example 9600 baud, instead of 4800 baud, and with extremely high reliability. The distribution assembly 30 connects the communications chips with respective pairs of external devices, e.g. modems via ports 41-48 cleanly, avoiding obstructions at the front and sides of the console 10, and achieving a minimal change in the appearance of the system. The location of the distribution assembly 30 in a stacked configuration between components 10 and 20, FIG. 1, is considered to actually improve the location of the monitor in comparison to a monitor resting directly on the console 10, and such improvement is attested to by the showing of a support pedestal of substantial height for elevating the position of the monitor in the first figure of Chapter One of the aforementioned User's Manual by Gilbert Held (FIG. 1-1. at page 2). The connectors 41-48, FIG. 2, may be a narrow DSUB Burndy connector, and such a connector is very readily soldered to conductive fingers formed on a distribution printed circuit board within enclosure 31. If desired, the overall height of enclosure 31 may be of the order of one inch, or less.
It will be apparent that many modifications and variations may be effected without departing from the scope of the teachings and concepts of the present disclosure. | In accordance with one illustrated embodiment herein, a personal computer system such as that known as the PC/AT is adaptable by means of its expansion slots so as to provide a multichannel communications capability, with a plug-in communications board providing interrupt vectors to the mother board of the personal computer. A communications distribution configuration for the communications channels does not enlarge the footprint of the system or detract from its appearance. As many as eight communications lines are connectable with the illustrated distribution configuration in a neat and orderly fashion. | 1 |
The present invention relates to a shell structure for a paper machine press section.
Conventional constructions use rubber-covered steel rolls as the press rolls of the paper machine press section, said rolls providing the nip for water removal from the web. As necessary, either one or two rubber-covered rolls are use.
Because the goal is to achieve a nip of maximum width, combined with maximally homogeneous and high linear pressure, rubber-covered rolls do not offer an optimal solution. Increasing the diameter of the rolls can, of course, permit a wider nip but the uneven distribution of nip pressure still remains a problem.
Disclosed in FI patent publication 79368 is a roll construction for a wide-nip press having support rolls arranged parallel with the axis of the felt roll, said rolls having a shell arranged enclosing the rolls, said shell being pressed against the felt roll via the web by virtue of the support rolls.
The arrangement disclosed in the publication is not detailed up to a specific embodiment of the shell structure that might implement an effective function of said arrangement. The shell should facilitate a sufficiently large local displacement without exceeding the maximum allowable stress of the outer face of the shell. On the other hand, the local stiffness of the structure should be sufficient to achieve a desired compressive pressure over the entire nip width. The shell structure is, however, described to be fabricated from a resilient material such as steel, carbon fiber or other suitable material. For the proper function of the equipment, the specific structure of the shell is of particular importance.
It is an object of the present invention to overcome the drawbacks of the above-described technique and to achieve an entirely novel type of shell structure for paper machine press section.
The invention is based on fabricating the shell using an at least three-layer structure in which an elastic core is covered on both sides with surface layers of higher stiffness.
The invention provides outstanding benefits.
The nip width can be designed up to twice the width achievable by conventional techniques, and moreover, the nip pressure can be maintained constant over the entire nip width.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is next examined in detail with the help of an exemplifying embodiment illustrated in the attached drawings.
FIG. 1 shows a side view of a shell structure in accordance with the invention in whole.
FIG. 2 shows a detail of the shell structure illustrated in FIG. 1.
DETAILED DESCRIPTION
According to FIG. 1, a shell structure 1 is adapted about support rolls 5, 6, 7. The shell structure extends over the entire width of the web in the cross direction of the web. A typical diameter H of the shell structure 1 is approx. 1 m. The shell structure is composed of a resilient but durable outer face 2, elastic core 3 and inner face 4 whose properties are practically identical to those of the outer face 2. The position of the rolls 5 and 6 can be varied according to the loading requirements. During the tests performed, the rolls 5 and 6 were adjusted symmetrically about the center line K while the angle α subtended between the center line K and the center point of the roll 6 was approx. 21°.
With the help of computer calculations, the layered structure illustrated in FIG. 2 was selected, said structure having an epoxy or urethane elastomer modified for extreme elasticity as the core 3. The materials of the outer faces 2 and inner faces 4 were carbon-fiber-reinforced epoxy. The radial modulus of elasticity in this material was in the range 50-100 GPa.
Since the specifications were set as to achieve a nip width of 250 mm and 4 N/mm 2 average nip pressure, the roll of 1 m diameter was dimensioned as follows:
- thickness of core 3: D=25 mm, and
- equal thicknesses A and B of outer face 2 and inner face 4: A=B=approx. 5 mm.
The core 3 had a modulus of elasticity of 1350 N/mm 2 and a shear modulus of 500 N/mm 2 . The results of computations were verified using a model scaled down by 1:5.
The dimensioning rules were characterized by a requirement stating that a sufficiently large local displacement must be achieved without exceeding the maximum allowable stress of the outer face. In addition, the local stiffness of the structure had to be sufficient for reaching a desired compressive loading over the entire nip width in the press. The stiffness and strength behaviour of the shell 1 can be varied over a wide range by altering the stiffness and strength properties of reinforced plastic composites. The local stiffness of the shell 1 can be changed in the structure by altering, e.g., the thickness and properties of the core 3. The thickness D of the core 3 for a roll of 1 m diameter can be varied within, e.g., 10-50 mm while correspondingly the thicknesses A and B of the surface layers is varied within 5-25 mm. Advantageously, the thickness of the shell structure 1 is approx. 2-5%, preferably approx. 3.5%, of the total diameter H of the shell structure 1. Furthermore, the thickness D of the core 3 is approx. 55-85%, preferably approx. 70%, of the total thickness of the shell structure 1.
Suitable materials for the surface layers 2 and core 4 are, e.g., glass or aramide fiber reinforced resins, of which further suitable of thermoset plastics are, e.g., different polyester, vinylester, methacrylate or phenol based resins. Of thermoplastics suitable are, e.g., polyethene, polyamide, polypropene and other resin systems compatible with the composites production techniques.
A shell structure in accordance with the invention can be fabricated, for instance, by:
- hand lay-up,
- RTM techniques,
- filament winding, or
- prepreg laying.
In hand lay-up, the reinforcing fabrics are impregnated with resin using, e.g., a brush or roller. The reinforcing layers are laminated layer by layer in a desired order up to the predetermined number of layers. The reinforcement is introduced in the form of chopped strand mats or different kinds of knit fabrics. The mold is provided by single-surface structure, which for the case of the shell structure is a cylindrical tube.
The RTM (Resin Transfer Molding) method is based on the use of closed molds (confined on both sides), in which the reinforcement or preforms made thereof are placed without preimpregnation in the first stage while the resin is injected into the mold in the second stage using either overpressure or vacuum (or both) to assist the process.
In the filament winding method, the reinforcement is introduced in preimpregnated form in layers onto a rotating mandrel. The typical reinforcement used in filament winding is called roving, which is a bundle of parallel strands. The roving bundles are wound onto the mandrel in single or multiple rovings at a time. Suitable reinforcements are also such fabrics as mats and knit fabrics. The preimpregnation of the reinforcing material with the resin is typically carried out in separate impregnation vats prior to their winding onto the mandrel.
The basic components of the resin matrix composite, that is, the reinforcement and resin, can also be delivered in the form of a prefabricated product in which the reinforcement is already combined with the resin. When using thermoplastics, the resin component can be brought into a workable state by reheating prior to the final fabrication stage. The use of thermoset resins requires precuring of the resin component into a state called B-stage that makes the resin component pliable and easy to form. Final curing of the resin is carried out using pressure and elevated temperature. The latter described method of using prefabricated materials called prepregs is suitable for use in the fabrication of the shell structure in accordance with the invention. The filament winding method is also applicable especially for large cylindrical shapes. | The invention is related to a cylindrical shell structure (1) for paper machine press section, said shell structure being arranged to enclose at least four support rolls (5, 6, 7). According to the invention the shell structure (1) has at least three layers so that the outer face (4) and inner face (2) of the shell (1) are of a resilient, durable material, and the core (3) is of an elastic material having a high shear elasticity. | 3 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a word game and more particularly to a word game utilizing a unique style of play incorporating a plurality of playing pieces. The present invention is unique, in that it allows the players to use all the playing pieces on the table to form words, unlike other games in which the player is simply dealt the playing pieces which they are allowed to use. When playing previous word games, a player uses the playing pieces dealt to them and sometimes an additional few pieces may be given the player, although generally this amounts to less than ten pieces.
[0002] There has always been a defining amount of playing pieces a player has been able to choose from in their quest to form a word in previous word games. During these games the number of playing pieces available to form a word and the length of the word that can be formed from those playing pieces generally has bounds and is totally dependent on the number of playing pieces the player chooses or the number of pieces dealt the player. The ability to form a particular word and the specific playing pieces used to form that word is restricted, making the game limited in scope. The present invention is not limited to the use of only the playing pieces that are dealt to a player or the few pieces in the middle of the table which the player may utilize. The only restriction to the amount of playing pieces a player may use is the number of pieces that come with the game and the number of pieces removed by other players during a round of play of the game.
[0003] As will be seen, the familiarity of the telephone rotary dial and the key pad used by a large segment of the world's telephones provides a unique basis for a word game that comprises the present invention and is unequalled among the word games presently available. The present invention is distinctly different from other word games or word card games in the method of play utilized. This distinction leads to a larger number of choices that are available at any one time to a player in order to form the word during a game.
[0004] The present invention was derived from the content of a newspaper puzzle which was created and subsequently copyrighted by Norman F. Irwin. This newspaper puzzle uses as a basis the individual keys on the telephone keypad and more specifically, the numbers and letters on the telephone keypad as is explained more completely in the following text.
[0005] The puzzle was submitted to a number of newspaper syndicates in the 1980's, by Norman F. Irwin the inventor of the present invention.
[0006] A newspaper syndicate located at the time in Anaheim, Calif. became interested in the newspaper puzzle, but unfortunately an agreement did not materialize. This was due in part to the various styles and alphabets used on the telephone key pad that were in place in other parts of the world at the time. These key pad alphabets differed too much from the North American standard to such an extent that the newspaper syndicate did not feel it could sell the puzzle worldwide and so the puzzle was put aside by the inventor for a time.
[0007] The inventor applied for a Canadian trademark for the words ‘DIAL A WORD’ in 2002 with the intension of using this name in resurrecting the newspaper puzzle again and submitting the newspaper puzzle to a number of different newspaper syndicates and book publishers, but due in part to the increase at the time of hand held video games and assorted online puzzles, the newspaper syndicates and book publishers gave a lackluster response.
[0008] To solve the newspaper puzzle, the player was required to decipher clues given as telephone numbers on the left side of the puzzle and sentence clues given on the right side of the puzzle. The player tried to determine the hidden words using the corresponding letters on the keypad of their telephone or cell phone. An example of a telephone key pad was printed on the puzzle face to aid any player who did not have access to a telephone at the time.
[0009] It must be noted, that the numbers on the key pad of a telephone or cell phone correspond to a very specific group of letters. Examples of these specific groups are the number 2 on a telephone or cell phone key pad, it corresponds to the letters ABC, the letter 7 on the a telephone or cell phone keypad which in turn corresponds to the letters PQRS and the number 5 on a telephone or cell phone keypad which corresponds to the letters JKL.
[0010] Using the cell phone or telephone keypad, the player tried to decipher the telephone number clues into the correct letters and write the correct letters in the printed squares on the page. When the player had deciphered all the clues, certain letters, written in the printed boxes, would have circles around them. The player would then use these circled letters to further decipher a cryptogram that was located below the printed squares. The answer was to be published in the next edition of the newspaper along with a new puzzle.
[0011] After the newspaper puzzle's lackluster response and knowing the concept of using the telephone key pad as a basis for a game was feasible, the present invention was devised, a word game based on the unique numbering and lettering of the telephone rotary dial and telephone key pad.
[0012] At the time of the newspaper puzzle's inception, there were no other newspaper puzzles, puzzle books, word games, word card games or any other game or puzzle of any description that was based on the keypad or rotary dial of the telephone, a fact that remains so today. There is not to be found anywhere, any board games, puzzle games, card games, puzzle cryptograms, jumbles or any similar word solving or word forming game or puzzle having as a basis, the key pad or rotary dial of a telephone or cellphone.
[0013] Many games are available which utilize the skill and imagination of the players. Word games in particular have become popular by utilizing such skill. These games are both challenging and enjoyable to play. These games are also educational since they require the player to use his imagination and his word knowledge to play the game.
[0014] Most of the word games that are available utilize a board and some kind of playing piece to form the words. These games, although they use the player's skill and creativity to form the words, tend because of the boards incorporated in their play, to be generally bulky and/or require letter holders and other playing apparatuses in order to play the game.
[0015] The present invention is a word game that features a very compact and almost utilitarian approach; in that the game requires no board, no apparatuses and does not need playing piece holders in order to play.
[0016] The public at large has over the years been exposed to the familiarity of a telephone number being used as a text or as an advertising slogan. An example is the telephone number 289-6636. When you look at the keys, on the telephone key pad corresponding to these numbers, you can spell the words BUY MOEN. Many companies have for years used this type of advertising as a simple and direct way to get their name or message before the public.
[0017] An example of a game that was based on this concept is the SLOGAN CARD GAME (U.S. Pat. No. 1,542,919 by Bloom) which involved the use of well known advertising slogans of the day as the part of the play of the game.
[0018] There are a number of games in which more than one letter is on the card. One that comes to mind is T.A.N.G.O. (Word Card Game U.S. Pat. No. 4,877,255 Canadian Patent Number CA1327617). This game utilizes cards that have a different letter on the top and another different letter on the bottom. Although this game utilizes more than one letter per card it does not allow for any greater number of choices than that which a player has with the cards he is dealt. In the present invention the number of letters that are available to a player include all the letters on all the playing pieces that come with game and decreases conversely as each player forms a word in a round, making the game a little more difficult for every subsequent player. This allows for a more challenging game than one in which the player has to rely only on the cards dealt him.
[0019] There are many word games, Scrabble, Boggle, Balderdash, and the aforementioned T.A.N.G.O. to name a few. There is also a number of word creating card games PDQ (The Pretty Darn Quick Word Game), Scrabble Slam, Tri-Versity. These games are based on the idea of forming words using a single lettered card or playing piece or using cards with a limited number of letters mostly no more than two. This is a decided inadequacy. The present invention solves this inadequacy, by using playing pieces which provide a greater number of choices when forming words, because of their increased letter count per piece, in comparison to other games. This greater choice of letters on the playing pieces, along with the public's already familiarity with the telephone key pad, increases the likelihood that the players will find the game challenging, educational, stimulating, and above all fun.
SUMMARY OF THE INVENTION
[0000]
1) Accordingly, it is the object of the present invention to provide a new and improved game utilizing a unique plurality of playing pieces for forming words.
2) Another object of the present invention is to provide a new and exciting game wherein a certain familiarity is already established.
3) Another object of the present invention is to utilize the playing in connection with a word game, wherein the letters on the face of all the face-up playing pieces are used by the players to form a word in subsequently decreasing amounts.
4) Another object of the present invention is to provide a plurality of playing pieces wherein a considerable number of the playing pieces have three different letters to choose from on different playing pieces and, further, that two of the differently numbered playing pieces have four letters to choose from and one style of playing piece has the unique ability of being able to be any of the letters in the twenty-six letter English alphabet. Thus there are a huge number of possible letter choices a player can use to form a word.
5) Another object of the present invention is to provide a plurality of playing pieces wherein each playing piece in said series has a unique combination of a particular numerical indicator and a particular alphabet indicator meaning such that no two playing pieces in the series are duplicates of one another.
6) Another object of the present invention is to provide a plurality of playing pieces wherein the numbers on the face of the playing pieces are of no specific size and the letters on the face of the playing pieces are also of no specific size, and the relationship as to size of the numbers to the letters is of no specific ratio, and further the numbers can be oriented in any position as to their placement next to or in proximity to the letters on the face of the playing pieces.
7) Another object of the present invention is to provide a plurality of playing pieces wherein six of the said playing pieces have a number on their face and more specifically the digit ‘1’ and also on the playing piece face are the words ‘ANY LETTER’. The number ‘1’ is of no particular size or ratio in relation to the words ‘ANY LETTER’ and the placement of the number ‘1’ and the words ‘ANY LETTER’ is such that the two may be in any position as to their placement on the face of the playing piece, next to and in proximity to each other. These six playing pieces are referred to as the ‘wild cards’.
8) Another object of the present invention, wherein distribution of the playing pieces is in a unique manner, such that all the playing pieces are turned face-up and placed in rows in the middle of the playing area.
9) Another object of the present invention is to allow players to accumulate points by forming words from the playing pieces in the play area and then removing the playing pieces that they used from the playing area. This creates a lesser number of playing pieces from which the player's subsequent opponent has to choose from, in order to form a word, thus making the game more difficult for that player and each subsequent player.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a view of a digital design that is meant to be representational of a typical key pad of a typical telephone. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0030] FIG. 2 is view of the face of the ‘number 1’ playing piece, the so called wild card. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0031] FIG. 3 is a view of the face of the ‘number 2’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0032] FIG. 4 is a view of the face of the ‘number 3’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0033] FIG. 5 is a view of the face of the ‘number 4’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0034] FIG. 6 is a view of the face of the ‘number 5’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0035] FIG. 7 is a view of the face of the ‘number 6’ piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0036] FIG. 8 is a view of the face of the ‘number 7’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0037] FIG. 9 is a view of the face of the ‘number 8’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0038] FIG. 10 is a view of the face of the ‘number 9’ playing piece. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0039] FIG. 11 is a depiction of the rotation of a playing piece showing that the playing piece's designation is equal at either end, regardless of orientation, if the playing piece is rotated around a center axis. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0040] FIG. 12 depicts a set of the nine different playing pieces, depicted as playing cards, which make up one of the equivalent series of the complete plurality with the individual playing pieces numbered. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0041] FIG. 13 is a depiction of the upper and lower designators as they are graphically laid out on a typical playing piece and as they relate to the sides of the playing piece if the playing piece is rectangular in shape. The number 87 and 89 indicates the relation to the short and long sides as they relate to where a player 90 is sitting. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0042] FIG. 14 is a depiction of the face of a typical playing piece, in this case the number 9 playing piece, showing the playing piece's designator (9WXYZ) which is made up of both a numeric indicia and alphabet indicia shown at 91 and again at 92 . NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0043] FIG. 15 is a depiction of the placement of playing pieces 93 as they appear at the beginning of a game. The number of rows and playing pieces shown is for reference only and does not constitute in any way an exact number of rows or an exact number of playing pieces. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0044] FIG. 16 shows the typical placement of the playing pieces 94 as they might appear when one player has formed a word, in this example the word ‘QUIZZED’ 95 and the player has subsequently removed the playing pieces used to form the said word from the playing area and lined the playing pieces in a row to show the other players. The number of rows and playing pieces shown is for reference only and does not constitute in any way an exact number of rows or an exact number of playing pieces. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0045] FIG. 17 shows how the playing area 96 as it might appear when one of the subsequent players has formed a word, in this example, the word ‘DODDERING’ 97 and has then removed the playing pieces used to form the said word from the play area and lined the playing pieces in a row to show the other players. The number of rows and playing pieces shown is for reference only and does not constitute in any way an exact number of rows or an exact number of playing pieces. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
[0046] FIG. 18 Shows the playing pieces as they would appear as square tiles or tablets. NOTE: the numeric indicia and alphabet indicia that make up the designators depicted on this drawing are for reference to the numeric indicia and alphabet indicia only and do not indicated specific placement, sizes or ratio of the numeric indicia as it relates to the alphabet indicia.
PRIOR ART
[0000]
Patent # CA1327617 Von Braunhut 3/1994
Patent # CA2138440 O'Connor 12/1994
Patent# CA773016 Salonsky 12/1967
U.S. Pat. No. 6,234,486 Wallice 5/2001
U.S. Pat. No. 4,877,255 von Braunhut 10/1989
U.S. Pat. No. 4,826,175 Quatrino 5/1989
U.S. Pat. No. 4,333,656 Sommer 6/1982
U.S. Pat. No. 5,409,237 Marcley et al. 4/1995
U.S. Pat. No. 4,219,197 Acuff 8/1980
U.S. Pat. No. 4,402,513 Head 9/1983
U.S. Pat. No. 4,192,513 Feeley et al. 3/1980
U.S. Pat. No. 5,727,788 Davis 3/1998
U.S. Pat. No. 4,775,157 Armstrong 10/1988
U.S. Pat. No. 1,542,819 Bloom 6/1925
DETAILED DESCRIPTION OF THE INVENTION
[0061] The present invention is a word game that can be played by 2 to 6 players. The present invention is also a word game consisting of a supplied plurality of playing pieces and the described method of play in which the playing pieces are used. Playing piece in this description means a playing piece that resembles a rectangular playing card as shown in FIG. 12 and/or a playing piece that resembles a square tile or tablet as shown in FIG. 18 . The term playing piece herein refers to either or both of the preceding descriptions and each of the preceding description is interchangeable with the other.
[0062] The plurality of said playing pieces is a combination of a number of series of nine playing pieces as shown in FIG. 12 and as shown in FIG. 18 . The described method of play begins by choosing the player who will form the first word in the round of the game. The selection process of this first player is as follows; each player selects, without looking at the playing pieces while the selection is taking place, one playing piece from a container that contains a complete set of playing pieces, the player who selects the playing piece with the highest numerically designated playing piece will be declared the player and will start the play first in the round. Further, another method of choosing the first player is with a die, the player who rolls the highest number on the die is declared the first player of the round. Either before or after the first player has been selected the game can commence with the playing pieces being placed in the playing area.
[0063] The present invention is a word game in which each and all of the playing pieces, at the commencement of the game, are randomly placed face-up in the middle of the playing area on an imagined grid as follows; each and all of the playing pieces are randomly laid out on the imagined grid which consists of no particular number of rows of no particular number of playing pieces, and further meaning that each one of the rows individually consist of no particular number of randomly placed playing pieces and the said playing pieces are placed side by side as to their relationship to each other means the imagined grid therefore consists of no particular number of rows of no particular number of playing pieces being laid out similar to the grid as is shown in ( FIG. 15 ) 93 (the number of rows and playing pieces shown is for reference only and does not constitute in any way an exact number of rows or an exact number of playing pieces). The player who has the first turn in the round selects from the grid of rows of playing pieces as is shown in ( FIG. 15 ) 93 (the number of rows and playing pieces shown is for reference only and does not constitute in any way an exact number of rows or an exact number of playing pieces), a specific number of the playing pieces, and this specific number is the number of playing pieces needed to match the number of letters in the word selected and as the letters on the individual playing pieces chosen relate to the player's selected word
[0064] The following is a description of a word being formed by a player in a typical manner and the relationship between the playing pieces and the player's chosen word when counting the points for the word: This description reflects the process by which the first player and each subsequent player would select the playing pieces and how the said playing pieces relate to the said player's chosen word.
[0065] A player using the following playing pieces, which have on their face the letters ‘PQRS’ FIG. 8 , ‘TUV’ FIG. 9 , ‘GHI’ FIG. 5 , two playing pieces with the letters ‘WXYZ’ FIG. 10 on both of the playing pieces and two playing pieces that have ‘DEF’ FIG. 4 on both of the playing pieces, uses these playing pieces to form the word ‘QUIZZED’ ( FIG. 16 ) 95 , by using one of the correct letters from each of the said playing pieces. The breakdown is as follows; the ‘Q’ as shown at 47 and again at 52 on the ‘7’ playing piece FIG. 8 containing the letters ‘PQRS’ would count as ‘seven points’ because the 7 is the numeric value of the 7 playing piece. The shown at 57 and again at 61 from the ‘8’ playing piece FIG. 9 , and containing the letters ‘TUV’, would count as ‘eight points’ because the 8 playing piece has a numerical value of 8. The ‘I’ shown at 24 and again at 28 from the ‘4’ playing piece FIG. 5 which contains the letters ‘GHI’ would count as ‘four points’ because the numerical value of the 4 playing piece is 4. The two ‘9’ playing pieces FIG. 10 which contain the letters ‘WXYZ’ would count as ‘nine points’ each (2×9 points=18 points) because each playing piece has a letter ‘Z’ shown at 67 and again at 72 and each letter ‘Z’ shown at 67 and again at 72 is used in the word ‘QUIZZED’ ( FIG. 16 ) 95 , two times. The ‘3’ playing piece FIG. 4 of which there are two, one using the ‘E’ shown at 15 and again at 19 from the letters ‘DEF’ and one using the D′ shown at 14 and again at 18 from the letters ‘DEF’ would count a point score of 6 (2×3 points=6 points), ‘three points’ for the ‘E’ shown at 15 and again at 19 , and ‘three points’ for the ‘D’ shown at 14 and again at 18 . The numeric count of each of the single letters ‘Q’, ‘U’, ‘I’, ‘Z’, ‘Z’, ‘E’, ‘D’ ( FIG. 16 ) 95 , is then added together to get the total for the word, these points being 7+8+4+9+9+3+3=39. The player who formed the word ‘QUIZZED’ ( FIG. 16 ) 95 would therefore accumulate 39 points toward their total points. The playing pieces the player selected to form the player's said word would be removed from the playing area and retained by the player ( FIG. 16 ) 95 .
[0066] Another example of the forming of a word and the point count as it relates to the chosen word is as follows, a player forms the word ‘DODDERING’ ( FIG. 17 ) 97 , which counts the same score of 39 points, as the word ‘QUIZZED’ shown above using the playing pieces with the letters ‘DEF’ FIG. 4 , ‘MNO’ FIG. 7 , ‘DEF’ FIG. 4 , ‘DEF’ FIG. 4 , ‘DEF’ FIG. 4 , ‘PQRS’ FIG. 8 , ‘GHI’ FIG. 5 , ‘MNO’ FIG. 7 , ‘GHI’ FIG. 5 and a single letter from each of these playing pieces, specifically the single letters ‘D’, ‘O’, ‘D’, ‘D’, ‘E’, ‘R’, ‘I’, ‘N’, ‘G’. The point count for the word ‘DODDERING’ ( FIG. 17 ) 97 , would be as follows, the ‘3’ playing piece FIG. 4 with letters ‘DEF’ would count ‘three points’ for the use of the letter ‘D’ shown at 14 , and again at 18 , because 3 is the numeric value of the 3 playing piece. The ‘6’ playing piece FIG. 7 with the letters ‘MNO’ would count ‘six points’ for the use of the letter ‘O’ shown at 40 , and again at 44 , because 6 is the numeric value of the 6 playing piece. The ‘3’ playing piece FIG. 4 with the letters ‘DEF’ would count ‘three points’ for the use of the letter ‘D’ shown at 14 , and again at 18 , because the numeric value of the 3 playing piece is 3. The ‘3’ playing piece FIG. 4 with the letters ‘DEF’ would count ‘three points’ again for use of the other letter ‘D’ shown at 14 and again at 18 , would count ‘three points’ because the numeric value of the 3 playing piece is 3. The ‘3’ playing piece FIG. 4 with the letters DEF′ would count ‘three points’ once again for use of the letter ‘E’ shown at 15 , and again at 19 , because the numeric value of the 3 playing piece is 3. The ‘7’ playing piece FIG. 8 with the letters ‘PARS’ would count ‘seven points’ for the use of the letter ‘R’ shown at 48 , and again at 53 , because 7 is the numeric value of the 7 playing piece.
[0067] The ‘4’ playing piece FIG. 5 with the letters ‘GHI’ would count ‘four points’ for the use of the letter ‘I’ shown at 24 , and again at 28 , because 4 is the numeric value of the 4 playing piece. Again the ‘6’ playing piece FIG. 7 with the letters ‘MNO’ is counted ‘six points’ for the use of the letter ‘N’ shown at 39 , and again at 43 , because 6 is the numeric value of the 6 playing piece. And finally another ‘4’ playing piece FIG. 5 with the letters ‘GHI’ is counted ‘four points’ for the use of the letter ‘G’ shown at 22 and again at 26 because the numeric value of the 4 playing piece is 4.
[0068] The point count for the word ‘D’, ‘O’, ‘D’, ‘D’, ‘E’, ‘R’, ‘I’, ‘N’, ‘G’, ( FIG. 17 ) 97 , is the total of the numeric value of all the playing pieces used to form the word when added together, 3+6+3+3+3+7+4+6+4=39.
[0069] The playing pieces used to form the word ‘DODDERING’ ( FIG. 17 ) 97 would be removed by the player who formed the said word ‘DODDERING’ ( FIG. 17 ) 97 , and said playing pieces would be retained by the player and the numerical count of the said playing pieces would be added to the said player' accumulated point count.
[0070] The playing piece used in the present invention has a face of a special design. The face of the playing piece used in the present invention is designed in such a way as to represent the individual keys on a typical telephone key pad as is depicted in FIG. 1 . The design of the face of playing pieces used in the playing of the game are shown in FIG. 12 and FIG. 18 and more specifically in FIG. 2 , FIG. 3 , FIG. 4 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 8 , FIG. 9 , and FIG. 10 . There are a number of series of the nine playing pieces shown, which when combined, make up the plurality of the playing pieces, this number is of no specific amount.
[0071] Although there are multiples of letters, on each individual playing piece, only one letter from each of the playing pieces may be used at any one time to form the words the players use. An example of this is playing piece number 2 FIG. 3 , the alphabet indicia for this playing piece is ‘ABC’. The player can only use one of the letters per playing piece, the ‘A’ shown at 6 , and again at 10 , or the ‘B’ shown at 7 , and again at 11 or the ‘C’ shown at 8 , and again at 12 . This is the same for all the playing pieces, only one letter from each playing piece may be used at any one time.
[0072] Referring now to FIG. 11 it will be seen that the playing pieces in the present invention use both numeric indicia 73 and alphabet indicia 74 . It will also be seen that if the playing piece is rotated on an axis the same numeric indicia 73 and alphabet indicia 74 , which are then shown at 75 and 76 respectively, only change position not value.
[0073] Any reference in this document to he, his, him, hers, her, she, they, their, theirs, or any other referral in regard to gender, is only for reference to a generic player and is not a specific reference to gender in any form.
[0074] A timer of some type may be used to speed the progress of the game. The timer used may be of any type electric, egg, etc.
[0000] A Typical Method of Play would be as Follows;
Starting The Game
[0075] The playing pieces may consist of different shapes depending on the game purchased. For example one shape may resemble a playing card and another shape may resemble a tile or small tablet.
[0076] To start the game, if the playing pieces are in the form of a playing card, the deck of cards is shuffled and is placed in the middle of the play area. Conversely, if the playing pieces are in a form of a tile or tablet, the playing pieces may be placed in a container and the container shaken to mix up the playing pieces before they are laid out for the play of the game. A die may be used to determine the player who goes first
[0077] The game begins with each player drawing one card from the deck of cards, or one playing piece from the aforementioned container. If a die is used the player who rolls the highest number is the player who goes first. Further the player who drew the card with the highest numerical value on the face of the card or the player who drew the tile style playing piece first, meaning this player is the first player that attempts to form a word using the laid out playing pieces as shown in FIG. 15 .
[0078] The playing pieces are laid out on the playing area in the following manner; The playing pieces are placed in eight rows consisting of eight playing pieces each as shown in FIG. 15 . The player who is declared the first player by virtue of winning the draw of the playing pieces or by the throw of the die, attempts to form a word using the letters on the playing pieces.
[0000] The player must form a word using the following criteria;
A word must be correctly spelled.
A word must be a least four letters in length.
A word, in order to qualify, has to be in the dictionary that the players are using during the game. In the event that the players have more than one dictionary, only one dictionary is allowed and the players must agree before the start of the game which dictionary will be used.
[0079] The use of a hyphen may be necessary, at times, in order to form a word. The playing pieces with the designator ‘1 any letter’ FIG. 2 must be used in this case to indicate the hyphen within the word. (For example, to spell the word X-RAY, a player would use the following playing pieces, ‘X’ shown at 65 , and again at 70 FIG. 10 , ‘ANY LETTER’ shown at 2 , and again at 3 FIG. 2 (ANY LETTER in this case is being used as the hyphen), ‘R’ shown at 48 , and again at 53 FIG. 8 , ‘A’ shown at 6 and again at 10 FIG. 3 and ‘Y’ shown at 66 and again at 71 FIG. 10 ).
[0000] The following is a description of a word being formed by a player in a typical manner:
[0080] A player using the following playing pieces, which have on their face the letters ‘PQRS’ FIG. 8 , ‘TUV’ FIG. 9 , ‘GHI’ FIG. 5 , two playing pieces with the letters ‘WXYZ’ FIG. 10 on both of the playing pieces and two playing pieces that have ‘DEF’ FIG. 4 on both of the playing pieces, uses these playing pieces to form the word ‘QUIZZED’ ( FIG. 16 ) 95 , by using one of the correct letters from each of the said playing pieces.
[0081] The breakdown is as follows; the ‘Q’ as shown at 47 and again at 52 on the ‘7’ playing piece FIG. 8 containing the letters ‘PQRS’ would count as ‘seven points’ because the 7 is the numeric value of the 7 playing piece. The ‘U’ shown at 57 and again at 61 from the ‘8’ playing piece FIG. 9 , and containing the letters ‘TUV’, would count as ‘eight points’ because the 8 playing piece has a numerical value of 8. The ‘I’ shown at 24 and again at 28 from the ‘4’ playing piece FIG. 5 which contains the letters ‘GHI’ would count as ‘four points’ because the numerical value of the 4 playing piece is 4. The two ‘9’ playing pieces FIG. 10 which contain the letters ‘WXYZ’ would count as ‘nine points’ each (2×9 points=18 points) because each playing piece has a letter ‘Z’ shown at 67 and again at 72 and each letter ‘Z’ shown at 67 and again at 72 is used in the word ‘QUIZZED’ ( FIG. 16 ) 95 , two times. The ‘3’ playing piece FIG. 4 of which there are two, one using the ‘E’ shown at 15 and again at 19 from the letters ‘DEF’ and one using the ‘D’ shown at 14 and again at 18 from the letters ‘DEF’ would count a point score of 6 (2×3 points=6 points), ‘three points’ for the ‘E’ shown at 15 and again at 19 , and ‘three points’ for the ‘D’ shown at 14 and again at 18 . The numeric count of each of the single letters ‘Q’, ‘U’, ‘I’, ‘Z’, ‘Z’, ‘E’, ‘D’ ( FIG. 16 ) 95 , is then added together to get the total for the word, these points being 7+8+4+9+9+3+3=39. The player who formed the word ‘QUIZZED’ ( FIG. 16 ) 95 , would therefore accumulate 39 points toward their total points. The playing pieces the player selected to form the player's said word would be removed from the playing area and retained by the player ( FIG. 16 ) 95 .
[0082] Another example of the forming of a word and the point count as it relates to the chosen word is as follows, a player forms the word ‘DODDERING’, ( FIG. 17 ) 97 , which counts the same score of 39 points, as the word ‘QUIZZED’ ( FIG. 16 ) 95 , shown above using the playing pieces with the letters ‘DEF’ FIG. 4 , ‘MNO’ FIG. 7 , ‘DEF’ FIG. 4 , ‘DEF’ FIG. 4 , ‘DEF’ FIG. 4 , ‘PQRS’ FIG. 8 , ‘GHI’ FIG. 5 , ‘MNO’ FIG. 7 , ‘GHI’ FIG. 5 and a single letter from each of these playing pieces, specifically the single letters ‘D’, ‘O’, ‘D’, ‘D’, ‘E’, ‘R’, ‘N’, ‘G’. The point count for the word ‘DODDERING’ would be as follows, the ‘3’ playing piece FIG. 4 with letters ‘DEF’ would count ‘three points’ for the use of the letter ‘D’ shown at 14 , and again at 18 , because 3 is the numeric value of the 3 playing piece. The ‘6’ playing piece FIG. 7 with the letters ‘MNO’ would count ‘six points’ for the use of the letter ‘O’ shown at 40 , and again at 44 , because 6 is the numeric value of the 6 playing piece. The ‘3’ playing piece FIG. 4 with the letters ‘DEF’ would count ‘three points’ for the use of the letter ‘D’ shown at 14 , and again at 18 , because the numeric value of the 3 playing piece is 3. The ‘3’ playing piece FIG. 4 with the letters ‘DEF’ would count ‘three points’ again for use of the other letter ‘D’ shown at 14 and again at 18 , would count ‘three points’ because the numeric value of the 3 playing piece is 3. The ‘3’ playing piece FIG. 4 with the letters ‘DEF’ would count ‘three points’ once again for use of the letter ‘E’ shown at 15 , and again at 19 , because the numeric value of the 3 playing piece is 3. The ‘7’ playing piece FIG. 8 with the letters ‘PQRS’ would count ‘seven points’ for the use of the letter ‘R’ shown at 48 , and again at 53 , because 7 is the numeric value of the 7 playing piece. The ‘4’ playing piece FIG. 5 with the letters ‘GHI’ would count ‘four points’ for the use of the letter ‘I’ shown at 24 , and again at 28 , because 4 is the numeric value of the 4 playing piece. Again the ‘6’ playing piece FIG. 7 with the letters ‘MNO’ is counted ‘six points’ for the use of the letter ‘N’ shown at 39 , and again at 43 , because 6 is the numeric value of the 6 playing piece. And finally another ‘4’ playing piece FIG. 5 with the letters ‘GHI’ is counted ‘four points’ for the use of the letter ‘G’ shown at 22 and again at 26 because the numeric value of the 4 playing piece is 4.
[0083] The point count for the word ‘D’, ‘O’, ‘D’, ‘D’, ‘E’, ‘R’, ‘I’, ‘N’, ‘G’, ( FIG. 17 ) 97 , is the total of the numeric value of all the playing pieces used to form the word when added together, 3+6+3+3+3+7+4+6+4=39.
[0084] The playing pieces used to form the word ‘DODDERING’ ( FIG. 17 ) 97 , would be removed by the player who formed the said word ‘DODDERING’ ( FIG. 17 ) 97 , and said playing pieces would be retained by the player and the numerical count of the said playing pieces would be added to the said player' accumulated point count.
[0085] The points for the word would be added to the total score a player has accumulated and the winner of the game is declared when any player's score reaches a predetermined amount, 500 points, 1000 points, etc. | The present invention relates to a word game utilizing playing pieces designed to represent the keys of a telephone. The object of the game is to form words from these playing pieces. The present invention is different from other word games, in that the players can use all the playing pieces associated with the game and all the playing pieces are face-up. When playing previous word games, a player could only use the playing pieces dealt them or picked blindly from a box. The remaining playing pieces in the game remained hidden. This limited choice of letters in other games could be frustrating to a player. The present invention solves this dilemma, by allowing the players to use all the playing pieces and further, all the playing pieces are placed face-up for all the players to see and use when playing the game. | 0 |
TECHNICAL FIELD
This invention relates to an antenna that is capable of communicating with both a satellite system and a terrestrial system simultaneously. For example, the antenna may be conveniently used to receive signals broadcast by a direct broadcast satellite radio system or other high altitude broadcast system, in which radio or other signals signals are broadcast directly from one or more satellites to mobile vehicles on or near the ground and are also received by terrestrial repeaters, and then rebroadcast terrestrially to the mobile vehicles on or near the ground.
BACKGROUND OF THE INVENTION
Satellite-based direct broadcast systems are currently used to broadcast TV and radio signals to fixed ground stations which typically use a dish-shaped antenna to receive the signals. These systems have become very popular and soon this direct broadcast satellite technology is moving into the vehicular field. Vehicles pose a number of interesting challenges for this technology. First, in the case of terrestrial vehicles which can move on or near the surface of the earth, their movement means that the satellite signal will be occasionally blocked due to natural and man-made obstructions near which the vehicles travel. Since the satellite signals can be blocked by obstructions such as buildings and mountains, it has been proposed to transmit a second signal terrestrially which is locally provided by a repeater located to receive the satellite or high altitude broadcast signals without interference. See FIG. 1 . The direct broadcast satellite signals will arrive at the vehicle 1 with circular polarization from a location possibly high above the horizon due to the altitude of satellite 2 . In contrast, the repeated signals will arrive with vertical polarization from a repeater location 3 frequently near the horizon. Services which will be using such technology include possibly XM Radio and Sirius Radio. The entire frequency range allocated for XM Radio is 2.3325 to 2.345 GHz, and the entire frequency range allocated for Sirius Radio is 2.320 to 2.3325 GHz. This includes the satellite signal as well as the terrestrial signals from the repeaters. The total bandwidth required is much less than the bandwidth of the antenna disclosed herein.
Using conventional antenna technology, the antennas on a vehicle 1 to receive such signals would tend to be (i) numerous, (ii) unsightly and/or non-aerodynamic, (iii) possibly expensive, and (iv) would be difficult to point properly.
Similarly, as demand for existing wireless services grows and other new services continue to emerge, there will be an increasing need for still more antennas on vehicles. Existing antenna technology usually involves monopole or whip antennas that protrude from the surface of the vehicle. These antennas are typically narrow band, so to address a wide variety of communication systems, it is necessary to have numerous antennas positioned at various locations around the vehicle or to complicate the antenna design by making them multiband antennas. Furthermore, as data rates continue to increase, especially with 3G, Bluetooth, direct satellite radio broadcast, wireless Internet, and other such services, the need for antenna diversity will increase. This means that, if conventional antenna technology is followed, each individual vehicle would require multiple antennas each operating in different frequency bands, and/or with different polarizations and sensitive at different elevations relative to the horizon. Since vehicle design often dictated by styling, the presence of numerous protruding antennas will not be easily tolerated.
With the increasing number of wireless data access systems that will be incorporated into future vehicles, the number of antennas is also apt to increase. Many of these new data access systems will involve communication with a terrestrial network and also with a satellite or other high altitude transmitter. One such system is the previously mentioned direct broadcast satellite radio which will soon be operational. Transmitting systems aboard satellites typically broadcast in circular polarization so that the receiving mobile vehicle can be in any orientation with respect to the satellite, without the need to orient the vehicle's antenna. However, terrestrial broadcast systems typically use linear polarization for multi-path reasons, with vertical polarization being preferred for moving receiving stations for reasons well known in the art. Hence there is a need for antennas which can receive both circular polarization from the sky as well as vertical linear polarization near the horizon. These antennas exist, with the most common example being the helix antenna. One disadvantage of the helix antenna is that it protrudes one-quarter to one-half wavelength from the surface of the vehicle. Since current direct broadcast radio systems operate at 2.34 GHz, this results in an antenna that is several centimeters tall. The presence of an unsightly vertical antenna and/or a plurality of antennas, is often unacceptable from a vehicle styling point of view. Additionally, such antennas increase the aerodynamic drag of the automobile which is undesirable for energy-conservation reasons.
As a consequence, there is a need for an antenna that can perform as well as the vertical helix antenna, but has a low profile so that it can easily be adapted to conform to the roof over the passenger compartment of a vehicle, for example. The antenna should preferably be simple to manufacture using common materials. The antenna should be capable of receiving signals having circular polarization from orbiting satellites as well as signals having vertical linear polarization from terrestrial stations or repeaters.
In the design of antennas for low-angle radiation, one must consider each section of the radiating aperture and how it contributes to the overall radiation pattern. If one restricts the antenna design to one having a low-profile (for example, an antenna having a thickness much less than a quarter wavelength), there are only a few fundamental elements available. The most common low-profile antenna is the patch antenna, which is shown in FIG. 2 . The patch antenna consists of a metal shape 10 supported above a ground plane 12 and fed by a coaxial probe or other feed structure 14 . While the patch is a common low-profile antenna element, it is a poor choice for receiving (or transmitting) radiation at low angles. The reason for this is that the two edges 10 - 1 , 10 - 2 of the patch 10 both radiate and the interference between the two determines the overall radiation pattern of the antenna. In the direction normal to the ground plane 12 , the interference is constructive and the patch 10 provides significant gain in that direction. However, in a direction toward the horizon (e.g. in a direction parallel to the ground plane 12 ), the interference is destructive, and the patch produces very little radiation in that direction. One way to avoid this problem is to bring the two edges 10 - 1 , 10 - 2 of the patch closer together. However the effective overall length must remain one-half wavelength, so this requires that the patch be loaded with a high dielectric material. Furthermore due to the difficulties of achieving very high dielectric materials, there is a limit to how small a patch can be. Moreover, as the patch size is reduced, its bandwidth is also reduced.
FEATURES OF THE PRESENT INVENTION
A unique feature of the preferred embodiments of antenna disclosed herein is that it can receive both circularly polarized signals from a satellite in the sky as well as vertical linearly polarized signals from a terrestrial repeater. For the purpose of this specification and the claims herein, the term “satellite” is defined to mean an object which is in orbit about a second object or which is at a sufficiently high altitude above the second object to be considered to be at least airborne and “terrestrial” or “earth” is defined to mean on or near the surface of the second object.
An advantage of the present invention is it can achieve these properties with a form factor that is much thinner than one-quarter wavelength in height, and only slightly larger than one-half wavelength square in area. Indeed, the height of the antenna is preferably under 5% of a wavelength.
Since the antenna form factor is very important to vehicle designers, the small package permitted by this antenna is preferable to other competing designs which typically involve protruding antenna elements that are one-quarter wavelength in height or taller. For upcoming direct broadcast satellite radio systems, this translates into an antenna height of several millimeters (mm) for the antenna disclosed herein compared to several centimeters for competing designs.
The most significant antenna problem for a direct broadcast satellite signal receiving system as shown by FIG. 1 is communicating with a terrestrial network, because this involves receiving radiation from low angles, across the metal roof of a vehicle, in addition to receiving signals directly from satellites. Typically this requires that the antenna have significant height, or that it be elevated above the ground plane. The present antenna achieves this unique form factor by utilizing a slot antenna which has a good fundamental geometry for receiving at low angles. This is because a single slot antenna has only one radiating aperture, which is the thinnest possible aperture for a given wavelength. Furthermore, a slot antenna generates the greatest currents in the surrounding ground plane which are responsible for radiation to low angles.
The preferred embodiments of the present antenna involve a crossed pair of slots which are slightly detuned from one another in order to generate circular polarization for satellite reception. Thus, this antenna achieves good performance for both satellite reception and terrestrial reception, in a very thin design.
The present invention also provides a unique feed geometry, which allows the antenna to be fed at only one location, and represents a significant improvement over existing designs. Optionally it includes a radome structure, and the capability for active electronics such as amplifiers to be included in the antenna package.
The antenna described below achieves these features and other in a volume that is only a few millimeters tall. While the specific embodiment of this antenna discussed below is specifically designed for a direct broadcast satellite radio system, it can also be applied to other systems involving communication with both a satellite and a terrestrial network.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, the present invention provides a crossed slot antenna having a resonance frequency, the antenna comprising an electrically conductive structure defining a cavity therein; first and second slots formed in the electrically conductive structure, the slots having different lengths such that one slot has a resonance frequency above the center frequency of the antenna and such that the second slot has a resonance frequency below the center frequency of the antenna; and a common feed point which is arranged to couple the radio frequency signal from the slots to said common feed point.
In another aspect, the present invention provides a method of fabricating a crossed slot antenna comprising the steps of: (a) forming a cavity using a printed circuit board plated with metal on opposed surfaces; (b) etching two slots in the plated metal, the slots having slightly different lengths and intersecting each other at a 90 degree angle; and (c) forming a metal plated via in said printed circuit board, said metal plated via defining a common feed point for the slots.
In still another aspect, the present invention provides a method of fabricating a crossed slot antenna comprising: (a) forming a cavity structure having conductive material on opposed surfaces thereof; and (b) etching two slots in the conductive material, the slots having slightly different lengths and intersecting each other at approximately a 90 degree angle.
In another aspect, the present invention provides a crossed slot antenna comprising: (a) a cavity structure having conductive material on or forming opposed surfaces thereof; and (b) two slots in the conductive material, the slots having slightly different lengths and intersecting each other at or close to a 90 degree angle.
The present invention, in yet another aspect, provides a slot antenna having: (a) a cavity structure having conductive material on or forming opposed surfaces thereof; (b) at least one slot in the conductive material on a first surface of the cavity structure; and (c) a feed point for the slot, the feed point being disposed in and penetrating the cavity structure, the feed point being coupled to the first surface at a point thereon which is spaced from the slot.
In still yet another aspect, the present invention provides an antenna unit for mounting on a vehicle, the antenna unit comprising: (a) a support surface and a mounting device for mounting the antenna unit on the vehicle; (b) an antenna adapted for receiving circularly polarized radio frequency signals in at least directions oblique to the support surface; and (c) a protective cover for the antenna.
The present invention, in yet another aspect, provides a method of receiving circularly polarized radio frequency signals comprising the steps of: (a) providing a slot antenna having two slots which cross each other in a surface of a cavity structure; (d) varying the lengths of the slots so that the slots have different individual resonance frequencies; and (c) providing an antenna feed point on the surface which is spaced from both of the slots.
In a different aspect, the present invention also provides a method of designing a crossed slot antenna capable of receiving both circularly polarized radio frequency signals and linearly polarized radio frequency signals, the crossed slot antenna having a pair of crossed slots formed in a surface of a cavity structure. The method comprises the steps of:
(a) calculating an effective dielectric constant in the slots of the crossed slot antenna that is the average of dielectric constant of the cavity and that of any radome or other environment located above the slots;
(b) calculating an effective index of refraction n, where n={square root over (∈ average )} and where ∈ average =the dielectric constant calculated in step (a);
(c) determining an initially calculated average length of the slots of λ/2n where λ=the wavelength of a desired resonance frequency of the crossed slot antenna;
(d) calculating an inherent bandwidth of crossed slot antenna based on the formula 6πV/λ 3 where V=the volume of the cavity structure;
(e) determining an initially calculated length of each slot by adding, for one slot, and subtracting, for the other slot, a distance equal to one-half of the inherent bandwidth, expressed as a percentage, of the antenna;
(f) adjusting the initially calculated length of each slot by experiment.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic view of a direct broadcast satellite radio system;
FIG. 2 is a cross-section view of a patch antenna;
FIG. 3 is a cross section view of a slot antenna with a new feed structure;
FIG. 4 a is a plan view of a crossed slot antenna with the new feed structure;
FIG. 4 b is a cross section view through the crossed slot antenna of FIG. 4 a taken line 4 b;
FIG. 5 shows the radiation pattern of a specific embodiment of the crossed slot antenna in linear polarization;
FIG. 6 shows the radiation pattern of the same antenna in circular polarization;
FIGS. 7 a , 7 b and 7 c , depict an embodiment of the crossed slot antenna in an integrated antenna unit or package, FIG. 7 a being a top plan view, FIG. 7 b being a bottom view taken along line 7 b shown in FIG. 7 c and FIG. 7 c being a cross section view taken along line 7 c shown in FIGS. 7 a and 7 b;
FIG. 7 d is a circuit diagram of a antenna switch with power amplifier and preamplifier for connecting a crossed slot antenna to a transmitter/receiver;
FIG. 7 e is a circuit diagram of a circuit which may be used to connect a crossed slot antenna to direct broadcast receivers having dual inputs;
FIG. 8 shows the use of the integrated unit embodiment of a crossed slot antenna as disclosed herein in a direct broadcast satellite radio system;
FIG. 9 shows an embodiment of a crossed slot antenna in which the cavity assumes a dome shape;
FIGS. 10 a and 10 b depict a parasitic ring structure which can be optionally used to improve low angle performance of the crossed slot antenna disclosed herein;
FIGS. 10 c and 10 d depict a pedestal structure which can be optionally used to improve low angle performance of the crossed slot antenna disclosed herein;
FIG. 11 is a plan view of a crossed slot antenna with bulbus or enlarged slot ends.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 is a cross sectional view of a slot antenna. The slot antenna shown in FIG. 3 has only a single radiating edge 16 in a given linear direction. This provides much greater radiation to low angles because there is no second edge in the same linear direction to create destructive interference. From one viewpoint, the radiation is diffracting through the aperture of the antenna, and the narrowest possible aperture will provide the broadest possible diffraction pattern. From a surface wave viewpoint, the currents in the slot antenna exist only in the surrounding ground plane. Hence, this antenna should have the greatest possible coupling to surface waves that can then radiate away from the antenna at low angles. FIG. 3 also shows a coaxial cable 14 probe feed 18 ; however this is not conventional for slot antennas and embodies one aspect of this invention. Another advantage of the slot antenna is that it contains a resonant cavity 20 that surrounds the backside of the antenna. In general, the bandwidth of this antenna will be determined by the volume of this cavity 20 , which does not need to contain a high dielectric material as does the patch antenna of FIG. 2 . Indeed, air would suffice as the dielectric material. However, the preferred dielectric material is a material which can function as a printed circuit board, since that choice simplifies the manufacture of the antenna.
Another advantage of the cavity is that it directs all of the radiation toward the hemisphere above the vehicle and prevents radiation from radiating into the vehicle, while allowing the antenna to sit directly on the metal roof 90 (see FIG. 7 c ) of the vehicle.
The slot antenna performs well at radiating toward low angles in vertical linear polarization along the E-plane of the antenna. In order to receive (or to generate) circularly polarized RF radiation towards the sky while enjoying a similar antenna gain for vertical linear polarization toward the horizon, the slot antenna is provided with two orthogonal slots 16 - 1 and 16 - 2 , as is shown in FIGS. 4 a and 4 b . The two orthogonal slots 16 - 1 , 16 - 2 are tuned to slightly different frequencies and cross each other at a 90 degree angle. Also, the two slots 16 - 1 and 16 - 2 are centered on each other. Because the slots resonate at slightly different frequencies, they experience a phase shift with respect to one another when driven between their two resonant frequencies. This phase shift is chosen to be 90 degrees for the generation of circular polarization, and is determined by the relative lengths of the two slots. They are driven by a single offset probe feed at point 21 , which passes through the cavity 20 at point 21 along (or close to) a line A which is rotated 45 degrees from each of the two slots 16 - 1 and 16 - 2 . The input impedance may be adjusted by varying the feed point along line A. Feeding the antenna closer to a comer C on the peripheral edge 22 of the cavity 20 will result in a lower input impedance, while feeding it nearer the center B of the cavity 20 will result in a greater input impedance. For a Teflon (poly tetra fluoro ethelene having a dielectric constant of 2.2) filled cavity 20 , a feed point 21 that is located one-quarter of the way from the comer C of the cavity 20 results in an input impedance that is close to 50 ohms.
The cavity structure 22 , 24 can be built using printed circuit board technology. In such an embodiment, the offset feed point 21 is preferably formed by plating a via 27 and the ground plane 26 on the back side of the cavity is preferably etched away to expose an annular region 28 of the dielectric material in the cavity. While a coaxial cable 14 is depicted as directly coupling to the plated via 27 and with the shield of the coaxial cable 14 being connected to the ground plane adjacent the annular opening around the annular region 28 , in a preferred embodiment, the feed point 21 is connected to circuity on another circuit board.
The cavity 20 is depicted as being square-shaped in plan view in FIG. 4 a ; however, the shape of cavity 20 is not important as other shapes are possible including circles, diamonds, or anything in between. The single offset feed point 21 is an important aspect of this invention, as well as its combination with a pair of orthogonal, slightly detuned slots 16 - 1 , 16 - 2 for the generation and/or reception of circular radio frequency polarization. Another important aspect of this invention is the use of such a crossed slot 16 - 1 , 16 - 2 antenna for the reception of both circular polarization from above and vertical linear polarization from the horizon. In such a case the major plane of the antenna is oriented to be (ideally) parallel to the major surface of the roof or other upward facing surface of a vehicle carrying the antenna. The major plane of the antenna is thereby typically oriented parallel or nearly parallel to the terrestrial surface most of the time as the vehicle moves about on or near the terrestrial surface.
One specific embodiment of a crossed slot antenna of the present invention is an antenna designed to operate at 2.34 GHz. The cavity 20 of this specific embodiment has a square shape in plan view and provided by a metal cavity 22 , 24 filled with a material, preferably Teflon which has a dielectric constant of 2.2. The cavity depth t is 3.175 mm (inside thickness, not including the metal cover 24 ) and the cavity measures 63 mm on each edge. The two orthogonal slots 16 - 1 and 16 - 2 formed in the top surface 24 of the cavity 20 are 51 mm and 54 mm long, respectively, and the feed point 21 is offset from the center B of the cavity 20 by 17 mm along the directions of both slots. The slots are 1 mm wide in this specific embodiment. The width of the slots is not as important as some of the other dimensions, such as the lengths of the slots, which is the most critical dimension. The metal 22 , 24 forming the exterior of the cavity 20 is preferably about 50 microns thick (the actual thickness is not critical). Copper is the preferred metal of the cavity 20 because of its high electrical conductivity. Often the copper is coated with gold or tin (depending on the cost allowed) to provide corrosion protection and solderability. For our experimental results reported herein, bare copper was used for the cavity 20 . This specific embodiment provided an operating frequency of 2.34 GHz, and a bandwidth of about 10% which is wider than needed for the direct broadcast satellite services previously mentioned. This specific embodiment was tested to produce the data plots discussed below with reference to FIGS. 5 and 6; however, this data and this specific embodiment it is provided for the purposes of example only. In general, the cavity 20 size and shape may be changed. The lengths of the slots 16 - 1 , 16 - 2 can be tuned as is described below.
For the frequency of interest of 2.34 Ghz, the wavelength λ is equal to 128 mm. Since the thickness t of the slot antenna of this specific embodiment is only 3.175 mm, that means that the height of the slots above the ground plane 26 is only about 2.5% of a wavelength λ at the frequency at which this antenna operates. If desired, the crossed slot antenna can be thicker or thinner depending on the desired bandwidth of the antenna.
The bandwidth of the antenna can be made arbitrarily narrow by making the cavity 20 thinner, but for a practical antenna there must be some allowance for manufacturing errors, so it is unwise to use an antenna with very narrow bandwidth even if the application does not require that much bandwidth, such as is the case with direct broadcast satellite radio services discussed above. Thus, the cavity 20 may well be thicker than needed for a particular application.
Assuming a bandwidth equal to about 12% of the frequency of interest and an operating frequency of 2.34 GHz, the height of the slots above the ground plane is only about 2.5% of one wavelength λ at that frequency. As a result, the crossed slot antenna of the present invention can be quite thin and still have a reasonably wide bandwidth. Crossed slot antennas having thicknesses less than 2.5% a wavelength λ of the frequency at which the antenna operates are very realistic. Given the fact that a prior art antenna might be 25% of a wavelength λ high, this crossed-slot antenna provides a significant improvement of about an order of magnitude in antenna height reduction (at this frequency of 2.34 GHz) and additionally provides sensitivity to both circular and linear radio frequency signal polarizations for communication with both satellites and terrestrial stations.
The following steps may be used as a guideline for the design of a crossed slot antenna. Since roughly half of the electric field in the slot exists inside the cavity 20 , the effective dielectric constant in the slot is the average of that of the cavity 20 and that of any radome 120 or other environment located above the slots (see FIG. 7 c ). For the case of no radome, or a large hollow radome, the dielectric constant of the adjacent environment is equal to 1 and thus the effective index of refraction is then n={square root over ((∈+1)/2)} where ∈=the dielectric constant of the material in the cavity 20 . The slots 16 - 1 and 16 - 2 should then have an average length of λ/2n. For the specific embodiment discussed above where the crossed slot antenna operates at a frequency of 2.34 GHz, this average length is about 51 mm. One slot should be slightly shorter than this average value (so that it is tuned to a frequency slightly above 2.34 Ghz in this specific embodiment) and the other should be slightly longer (so that it is tuned to a frequency slightly below 2.34 GHz in this specific embodiment). The lengths of the two slots 16 - 1 and 16 - 2 should differ by approximately one-half of the inherent bandwidth (expressed as a percentage) of the antenna. The inherent bandwidth of the antenna is determined by the cavity volume, V. The bandwidth of a cavity-backed slot antenna is roughly 6πV/λ 3 , which is equal to 3πt/2λ for a square cavity having sides with a length of roughly one-half a wavelength (≈λ/2) for the frequency of interest and having a thickness t. For the described specific embodiment, this gives a bandwidth of about 12%. Thus, the two slots 16 - 1 , 16 - 2 should differ in length by about 6%, or about 3 mm. Based on this analysis, one would be lead to specify slot lengths of 51+1.5 or 52.5 mm and 51−1.5 or 49.5 mm. Some fine-tuning may be required, and empirically it was determined that slot lengths of 51 mm and 54 mm seem to work well for this specific embodiment of an antenna resonant at 2.34 GHz. The described procedure for calculating the slot lengths is not exact, but experimental testing to fine tune the antenna typically produces results which differ from the calculated values by only a few percent. As such, this procedure provides a useful guide for determining starting points for lengths of the slots for the crossed slot antenna described herein. The starting points are then adjusted by experiment. The location of the feed point and the other parameters can similarly be adjusted by experiment.
For the case of a circular cavity, or a cavity having another shape, the volume should be maintained roughly the same as the square case. In any event, the feed point 21 should be preferably located on (or very close to—see the discussion below) a line A that is at 45 degrees to both of the slots 16 - 1 , 16 - 2 . The input impedance may be adjusted by varying the position of the feed point 21 along line A. Feed points near the peripheral edge 22 of the cavity will have lower input impedance and feed points near the center B of the cavity will have higher input impedance. The optimum location may be determined by experiment, but a distance roughly one-quarter cavity length from the edge on line A was found to be acceptable for the specific embodiment described above. If the feed point is located off line A, then it is believed that the two slots would usually have different input impedances which might be undesirable in most applications. However, the feed point 21 might be placed off the 45 degree line A slightly to obtain a better input impedance consistency between the two slots 16 - 1 and 16 - 2 in recognition of the fact that they have slightly different lengths and therefore the feed point might be located slightly different distances from the respective slots in compensation therefore. Thus the feed point 21 might be located close to line A but displaced off it slightly to provide a better input impedance match to both antennas.
The width of a slot 16 is much thinner than its length, but the absolute width is not very important. In the specific embodiment disclosed, the width was arbitrarily selected to be 1 mm, a dimension which seemed to work well.
Antennas with the described crossed slots 16 - 1 and 16 - 2 produce circular polarization because the lengths of the two slots are slightly different and thus the two slots have slightly different resonance frequencies. If the slots are driven (either by a transmitted signal or by a received signal) between their two resonance frequencies, then one slot will slightly lead the applied signal, and the other slot will slightly lag the applied signal, depending on the frequency of the applied signal with respect to the natural resonance frequency of each antenna slot. In this antenna design, the lengths of each antenna slot 16 - 1 and 16 - 2 are selected so that the phase difference produced by this lead and lag is preferably exactly 90 degrees total, thereby radiating (or receiving) circular polarization. If the phase difference is not exactly 90 degrees, then the antenna will not have exactly true circular polarization.
FIG. 5 shows the radiation pattern of the previously described specific embodiment of the crossed slot antenna in linear polarization. The radiation pattern of the vertical component is biased toward the horizon, and the crossed slot antenna achieves significant gain at low angles. FIG. 6 shows the radiation pattern of the same antenna in circular polarization. The antenna achieves significant gain in left-hand circular polarization over most of the upper hemisphere. Furthermore, right-hand circular polarization is significantly suppressed at high angles. An antenna designed for right-hand circular polarization would be obtained by making the antenna a mirror image of the antenna depicted by FIGS. 4 a and 4 b.
Having described the basic structure of the cavity-backed crossed-slot antenna with offset probe feed, an embodiment of the crossed slot antenna in the form of an integrated antenna unit 100 which can be easily installed on a vehicle will now be described. The integrated antenna unit or package 100 is shown in FIGS. 7 a , 7 b and 7 c . The unit 100 preferably includes a crossed slot antenna with offset probe feed as previously described, a RF preamplifier 102 and bias circuit 104 . The preamplifier 102 is preferably of a low noise type. The unit 100 also preferably includes a cover 108 that serves to connect the antenna's ground plane 26 (see FIG. 4 b ) to the surrounding metal 90 of the vehicle, as well as to protect the internal circuitry, provide RF shielding and to act as a support surface. The unit 100 also preferably includes a bracket 112 to aid in attachment to the vehicle 90 , a cable 114 , an RF connector 116 , and a radome 120 to protect the entire structure 100 from the environment, to aid in styling, and to provide a more aerodynamic shape.
The antenna in the structure 100 has been described previously with respect to FIGS. 4 a and 4 b as including a crossed slot antenna, a cavity 20 (where the two slots 16 - 1 , 16 - 2 are slightly detuned from one another to provide circular polarization), and a single offset probe feed 21 . In order to overcome cable losses before the radio receiver, and the associated noise gain, it is desirable to include an integrated radio frequency preamplifier 102 in the antenna package 100 . The same cable 114 through which the RF signal is drawn (or supplied) may supply a DC bias for this amplifier. This is accomplished using an appropriate bias circuit 104 consisting of an RF choke 104 a and a DC blocking capacitor 104 b in the case of a receiving embodiment. The circuit has a pad 29 for mating with the antenna feed point 21 . This circuit may be built as an additional layer of circuit board material 106 on the crossed slot antenna cavity structure 24 , which itself can be fabricated as a printed circuit board having an upper metal surface and a lower metal surface, with the slots 16 - 1 , 16 - 2 being formed in the upper metal surface thereof and the lower metal surface thereof acting as the ground plane 26 . Those skilled in the art of RF receiver design may well choose to include other RF components such as filters and multiple-stage amplifiers. The circuit lines shown in FIG. 7 b on circuit board 106 are typically microstrip lines.
The cover 110 shown in FIG. 7 c is a metal plate that may be made using metal stamping, which is placed over the circuitry and electrically connected to the antenna ground. The purpose of the metal cover is to provide RF shielding to the circuitry, and also to extend the antenna ground so that it is in close proximity to the metal exterior of the vehicle. This cover 110 may also be shaped to conform to the vehicle surface. A bracket 112 for attachment to the vehicle may be a scored or threaded metal cylinder upon which a snap ring or nut (not shown) may be applied to retain unit 100 in place on the vehicle. The bracket 112 is inserted through a hole in the vehicle exterior 90 , and the matching ring or nut is applied from the other side. An antenna cable 114 extends through the circular bracket and the hole in the vehicle, and is terminated with a RF connector 116 .
The unit 100 includes a radome structure 120 which surrounds the top of the unit 100 and provides protection from the environment, as well as helping aerodynamic and styling considerations. The radome 120 may either be solid dielectric, such as injection molded plastic, or it may be a hollow dielectric shell. It may also be painted to match the vehicle exterior.
Circuits 102 and 104 are intended to be used in a receiver embodiment; however, the crossed slot antenna can be used with both receivers and/or transmitters. The circuitry 104 - 1 of FIG. 7 d can be used in place of circuits 102 and 104 in a transmitter/receiver embodiment. A power amplifier 102 b is used in a transmit mode and is labeled PA. A low noise preamplifier 102 a is used in a receive mode and is labeled LNA. Switches 103 a , 103 b are used to isolate these components during transmit/receive cycles. A DC blocking capacitor 104 b and a RF choke 104 a are used to isolate the DC power and the RF signals. Additional switches may be used to turn the amplifiers on or off, as needed. Microstrip lines are preferably used to interconnect these components as shown in FIG. 7 d.
A microstrip is a popular transmission line for RF circuits. However, to feed the crossed slot antenna directly, a microstrip internal to the cavity would require an additional circuit layer inside the cavity 20 , which would add cost. Given the additional cost, the techniques shown in the figures and described herein are presently preferred. However, some practicing the present invention may prefer to use a microstrip feed. When used in conjunction with an amplifier circuit, a microstrip line would naturally be used for the amplifier. However, in FIG. 7 b the amplifier circuit 104 is external to the cavity and feeds the antenna by way of the probe feed 21 described herein. This is also true for the alternative circuit designs shown in FIGS. 7 d and 7 e.
It is understood that others are having difficulty in developing a single antenna structure which can receive both the satellite and the terrestrial signal with different polarizations and that they are opting for two separate antennas. Such antenna system will have two separate outputs, one for the satellite signal and another for the terrestrial signal. If this becomes part of the industry specifications for direct broadcast satellite radio receivers, then circuits 102 and 104 may need to have two separate outputs—one for the satellite signal and one for the terrestrial signal—in order to conveniently connect to such receivers. One possible modification to circuits 102 and 104 is circuit 104 - 2 , shown in FIG. 7 e , which can be used to connect the crossed slot antenna disclosed herein to such dual input receivers. This circuit 104 - 2 uses two low noise preamplifiers 102 a and 102 c labeled LNA 1 and LNA 2 , each of which is connected to a respective output 1 and 2 . Those two outputs 1 , 2 are connected by suitable coaxial cables to the aforementioned dual input receiver.
FIG. 8 is similar to FIG. 1 but shows the use of this integrated antenna unit 100 on a vehicle 1 to receive direct broadcast satellite communications. The signals to be received originate at an orbiting satellite 2 and are transmitted to earth for reception by a receivers 125 in moving vehicles such as vehicle 1 . The receiver 125 is mounted in the vehicle and is connected to antenna 100 . A plurality of terrestrial base stations 3 receive the signals from the transmitter aboard satellite 2 and rebroadcast them at a different frequency. The frequencies of the direct broadcast signals from the satellite(s) and from the repeater(s) should fall within the bandwidth of the crossed slot antenna disclosed herein. The satellite broadcasts in circular polarization and the terrestrial repeater broadcasts in vertical linear polarization, but both are received by the same antenna unit 100 on the vehicle 1 . The crossed slot antenna disclosed herein is ideal for this application because it is capable of receiving circular polarization from high angles and vertical linear polarization from low angles and can easily have sufficient bandwidth to receive both the circularly polarized signals and the vertically polarized signals.
Additional variations of the crossed slot antenna will now be described FIG. 9 shows one aspect of this invention in which the cavity 20 forms a dome shape. This has the advantage of eliminating the curved radome 120 , while maximizing the cavity volume for the smallest possible volume on the exterior of the vehicle. This embodiment may be built by forming the cavity 20 using injection molding of plastic and then metallizing the cavity 20 with a layer of metal 24 and etching the slots 16 - 1 , 16 - 2 into it. A thin dielectric cover may then be applied to the entire structure to protect the slots from the environment. The slots 16 - 2 , 16 - 2 , when viewed in a plan view (similar to FIG. 10 a ) would appear to cross each other at a ninety degree angle.
The dome shaped structure is preferably formed by molding a suitable dielectric material in to dome shape depicted in FIG. 9 and then plating it with a conductive material such as copper.
To further reduce the volume on the exterior of the vehicle, the electronics may be included in a separate package, which is snapped or screwed onto the antenna on the interior side of the vehicle. By adding curvature and thickness to the crossed slot antenna, as is done according to the embodiment of FIG. 9, one may also improve its low angle radiation performance.
There are various other methods that may be employed to improved low angle performance. One of these is shown in FIGS. 10 a and 10 b . This is the use of an additional resonance structure 200 adjacent to the main antenna which is excited as a parasitic element. A resonant ring structure 200 shown in FIGS. 10 a and 10 b , which tends to direct the radiation from the antenna towards the horizon much like the parasitic directors of a Yagi-Uda antenna. Other parasitic structures may be employed for the same purpose, such as a region of high dielectric surrounding the main antenna, or other parasitic cavities or resonators.
FIGS. 10 a and 10 b show a parasitic director which is provided by the resonant ring structure 200 . It is preferably made from metal and the metal ring 200 extends from the top edge of the slot antenna and overhangs the bottom surface 26 .
FIGS. 10 c and 10 d depict yet another technique for improving low angle performance of the disclosed crossed slot antenna to vertically polarized signals. This embodiment is related to the parasitic ring geometry of FIGS. 10 a and 10 b , except that the antenna is raised by a small amount above ground plane 90 on a pedestal 30 , which may contain preamplifier circuits such as circuits 104 , 104 - 1 , or 104 - 2 previously described. The overhang region, as well as the slight increase in height, tends to increase the radiation toward the horizon. The embodiment of FIGS. 10 a and 10 b and the embodiment of FIGS. 10 c and 10 d both show a parasitic director. In the embodiment of FIGS. 10 a and 10 b the parasitic director is formed by an overhanging ledge of metal 200 . In the embodiment of FIGS. 10 c and 10 d the parasitic director is formed by the cavity itself overhanging the smaller diameter pedestal 30 at numeral 200 .
FIG. 11 shows a feature from a prior art patent (U.S. Pat. No. 5,581,266). This patent suggests the use of a bulb-like expansion 16 - 5 at the ends of the slots to improve the antenna bandwidth. The patent also suggests the use of vias to form the cavity which feature could be adapted for use with the present invention.
In the embodiments utilizing cross slots, the slots are defined as crossing each other at a ninety degree angle. Of course, the angle can be varied somewhat, but such variation is not preferred since it should tend to degrade the ability of the antenna to receive (or transmit) circularly polarized radio frequency signals. As such, while it is preferred that the slots cross each other at exactly a ninety degree angle, they should certainly cross each other within a range of 85 to 95 degrees.
Having described the invention in connection with a number of embodiments thereof, modification will now likely suggest itself to those skilled in the art. As such the invention is not to be limited to the disclosed embodiment expect as required by the appended claims. | A crossed slot antenna, a method of fabricating same and a method of designing same. The antenna includes a cavity structure having conductive material on opposed surfaces thereof; and two slots in said conductive material, the slots having slightly different lengths and intersecting each other at or close to a 90 degree angle. | 7 |
TECHNICAL FIELD
The present invention relates to the field of tunable liquid crystal optical devices.
GENERAL DESCRIPTION
The refractive index of a material is usually proportional to the density of the material. Accordingly, since most materials expand upon heating, the refractive index of most materials decreases with increasing temperature. This is not the case for specific ordered materials, such as oriented liquid crystals (LC), since the ordering of LC molecules can drastically change their optical properties. Thus, the extraordinary polarized light will usually see different refractive index n e compared to the ordinary polarized light, which will see ordinary refractive index n o . Consequently, the degradation of that ordering due to the heat may also generate corresponding modulations of its refractive index. In the case of positive anisotropy (n e >n o ) the heat may reduce the n e but increase n o . In fact, different LCs will have different behaviors in different temperature ranges (e.g., in some cases, both n e and n o may be decreasing with increasing temperature, etc.). The corresponding refractive index variations (with temperature) in those kinds of materials may be very strong. Differentially heating a uniform body of material will lead to a gradient in the refractive index of the material corresponding to the temperature gradient in the material. More specifically, in the above mentioned example, the refractive index n e will be lowest where the greatest increase in temperature occurs.
It follows that, for materials with temperature sensitive optical properties, such as liquid crystals, a lensing effect can be created by taking advantage of the temperature dependence of the refractive index of the material.
FIG. 1 illustrates a typical example of the temperature dependence of the refractive index (n) of a liquid crystal material. The experimental results reveal the material's dn/dT, which is higher for some materials than for others.
FIG. 2 illustrates an example of the temperature-dependent refractive indices for two different liquid crystal materials. In this case, both materials are high temperature-gradient refractive index (dn/dT) liquid crystal materials. The experimental results reveal that, for such materials, an important change in refractive index can be obtained for a relatively small change in temperature.
The following are rough estimations of temperature dependent optical power, taking for example certain predefined material parameters:
Material Data:
Going from room temperature T to isotropic phase, we can change the n by almost Δn=0.1 Let us suppose we use the half of the above mentioned range, the slope becomes: 0.05/20° C.=2.5×10 −3 /° C. LC film thickness is h=50 um
Optical Basics:
Optical Power (OP)=2 (Δn h)/r 2
We need to have 10 diopters (OP=1/0.1 m=1/100 mm).
For r=0.87 mm, between 40 and 80° C. (giving a total of Δn=40° C.×2.5×10 −3 /° C.≈0.1), OP=2×0.1×0.05 mm/0.757 mm 2 =0.0132/mm=13 Diopters.
Thus the non uniform heating of a high dn/dT material in order to produce a lensing effect could be a cost-effective way of producing tunable lenses.
SUMMARY
The present invention provides a novel heating system for generating a thermally actuated optical lens, and the use of this heating system to create a tunable liquid crystal lens, as well as modules and devices made thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by way of the following detailed description of embodiments of the invention with reference to the appended drawings, in which:
FIG. 1 illustrates a prior art example of the temperature-dependent refractive index of a liquid crystal material;
FIG. 2 illustrates a prior art example of the temperature-dependent refractive indices of high do/dT liquid crystal materials;
FIG. 3 is a schematic representation of a novel liquid crystal (LC) lens configuration, according to a non-limiting example of implementation of the present invention;
FIG. 4 illustrates the differential temperature gradient across the lens aperture, for the LC lens configuration shown in FIG. 3 ;
FIGS. 5 to 7 illustrate variant homeotropically aligned LC providing a positive tunable lens configurations in the case of positive optical anisotropy, according to non-limiting examples of implementation of the present invention, in which the liquid crystal cell director is in the normal direction to the substrates.
FIGS. 8 to 9 schematically illustrate alternative variants of LC lens configurations, according to non-limiting examples of implementation of the present invention.
DETAILED DESCRIPTION
The present invention is directed to a novel heating system for generating a thermally actuated optical lens, and the use of this heating system to create a tunable liquid crystal lens, as well as modules and devices made thereof.
In order to have differential refractive index modulation and corresponding lensing effect when heating a liquid crystal body of material arranged in a lens configuration, we need:
1—Appropriate thermal conduction and diffusion across the lens aperture; and 2—different temperatures across the aperture.
FIG. 3 is a schematic representation of a liquid crystal (LC) lens configuration, according to an example of implementation of the present invention. A planar layer of liquid crystal is arranged on top of a bottom substrate, and is itself coated with a top substrate. An optically transparent, electrically controlled local heater is arranged between the LC layer and the bottom substrate, positioned centrally with respect to the LC layer. A ring-shaped thermal radiator is arranged on top of the top substrate, proximate to a periphery of the LC layer. This thermal radiator, which may be implemented by any appropriate heat-radiating material (e.g. metal), act as a heat sink for cooling the top substrate and the LC layer.
FIG. 4 illustrates an example of the variable temperature gradient across the LC lens that can be achieved by heating and cooling the substrate-coated LC layer with the heating system of FIG. 3 . As shown, a peak temperature T C is obtained at the center of the lens aperture, while the temperature of the material at the border, T B , is significantly lower as a result of the cooling by the thermal radiator.
Advantageously, the use of an annular thermal radiator to cool a portion of the substrate-coated LC layer, in combination with an electrically controllable local heater for applying heat directly to the center of the LC layer, provides for an improved control over the optical properties of the LC lens.
FIGS. 5 to 9 are schematic representations of variant LC lens configurations using the novel heating system described above, according to non-limiting examples of implementation of the present invention.
In FIG. 5 , a patterned fixed conductive structure, formed of a fixed conductor electrode and an integrated, electrically-controllable heater, is arranged between the bottom substrate and the LC layer. This conductive structure may perform multiple functions, including heating of the electrode and thus of the LC material, as well as a thermal sensing function (to help with the heating function, etc). Advantageously, this configuration would not require two cross layers of LC to handle light polarization.
In FIG. 6 , an additional top transparent electrode (e.g. ITO layer) is added to the lens configuration of FIG. 5 . The electrode system formed of the top and bottom electrodes is operative to generate an electric field acting on the LC layer, in response to an applied drive signal. Advantageously, this configuration would not require two cross layers of LC to handle polarization. Furthermore, this configuration would allow a double control of the optical properties of the lens, notably electric and thermal control. In a specific example, for an initial planar alignment of the LC molecules and no electric field, a negative tunability can be achieved (by heating the electrode from the center). In another specific example, for an initial planar alignment of the LC molecules and a strong electric field (vertical alignment), positive tunability can be achieved.
In FIG. 7 , there is shown a simplified fabrication of the LC lens, without the alignment layers. In this case, the centrally-positioned local heater is separate from the bottom electrode (which is optional) and can itself perform multiple functions, including heating of the electrode and a thermal sensing function.
In FIG. 8 , the patterned fixed conductive structure of FIG. 5 is sandwiched between a pair of cross layers of LC and provides all of the above-described advantages. This configuration may provide useful modes of manipulation of light depending upon its polarization.
In FIG. 9 , the LC cross layer lens configuration of FIG. 8 is adapted to include top and bottom electrodes. Accordingly, the two cross oriented LC layers compensate for the light polarization dependency and the patterned fixed conductive structure combined with the electrode structure provide for a double control (electric and thermal) of the lens optical properties. In a specific example, for an initial planar alignment of the LC molecules and no electric field, a negative tunability can be achieved (by heating the electrode from the center). In another specific example, for an initial planar alignment of the LC molecules and a strong electric field (vertical alignment), positive tunability can be achieved. The choice of the type of the liquid crystal (particularly of the temperature dependence of its refractive indexes n e and n o ) and the control zone of temperature changes will provide very rich control possibilities.
It is important to note that the above-described embodiments of the present invention have been presented for illustration purposes but that additional variants and modification are possible and should not be excluded from the scope of the present invention.
It should also be appreciated by the reader that various optical devices can be developed using the device described above. | A variable optical device for controlling the propagation of light has a body of liquid crystal optical material with a center and a periphery, a heating system including an electrically controllable heat source and a thermal radiator arranged at the periphery for cooling a portion of the body of material. The heating system is operative to generate a spatially modulated temperature gradient and to provide a desired light propagation behavior. | 6 |
BACKGROUND OF THE INVENTION
Remote control transmitters, particularly for the transmission of Radio Frequency (R F) signals, are commonly used for items such as garage door openers, vehicle security systems, television controllers, and other consumer appliances. As presently produced, these transmitters are somewhat bulky and large and cannot be comfortably carried in a pocket or purse. In many cases, this bulk is due to the means employed within the transmitter, such as dip switches, to select the encoded signal the transmitter broadcasts. An example of an R F transmitter of the type referred to is a transmitter described in our U.S. Pat. No. 4,754,255.
OBJECTS OF THE INVENTION
It is the principal object of the present invention to provide a transmitter which is extremely thin and small so that it can be comfortably carried in a person's pocket or purse and in addition, be connected to an item such as a key ring, providing the minimum difficulties to the user in carrying and using the transmitter.
A further object of the invention is to provide a transmitter for use in transmitting a predetermined signal (R F, infrared, ultrasonic, etc.) to a receiver for any particular purpose that is desired by the operator, such as a garage door opener or a vehicle security alarm system.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the invention will be clear from a description of the invention and the enclosed drawings in which:
FIG. 1 is an exploded view of the transmitter of the present invention, and;
FIG. 2 is an exploded view of the internal elements of the transmitter.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is shown the bottom casing 10 of the transmitter housing with a hole 12 for insertion of a locking device such as a screw 14 which fits into a female receiver 16 contained in the top of the casing 18.
The top casing 18 has a receiving area 20 for the placement of a battery or batteries 22 which provide power to operate the device.
Alignment means such as one or more guideposts 24 are contained in the top casing 18 and provide means to align a first element 30, an insulator 42, and a printed circuit board 52, as they are assembled into the transmitter housing. A slot 28 is provided in the top casing 18 through which the user can press a button or buttons 40 which activate the transmitter.
Contained within the bottom casing 10 and the top casing 18 are the three elements as stated. In this description the first element 30 contains a plurality of rubber protrusions 32, plus one or more buttons 40 which, when depressed by the operator, activate the transmitter. The protrusions apply pressure to the PC board at area 62 (FIG. 2) when the transmitter is assembled. The buttons 40 and protrusions 32 have an electrically conductive coating thereon.
Instead of the first element 30 having protrusions, the first element 30 may be flat in the area where the protrusions 32 are located, having just the conductive coating and buttons 40, and instead, the top casing 18 may have the protrusions in the same alignment position, to apply pressure, when the transmitter is assembled, through the first element 30, at the surface area 32, to the PC board at area 62.
The first element 30 is a thin pad composed of silicon rubber or other flexible non-conductive material. The electrically conductive coating can be a conductive ink applied to the surface of or can be a conductive substance, such as carbon, impregnated into the protrusions or surface area 32 and the buttons 40. The use of an electrically conductive coating is well-known in the art.
Element 30 has holes 34 and 36 for alignment on guide posts 24 and a second guidepost hidden by receiver 16. A hole 38 is provided in the pad for the accommodation of an LED, if desired, which would give an indication that the transmitter is transmitting when the button(s) 40 are depressed.
A middle element comprising insulator 42 containing alignment holes 44 and 46 is placed over the first element 30 containing the conductive rubber protrusions 32. The insulator 42 contains a plurality of circular areas 48 which are designed to be easily and selectively punched out, either at the time of manufacture or later by the user, to create a specific pattern of holes through the insulator 42. While the areas are described as circular, they, of course, can be of any shape. Insulator 42 can be made of any convenient non-conductive material such as Mylar, paper, plastic, or any other non-conductive material. A slot 50 is also provided in insulator 42 so that button(s) 40 extending through both the transmitter casing 28 and the insulator 42 can activate the electronics contained on the PC board 52. Hole 45 is for an LED, if desired.
The third element 52 comprising the PC board is placed over the insulator 42. The PC board 52 has holes 54 and 55 for alignment on posts 24. Hole 56 is provided for the possible accommodation of an LED. PC board 52 comprises an optional adjustment component 58 which is a means to adjust the operating frequency upon which the encoded signal is broadcast, if desired.
As is shown more clearly in FIG. 2, PC board 52 on the side facing the insulator 42 has a series of contacts 62 which are adapted to come into continuous electrical contact with the conductive protrusions 32 only at those locations corresponding to those circular areas 48 that have been punched out of the insulator 42, leaving holes. Because the three elements 30, 42, and 52 are pressed together in the transmitter when they are assembled into the transmitter casing 10 and 18, the conductive protrusions 32 extend only through the holes which are created when one or more of the circular areas 48 are punched out. Those specific protrusions physically contact PC board 52 making electrical contact with contacts 62. By determining which pattern of circular areas 48 are punched out in insulator 42, the transmitter can be programmed to emit a uniquely encoded signal so that the transmitter may be personalized for the owner and user.
PC board 52 contains an integrated circuit area 60 which is adapted to generate a unique signal established by the pattern of circular area 48 punched out as described above. When button(s) 40 are depressed, electrical contact is established between a plurality of circuit traces 64 contained on PC board 52, activating the transmitter to broadcast the unique signal. Circuit traces 64 are comprised of a geometric pattern of conductive material which constitute the printed circuit on PC board 52.
The particular encoded signal, which is transmitted by the transmitter once it is programmed, assembled, and activated, is recognized only by a receiver programmed to receive and decode that uniquely encoded signal. The receiving of such a signal is well-known in the art as described in our U.S. Pat. No. 4,754,255.
The elements comprising the conductive area 32, with or without the rubber protrusions 32, and the PC board 52 may be made of any convenient material, such as plastic, etc. Because the casing and the elements can be made very small and very thin, the resulting transmitter can be made in a very sturdy manner and still be only approximately one-quarter of an inch thick and as small as approximately 2 inches in length and 1 inch in width. This provides an extremely easily carried transmitter for transmitting signals for a variety of uses as described, such as garage door openers and vehicle security alarm systems.
Having thus described the invention, it is requested that the scope of the invention be limited only by the scope of the appended claims. | A transmitter includes case, a thin non-conductive pad with an electrically conductive coating applied to selective areas of the pad, one or more electrically conductive actuator buttons on the pad to activate the transmitter, a thin insulator containing a plurality of separate areas which can easily be selectively punched out leaving open holes, and a printed circuit board containing the electronic circuits of the transmitter. Because all of the internal components can be manufactured as extremely thin elements, the transmitter can be made extremely small and thin. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending application Serial No. 08/438,441 filed Mar. 10, 1995 and assigned to the assignee of the present invention, the entire substance of which is hereby incorporated by reference herein as if fully set forth in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates generally to burial caskets, and more particularly to a casket with a memorabilia compartment forming a part thereof.
BACKGROUND OF THE INVENTION
[0003] Currently caskets, whether fabricated from wood or metal, do not provide any designated, easily accessible, receptacle or compartment for either the placement of personal effects of the deceased therein or the inclusion therein of mementos of memorialization by the deceased's family and friends.
[0004] Prior attempts at solving this shortcoming have generally taken the form of the placement of a small memento box into the casket alongside the deceased. However, such memento boxes often appear as an afterthought, simply placed alongside the deceased in the casket somewhat haphazardly. Thus, no designated receptacle or compartment which is an integral part of the casket has been provided which could be utilized by the family to commemorate the passing of the deceased.
[0005] It is therefore the main objective of the present invention to provide a casket having a memorabilia compartment which is a designated compartment or receptacle specifically for mementos which is an integral part of the casket and which does not present the haphazard appearance of prior memento boxes simply placed alongside the deceased in the casket.
SUMMARY OF THE INVENTION
[0006] The present invention attains the stated objective by providing a casket with an integral memorabilia compartment for the placement, display and storage therein of personal effects and mementos of memorialization of the deceased. In one form the casket comprises a shell, a cap pivoted to the shell, and an openable and closable memorabilia compartment forming a part or the cap. In another form the casket comprises a shell, a cap pivoted to the shell, and an openable and closable memorabilia compartment forming a part of the shell. In both forms the memorabilia compartment is so positioned and configured as to provide convenient access to mourners paying respects to the deceased for placing personal effects and mementos therein and to provide display of the personal effects and mementos placed therein for viewing by the mourners.
[0007] The cap memorabilia compartment may take the form of any of at least six preferred embodiments.
[0008] In one embodiment the casket cap includes a rim and a crown pivoted to the rim, and a memorabilia tray disposed within the cap and accessible upon pivoting the crown away from the rim. In a second embodiment, the casket cap includes a rim and a crown slidably mounted to the rim, and a memorabilia tray disposed within the cap and accessible upon sliding the crown relative to the rim. In a third embodiment, the casket cap includes a rim and a crown attached to the rim, and a memorabilia drawer disposed within the cap and accessible upon pivoting the cap away from the shell and pivoting the drawer away from the rim.
[0009] The tray of the first two of these three memorabilia compartments preferably includes a head end compartment, a foot end compartment and a compartment intermediate the head end and foot end compartments. The head and foot end compartments are about one inch deep and the intermediate compartment is about 4 inches deep. The drawer of the second of these two memorabilia compartments preferably includes a front wall, a back wall and a pair of generally triangular shaped end walls connecting the front and back walls. In a casket which includes a single cap the tray is preferably located in the foot end of the single cap, whereas the pivoting drawer is preferably located in the head end of the single cap. In a casket which includes separate head end and foot end caps the tray is preferably located in the foot end cap, whereas the pivoting drawer is preferably located in the head end cap. The casket may be fabricated of either wood or metal.
[0010] In a fourth embodiment, the casket cap includes a rim, a header panel attached to one end of the rim and a crown attached to the rim; a memorabilia drawer is disposed within the cap and is slidably accessible through the header panel. In a fifth embodiment, the casket cap includes a rim, a header panel or a portion of the header panel pivoted to one end of the rim and a crown attached to the rim; a memorabilia drawer is disposed within the cap and is slidably accessible upon pivoting the header panel or a portion of the header panel away from the rim.
[0011] The drawer of each of these two memorabilia compartments preferably is divided into two compartments. In a casket which includes separate head end and foot end caps the drawer is preferably located in the foot end cap. The casket may be fabricated of either wood or metal.
[0012] In a sixth embodiment, the casket cap includes a rim, a crown attached to the rim and puffing peripherally mounted within the interior of the cap to the rim. A memorabilia capsule is disposed in the puffing. At least a portion of the capsule is transparent to allow viewing of memorabilia placed therein. The transparent portion of the capsule is hinged to the balance of the capsule to form a pivoting access door providing access to the interior of the capsule. The puffing is generally quarter-circular in cross section and the capsule is of the same general quarter-circular cross section. In a casket which includes a single cap the capsule is preferably located in the head end of the single cap. In a casket which includes separate head end and foot end caps the capsule is preferably located in the head end cap. The casket may be fabricated of either wood or metal.
[0013] The shell memorabilia compartment may take the form of any of at least four preferred embodiments.
[0014] In one embodiment the casket shell includes a pair of side walls and a pair of end walls and a memorabilia tray supported by the shell walls and accessible upon pivoting the cap away from the shell. As in the prior embodiments, the tray of this form of the invention includes head end, foot end and intermediate compartments, the head and foot end compartments being about one inch deep and the intermediate compartment being about four inches deep. In a casket including a single cap pivoted to the shell the tray is preferably located in the foot end of the shell. In a casket including separate head end and foot end caps the tray is preferably located in the foot end of the shell. The casket may be fabricated of either wood or metal.
[0015] In a second embodiment, the shell includes a pair of side walls and a pair of end walls and a memorabilia drawer disposed within one of the end walls and accessible upon pivoting the drawer away from the one end wall.
[0016] In a third embodiment, the shell includes a pair of side walls and a pair of end walls with one of the end walls including a sliding panel portion slidable relative to the balance of the one end wall and providing access to the interior of the one end wall.
[0017] In a fourth embodiment, the shell includes a pair of side walls and a pair of end walls and decorative trim movably mounted to a portion of the shell walls and normally concealing a compartment therebehind; the decorative trim is movable from a first position in which the compartment is concealed to a second position in which the compartment is exposed. The decorative trim utilizable for this embodiment may be the basemold, an ear or a corner post. The decorative trim may be pivotally mounted to the portion of the shell walls or may be removably mounted to the portion of the shell walls.
[0018] According to a further aspect of the invention, a casket having a memorabilia compartment comprises a shell and a cap closable upon the shell. The cap includes a crown and a header panel at one end of the crown. A memorabilia drawer is within the cap. The drawer is slidably mounted within a frame mounted to the under side of the crown. The drawer is movable to and between a display position and a storage position.
[0019] The frame is preferrably rectangular and comprises a pair of side walls and a pair of end walls. The drawer comprises a pair of side walls, a pair of end walls and a bottom wall. The frame and drawer side walls include cooperating tongue and groove joints slidably guiding the drawer as it is withdrawn from and inserted into the frame.
[0020] The frame end walls comprise a head end wall and a foot end wall, one of which is formed by the header panel. The header panel includes an opening therein permitting the drawer to be moved therethrough.
[0021] The cap further preferrably includes a retainer mounted to and depending into the drawer. The retainer retains the drawer partially within the cap thereby preventing the drawer from being completely withdrawn from the cap.
[0022] The retainer is preferrably a spring steel clip mounted to the header panel. The clip includes a leg which depends downwardly into the drawer to contact a drawer end wall to prevent the drawer from being completely withdrawn from the cap. The clip is upwardly deflectable with a hand of a person to cause the depending leg to clear the drawer end wall to allow selective removal of the drawer from the cap.
[0023] The cap still further preferrably includes a magnetic latch and a drawer end wall includes a metallic object secured thereto. The magnetic latch and metallic object cooperate to retain the drawer within the cap in the storage position, and cooperate to release one from another upon a person's pressing inwardly on the drawer thereby releasing the drawer and permitting the drawer to be moved from the storage position to the display position. The magnetic latch is preferrably mounted to one of a pair of framed end walls, the one frame end wall including a notch therein for accepting the magnetic latch, and a metallic object is a metallic plate.
[0024] According to yet another aspect, a casket is provided having a memorabilia compartment comprising a shell including a pair of side walls and a pair of end walls, and a cap closable upon a shell. A cover member is supported by the shell, is positioned at a foot end of the shell and is adapted to cover the legs and lower torso of a deceased lying in the casket. A memorabilia drawer is movably mounted within the cover member and is movable to and between the display position in a storage position.
[0025] The memorabilia drawer is preferrably slidably mounted within the cover member. The casket is preferrably a full-couch casket having a single, full-length cap pivoted to the shell. The cover member is preferrably supported by the shell walls, as by being supported atop dowels pressed into holes in the shell walls. The cover member is preferrably elongated, generally rectangular and with a convex top.
[0026] The main advantage of the present invention is that a casket having a memorabilia compartment therein is provided which provides a designated receptacle or compartment for the placement of mementos therein which is an integral part of the casket and which does not present a haphazard, afterthought type of appearance.
[0027] Another advantage of the present invention is that a memorabilia compartment according to the principles of the present invention utilizes the wasted or otherwise unutilized space located above the legs of the deceased and/or within the casket cap to form the volume which is utilized as the receptacle or compartment.
[0028] Yet another advantage of the present invention is that a designated, easily accessible receptacle is provided which is integral to the casket and which will allow for family and friends of the deceased to include within the casket at the time of final closing or prior thereto mementos or other items of remembrance of the deceased.
[0029] Still another advantage of the present invention is that the invention will allow family members and friends of the deceased a more meaningful ceremony of memorialization and thereby greater consumer satisfaction with the purchase of the casket.
[0030] A further advantage of the present invention is that the invention will extend the functional utility of the casket to a new dimension, one that may significantly aid the cathartic process.
[0031] These and other objects and advantages of the present invention will become more readily apparent during the following detailed description taken in conjunction with the drawings herein, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 is a perspective view of a casket including one embodiment of a cap memorabilia compartment;
[0033] [0033]FIG. 1A is a perspective view of another tray for the memorabilia compartment of FIG. 1;
[0034] [0034]FIG. 1B is a perspective view of yet another tray for the memorabilia compartment of FIG. 1;
[0035] [0035]FIG. 2 is a partial perspective view of a casket including a second embodiment of a cap memorabilia compartment;
[0036] [0036]FIG. 3 is a partial perspective view of a casket including a third embodiment of a cap memorabilia compartment;
[0037] [0037]FIG. 4 is a partial perspective view of a casket including a fourth embodiment of a cap memorabilia compartment;
[0038] [0038]FIG. 4A is a partial perspective view of the memorabilia compartment of FIG. 3 for a metal casket;
[0039] [0039]FIG. 4B is a partial perspective view of the memorabilia compartment of FIG. 3 for a wood casket;
[0040] [0040]FIG. 5 is a partial perspective view of a fifth embodiment of a cap memorabilia compartment;
[0041] [0041]FIG. 6 is a partial perspective view of a sixth embodiment of a cap memorabilia compartment;
[0042] [0042]FIG. 7 is a perspective view of a casket including one embodiment or a shell memorabilia compartment;
[0043] [0043]FIG. 8 is a partial perspective view of a casket including a second embodiment of a shell memorabilia compartment;
[0044] [0044]FIG. 9 is a partial perspective view of a casket including a third embodiment of a shell memorabilia compartment;
[0045] [0045]FIG. 10A is a partial perspective view of a casket including one form of a fourth embodiment of a shell memorabilia compartment;
[0046] [0046]FIG. 10B is a partial perspective view of a casket including a second form of the fourth embodiment of the shell memorabilia compartment;
[0047] [0047]FIG. 10C is a partial perspective view of a casket including a third form of the fourth embodiment of the shell memorabilia compartment;
[0048] [0048]FIG. 10D is a partial perspective view of a casket including a fifth form of the fourth embodiment of the shell memorabilia compartment;
[0049] [0049]FIG. 10E is a partial perspective view of a casket including a sixth form of the fourth embodiment of the shell memorabilia compartment;
[0050] [0050]FIG. 11 is a view similar to FIG. 4 of a preferred embodiment of the cap memorabilia compartment of FIG. 4;
[0051] [0051]FIG. 12 is a bottom view looking into the foot cap of FIG. 11;
[0052] [0052]FIG. 13 is a view taken alaong line 13 - 13 of FIG. 11; and
[0053] [0053]FIG. 14 is a perspective view of yet another emobidment of memorabilia compartment.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Referring first to FIG. 1, there is illustrated a casket 10 constructed according to the principles of the present invention. While the casket 10 is illustrated as being fabricated from wood, it will be appreciated that the present invention may be included in either wood caskets or metal caskets. Referring now to the Figure, the casket 10 includes a casket shell 12 and a pair of half or split caps 14 and 16 pivoted to the shell 12 by hinges or other means known to those skilled in the art. Arms 18 attach a handle bar 20 to the casket shell side walls 22 . The shell 12 includes conventional decorative interior components such as a big body 24 , a small body 26 , a pillow 28 and the like.
[0055] Cap 14 includes side rim members 30 , 30 , a head end rim member 32 secured to the head ends of the side rim members 30 , 30 and a header panel 34 secured to the foot ends of the side rim members 30 , 30 . A decorative dish assembly 36 includes a cap panel 38 and peripheral puffing members 40 positioned around the perimeter of the cap panel 38 and is installed within the head end cap 14 . The foot end cap 16 may include a similar decorative interior but it is not shown in FIG. 1. Foot end cap 16 similarly includes side rim members 50 , 50 , a foot end rim member 52 secured to the foot ends of the side rim members 50 , 50 and a header panel 54 secured to the-head ends of the side rim members 50 , 50 . A crown 56 , which normally would be fixedly secured to the upper edges of the rim members 50 , 50 , 52 and the header panel 54 , is instead pivoted to the rear side rim member 50 as by hinges 58 . A crown brace 60 supports the crown 56 in the upward position, as shown in FIG. 1. Suitable latch structure 62 and 64 may be mounted in side rim member 50 and crown 56 to latch the crown 56 in the lowered, closed position.
[0056] Pivoting the crown 56 upward away from the balance of the cap 16 reveals a memorabilia tray 70 which is disposed within the rim members 50 , 50 , 52 and header panel 54 . The memorabilia tray 70 is preferably fabricated of plastic, for example crematable high density polyethylene or HDPE, and may include a plurality of memorabilia containing compartments, for example two rectangular compartments 72 and 74 . The tray itself may include a convex upper surface 76 for nesting within the concave inner surface 73 of the crown 56 . Alternatively, surface 76 could be flush with the top edges of the side rim members 50 , 50 , end rim member 52 and header panel 54 . The tray 70 is generally a press fit within the side rim members 50 , 50 , end rim member 52 and header panel 54 . While latch structure 62 , 64 is illustrated on the front, or viewing side of the casket, this latch structure could as well be placed centrally on the head end of the crown 56 or the foot end of the crown 56 .
[0057] Referring now to FIG. 1A, there is illustrated another tray 90 which could be installed in the casket of FIG. 1. Tray 90 includes a generally flush top surface 92 and three memorabilia receptacles or compartments 94 , 96 and 98 . Head end compartment 94 and foot end compartment 98 are preferably about one inch deep and intermediate compartment 96 is preferably about four inches deep. The intermediate compartment 96 can be deeper than the foot end compartment 98 , which is located generally directly above the feet of a deceased in the casket 10 . When the body support structure of the casket 10 is raised to the highest position, the one inch deep compartment 98 still provides for the minimal required clearance above the deceased's feet. Intermediate compartment 96 , however, is located just forward of a deceased's feet, and therefore it can be substantially deeper, for example about four inches deep as described above. Head end compartment 94 is preferably made of the same depth as foot end compartment 98 to make the tray 90 aesthetically symmetrical.
[0058] Referring now to FIG. 1B, another tray 100 is illustrated which can be included in the casket of FIG. 1. Tray 100 likewise similarly includes a generally flat top surface 102 with the three separate memorabilia receptacles 104 , 106 and 108 similar to that illustrated in FIG. 1A. In addition, however, the tray 100 includes curved side walls 110 , 110 and curved end walls 112 , 112 . Rather than being a press fit into the side rim members 50 , 50 , end rim member 52 and head wall 54 , this tray would be installed from underneath the cap 16 . The free edges of the walls 110 and 112 would then be secured to the rim members 50 , 50 and 52 and head wall 54 by any suitable means, for example such as snapping into grooves or utilizing wood dowels or the like pressed into holes in the rim members 50 , 50 , 52 and head wall 54 atop which the free edges of the walls 110 , 112 of the tray 100 would be supported after installation up into the cap 16 . The underneath side of this form of tray 100 could be made to look substantially similar to the dish 36 in head end cap 14 including cap panel 38 and peripheral puffing members 40 so as to present the same general decorative look when the entire foot end cap 16 is pivoted upwardly.
[0059] Referring now to FIG. 2, and with like numbers representing like elements, a second embodiment of the cap memorabilia compartment is illustrated. In this embodiment, the crown 56 is slidably mounted to the rim members 50 , 50 , 52 and head wall 54 as by tongue and groove joints or the like. In this embodiment, either of the alternative forms of the tray 90 and 100 illustrated in FIGS. 1A and 1B, respectively, would be employed which have flat top surfaces and which sit flush with the top edges of the rim members 50 , 50 , 52 and head wall 54 .
[0060] Referring now to FIG. 3, and with like numbers representing like elements, a third embodiment of the cap memorabilia compartment is illustrated. In this embodiment, the head end cap 14 is provided with a pivoting drawer 120 . Drawer 120 is pivoted at its lower edge 122 to a portion of the cap 14 , for example to cap panel 38 , by hinges or other means known to those skilled in the art. The pivoting drawer 120 will preferably be generally triangular in cross section, having a front wall 124 , a pair of triangular shaped opposed end walls 126 and back wall 128 . Access is gained to the interior of the pivoting drawer 120 by first of course pivoting cap 14 upwardly relative to the shell 12 to its open position and then pivoting drawer 120 downwardly relative to crown 56 to its open position.
[0061] Referring now to FIG. 4, there is illustrated a fourth embodiment of cap memorabilia compartment in a metal casket 140 . In the foot end cap 142 of the casket 140 there is slidably disposed a drawer 144 . FIG. 4A illustrates the construction of the cap 142 so as to accommodate the drawer 144 . The header 146 includes opening 148 for accepting an inner compartment 150 having a flange 152 to be welded or epoxied in place against the header 146 . Drawer 144 slides into and out of the interior of the compartment 150 , and may be provided with a recess or groove 154 for grasping the drawer 144 .
[0062] [0062]FIG. 4B illustrates this same embodiment but in a wooden casket. Foot end cap 16 has a header wall 54 with an opening 160 therein for accepting a drawer 162 which may have one or several, and as illustrated, has two generally equally sized memorabilia compartments or receptacles 164 and 166 . A recess may be provided in the header 54 along the lower edge of opening 160 to allow one's fingers to grasp beneath the lower edge of drawer front 168 to pull the drawer 162 out. Suitable supporting structure such as a panel or the like underlies the drawer 162 to support it when pushed in.
[0063] Referring now to FIG. 5, there is illustrated a fifth embodiment of cap memorabilia compartment. This embodiment is substantially the same as the FIG. 4 embodiment, especially the FIG. 4B embodiment, except that rather than the drawer front 168 forming a part of the header wall 54 when the drawer 162 is inserted or slid into the cap 6 , all or a portion of the header wall 54 is hinged for example portion 130 hinged at its lower edge to header wall 54 by hinges or other conventional means known to those skilled in the art, to provide access to a hidden drawer. Thus, the header wall 54 is pivoted downwardly, or a portion of the header wall for example that shown at 130 is pivoted downwardly, to provide access to a drawer disposed in opening 160 and normally concealed by header wall 54 .
[0064] Referring now to FIG. 6, a sixth embodiment of cap memorabilia compartment is illustrated. In this embodiment, a capsule 200 is disposed in the puffing member 40 . The capsule 200 has a generally quarter-circular cross section to match the generally quarter-circular cross section of the puffing member 40 . The capsule 200 would include a rear wall 202 , a bottom wall 204 and opposed end walls 206 . A transparent cover 208 is hinged alone its lower edge 210 to the bottom wall 204 of the capsule 200 by hinges or other means known to those skilled in the art. Pivoting transparent cover 208 allows for access to the interior of the compartment 200 as well as continuous viewing of the memorabilia placed therein.
[0065] Referring now to FIG. 7, there is illustrated one embodiment of a shell memorabilia compartment. In this form of the invention, a memorabilia tray 250 , having compartments 252 and 254 similar to the tray 70 of FIG. 1, is positioned directly in the shell 12 as opposed to being installed in the foot end cap 16 . The tray 250 may be supported atop wooden dowels (not shown) pressed into holes (not shown) in the casket shell side and end walls. Alternatively, tray 250 could include the compartment configuration illustrated in FIGS. 1A and 1B.
[0066] Referring now to FIG. 8, and with like numbers representing like elements, a second embodiment of a shell memorabilia compartment is illustrated. In this embodiment, shell end wall 300 is provided with a pivoting drawer 302 pivoted at its lower edge 304 by hinges or other means known to those skilled in the art to end wall 300 . Pivoting of drawer 302 away from the end wall 300 provides access to the interior 306 of drawer 302 .
[0067] Referring now to FIG. 9, and with like numbers representing like elements, there is illustrated a third embodiment of shell memorabilia compartment. In this embodiment, shell end wall 300 is provided with a sliding panel portion 310 slidable relative to the balance of the end wall 300 to provide access to an interior 312 normally concealed by the sliding panel portion 310 .
[0068] Referring now to FIGS. 10 A-E, six forms of a fourth embodiment of a shell memorabilia compartment are illustrated. In this fourth embodiment, decorative casket trim is movably mounted to a portion of the casket shell walls and nor-ally conceals a compartment therebehind. The decorative trim is movable from a first position in which the compartment is concealed to a second position in which the compartment is exposed. The trim may be pivotally mounted, slidably mounted or removably mounted to the casket shell walls. In one form as shown in FIG. 10A, base mold 350 is pivoted at its lower edge 352 by hinged or other means known to those skilled in the art to end wall 300 . Pivoting the base mold 350 away from the end wall 300 exposes the interior 354 of the compartment. In a second form shown in FIG. 10B, an ear or escutcheon plate 360 is pivoted at its lower edge 362 by hinges or other means known to those skilled in the art to one of the casket walls. Pivoting the ear 360 away from the casket wall exposes the interior 364 of the compartment.
[0069] Referring now to FIGS. 10 C-E, three other forms of the invention utilizing movably mounted decorative trim to form the shell memorabilia compartment are illustrated. In FIG. 10C, a corner post 370 including walls 372 and 374 is pivoted to the shell end wall 300 by hinges or other means known to those skilled in the art at edge 376 of wall 372 . Pivoting the corner post 370 away from the end wall 300 provides access to the interior 378 of the compartment. FIG. 10D is similar, except that corner post 380 is a rectangular receptacle having an open top 382 , access to which is provided by sliding the receptacle 380 longitudinally or transversely relative to the casket shell. In FIG. 10E, corner post 390 is similar to that shown in FIG. 10D, except that the post 390 is completely removable from the casket shell and includes a cap 392 for closing the open upper end 394 of the post 390 .
[0070] Referring now to FIGS. 11 - 13 , there is illustrated a preferred construction of a wooden casket with memorabilia drawer slidably mounted within a cap of the casket. More particularly, in FIG. 11 there is illustrated a casket 400 including a shell 402 and head end 404 and foot end 406 caps or lids pivoted to the shell 402 with hinges or the like known to those skilled in the art and closable upon the shell 402 . Foot and cap 406 includes a memorabilia drawer 410 slidably mounted to the cap 406 and slidable to and between a display position and a storage position.
[0071] As shown in FIG. 12, when viewing the cap 406 from underneath, it will be seen that drawer 410 is slidably mounted within a frame 412 mounted to the underside of the crown 414 of the cap 406 . Frame 412 is generally rectangular and comprises a pair of side walls 416 , 416 and a pair of end walls 418 , 420 . Drawer 410 comprises a pair of side walls 422 , 422 , a pair of end walls 426 , 428 and a bottom wall 430 . The frame side walls 416 , 416 and drawer side walls 422 , 422 include cooperating tongue-in-groove joints 432 for slidably gliding the drawer 410 as it is withdrawn from and inserted into the frame 412 . Preferably the drawer sidewalls 422 , 422 include the groove 434 portion of the tongue-in-groove joint and the frame side walls 416 , 416 include the tongue 436 portion of the tongue-in-groove joint.
[0072] As is seen in FIG. 12, frame end wall 420 is formed by the header, which includes an opening 440 therein permitting the drawer 410 to be moved there through.
[0073] Frame end wall 418 is secured to the crown 14 via brackets 442 and screws 444 . Sidewalls 416 , 416 are secured to end wall 418 via any suitable fasteners, for example, staples, glue, screws, tongue-in-groove joints, dowels, or any suitable combination thereof. The drawer side 422 , 422 , end 426 , 428 and bottom 430 walls are secured together with the same or similar fastening means. Sidewalls 416 , 416 are secured to header 420 also via the same or similar fastening means. Further, the upwardly facing surface of bottom 430 may be flocked or lined with velvet or other attractive material. Drawer side 422 , 422 and end 426 walls may be fabricated of suitable wood, for example maple; bottom wall 430 is preferably hardboard; and end wall 428 is preferably wood of the same type as, or is otherwise finished to match, the wood of the balance of the casket 400 . Frame sidewalls 416 , 416 and end 418 may be fabricated of any suitable wood, for example maple, and end wall 420 , or header, is preferably wood of the same type as, or is otherwise finished to match, the wood of the balance of the casket 400 .
[0074] Referring now to FIGS. 12 and 13, it will be seen that the cap 406 includes a retainer 450 mounted thereto which depends into the drawer 410 to retain the drawer 410 partially within the cap 406 , thus preventing the drawer 410 from being completely withdrawn from the cap 406 . More particularly, retainer 450 is a spring steel clip 452 which includes a leg 454 which depends downwardly into the drawer 410 and which is operable to contact drawer end wall 426 to prevent the drawer 410 from being completely withdrawn from the cap. Clip 452 is secured to header panel 420 via a screw 456 . Clip 450 is preferably fabricated of spring steel, is plated to prevent oxidation, and is available from Hoffco of Woodlake, Minn. as part no. 727. Leg 454 of clip 452 is upwardly deflectable by the hand of a person reaching into the open drawer 410 to allow the end wall 426 to clear the leg 454 to allow selective removal of the drawer 410 from the cap 406 as desired. Frame 412 includes a top wall 460 secured to the side 416 , 416 and end 413 walls of the frame 412 via staples or the like, fabricated of hardboard, and including a slot 462 formed therein which allows leg 454 of clip 452 to depend downwardly into the drawer 410 .
[0075] Cap 406 further includes a magnetic latch 470 which is mounted to frame end wall 418 within a notch 472 . Magnetic latch 470 cooperates with a metallic plate 474 secured via a screw 476 to drawer end wall 426 . Magnetic latch 470 may be of a type available from Hoffco of Woodlake, Minn. as part no. 453-C. Magnetic latch 470 and plate 474 cooperate to retain the drawer 410 within the cap 406 in a storage position, and cooperate to release one from another upon a person's pressing inwardly on the drawer 410 which releases the magnetic latch 470 from the plate 474 and causes the drawer 410 to be ejected slightly out of the frame 412 whereby it is easily grasped and pulled to the open position.
[0076] Referring to FIG. 14, there is illustrated yet another form of the invention. In FIG. 14 there is shown the casket 500 comprising a shell 502 to which is pivoted via hinges or the like known to those skilled in the art a cap or lid 504 closeable thereon. Casket 500 is a so-called full-couch casket wherein the cap or lid 504 is a single, full-length cap pivoted to the shell 502 . The shell 502 includes a pair of side walls 506 and a pair of end walls 508 . A cover member 510 is supported by the shell 502 , for example, is supported upon wooden dowels 512 pressed into holes 514 in the shell wall 516 , is positioned at the foot end of the shell 502 and is adapted to cover the legs and torso of a deceased lying in the casket 500 . There is a memorabilia drawer 520 movably mounted within the cover member 510 and movable to and between a display position and a storage position. Drawer 520 could be supported within the frame structure 112 described above, including all the features thereof such as magnetic latch 470 and retainer clip 450 , or it could be simply supported by, for example, a panel or the like underlying the drawer 520 . Cover member 510 is elongated, rectangular and includes a convex top or crown 524 . Cover member 510 may also include a header panel 526 similar to that discussed above in connection with the casket caps. Cover member - 10 may further include a pie-shaped section 528 at a footend thereof. Cover member 510 is sometimes referred to as an “inner panel” in the trade. Cover member 510 is also sometimes referred to as a “cap” in the trade, since the structure of the cover member 510 is generally the same as that of a casket cap pivoted to its shell, less the peripheral rim portion of the cap.
[0077] While the present invention has been described in conjunction with wood and metal caskets, it will be readily appreciated that the invention could also be incorporated in caskets of other constructions, for example, composites, plastics, paperboard, cardboard, hardboard, papier-maché or the like. The invention therefore is not to be limited to simply wood and metal caskets.
[0078] Further, while the drawer type memorabilia compartments illustrated herein may be shown to be pullable from one particular end of a casket cap, lid, cover member and/or inner panel, it will be appreciated that the drawer may be mounted so as to be withdrawable from the other end of the cap, lid, cover member and/or inner panel, and that both are within the scope of the present invention.
[0079] Still further, the drawer type memorabilia compartment could be employed with the single, full-length cap or lid of a full-couch casket, and withdrawable from either the head end or foot end thereof, and that the same is also within the scope of the present invention.
[0080] Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present invention which will yield an improved casket having memorabilia compartment, yet all of which will fall within the spirit and scope of the present invention as defined in the following claims. Accordingly, the invention is to be limited only by the scope of the following claims and their equivalents. | A casket is provided with an integral memorabilia compartment for the placement, display and storage therein of personal effects and mementos of memorialization of the deceased. In one form the casket comprises a shell, a cap pivoted to the shell, and an openable and closable memorabilia compartment forming a part of the cap. In another form the casket comprises a shell, a cap pivoted to the shell, and an openable and closable memorabilia compartment forming a part of the shell. In both forms the memorabilia compartment is so positioned and configured as to provide convenient access to mourners paying respects to the deceased for placing personal effects and mementos therein and to provide display of the personal effects and mementos placed therein for viewing by the mourners. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-140276, filed May 10, 2001, 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 improvement of a digital recording/reproducing apparatus which uses a removable optical disc. The present invention relates particularly to a technique for eliminating intricacy regarding a recording setting associated with sound in a DVD recorder in which a plurality of types of sound languages (English, Japanese, and the like), a plurality of types of sound modes (monaural, dual-monaural, stereo, and the like) and a plurality of types of video formats (DVD video, DVD real-time recording, and the like) are supported.
[0004] 2. Description of the Related Art
[0005] In recent years, an optical disc reproducing system in which audio-visual (AV) information including a dynamic image is recorded has been developed, and has generally spread for a purpose of movie software, karaoke, and the like. Above all, DVD video has remarkably spread. For a standard of DVD video, in accordance with a MPEG2 system layer, MPEG2 is supported in a dynamic image compression system, and AC audio and MPEG audio are supported in sound. Moreover, in the DVD video standard, sub image data in which bit map data is subjected to run length compression for subtitle and menu, and special control data (navigation pack) for special reproducing such as fast forward/rewind are defined. Furthermore, in the DVD video standard, ISO9660 and micro UDF (UDF bridge) are supported so that data can be read with a computer. As the standard of an information medium itself for storing AV information, following DVD-ROM as media for use in DVD video, standards of DVD-RAM (repeatedly readable/writable), DVD-R (write once), and DVD-RW (repeatedly rewritable) have been completed. Moreover, DVD-RAM drive (or DVD-R/DVD-RW drive) has also started to spread as computer peripherals.
[0006] At present, the standard of DVD-real-time recording (RTR) has been completed as DVD standard which utilizes DVD-RAM (or DVD-R/DVD-RW) and which is recordable/reproducible in real time, and a verification operation ended in spring, 2000. This standard is based on the standard of the presently spread DVD video (DVD-ROM). A file system for the DVD-RTR has also been standardized. Under these situations, DVD video recorder based on the DVD-RTR standard has started to be on the market.
[0007] Many of DVD recorders now on the market support both formats of the DVD video and DVD-RTR. These are formats of the same DVD family. Unless both formats are supported, commercial property (appeal to a buyer layer) of DVD recorder is remarkably deteriorated.
[0008] However, even when both formats are supported, the formats have no correlation with respect to various initial settings, and settings are completely different. Therefore, even with the single recorder, a user needs to individually perform a similar setting with respect to both formats (in both modes). A problem occurs that the settings become intricate.
BRIEF SUMMARY OF THE INVENTION
[0009] In a digital recording/reproducing apparatus according to an embodiment of the present invention, a sound language setting in a second format (DVD-RTR) can be matched with the sound language setting in a first format (DVD video).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] [0010]FIG. 1 is a block diagram showing the whole constitution of a digital recording/reproducing apparatus (DVD-RTR video recorder) with a sound changeover function according to one embodiment of the present invention.
[0011] [0011]FIG. 2 is a diagram showing a directory structure of an information file recorded by the apparatus of FIG. 1.
[0012] [0012]FIG. 3 is a diagram showing a data structure of information (video object) recorded by the apparatus of FIG. 1.
[0013] [0013]FIG. 4 is a diagram showing a data structure of management information (M_VOB_STI, and the like) recorded by the apparatus of FIG. 1.
[0014] [0014]FIG. 5 is a diagram showing a pack structure of audio information (linear PCM audio) recorded by the apparatus of FIG. 1.
[0015] [0015]FIG. 6 is a diagram showing a pack structure of audio information (MPEG audio) recorded by the apparatus of FIG. 1.
[0016] [0016]FIG. 7 is a flowchart showing the whole operation of the apparatus of FIG. 1.
[0017] [0017]FIG. 8 is a flowchart of an operation for selecting a broadcast program in the apparatus of FIG. 1.
[0018] [0018]FIG. 9 is a flowchart of a recording operation in the apparatus of FIG. 1.
[0019] [0019]FIG. 10 is a flowchart of an interrupt processing in the apparatus of FIG. 1.
[0020] [0020]FIG. 11 is a flowchart of a setting processing of stream information (STI) in the apparatus of FIG. 1.
[0021] [0021]FIG. 12 is a flowchart of an encoding processing of audio data in the apparatus of FIG. 1.
[0022] [0022]FIG. 13 is a flowchart showing the whole reproducing operation (former half) in the apparatus of FIG. 1.
[0023] [0023]FIG. 14 is a flowchart showing the whole reproducing operation (latter half) in the apparatus of FIG. 1.
[0024] [0024]FIG. 15 is a flowchart showing a cell reproducing processing (former half) in the apparatus of FIG. 1.
[0025] [0025]FIG. 16 is a flowchart showing the cell reproducing processing (latter half) in the apparatus of FIG. 1.
[0026] [0026]FIG. 17 is a diagram showing contents of management information to be recorded by the apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0027] A digital recording/reproducing apparatus (DVD-RTR recorder) according to one embodiment of the present invention will be described hereinafter with reference to the drawings. FIG. 1 is a block diagram showing a whole constitution of a digital recording/reproducing apparatus (DVD-RTR video recorder) with a sound changeover function according to one embodiment of the present invention. The apparatus basically performs real-time video recording using a recordable optical disc (DVD-RAM disc, DVD-RW disc, DVD-R disc) 100 , and includes a reproducing function of an optical disc for exclusive use in reproducing (DVD-ROM disc, recorded DVD-R disc).
[0028] The apparatus of FIG. 1 is constituted of: an encoder section 601 ; a decoder section 602 ; a main microcomputer (MPU) section 604 : a video (V) mixing section 605 ; a frame memory 606 ; a key input section 607 ; a display 608 ; a DVD-RAM (and/or DVD-R/DVD-RW) drive 609 ; a data processor (D-PRO) 610 ; an A/V input 612 ; a TV tuner 613 ; an audio digital I/F 631 ; an audio D/A section 632 ; a speaker 633 (a driving audio amplifier is not shown); a video digital I/F 634 ; a TV D/A section 636 ; an external monitor TV 637 ; a system time counter (STC) 650 ; a temporary storage (large-capacity IC memory and/or HDD recorder unit) 700 ; a selector 750 of an audio signal; a bilingual broadcast detector (multilingual detector) 900 ; and the like.
[0029] A main MPU section 604 has therein a stream information (STI) setter 6044 and other control program (firmware). Moreover, the MPU section 604 has therein a work RAM 604 a for use in executing the control program. A management information (VMG) holder 6043 is disposed in the work RAM 604 a.
[0030] The encoder section 601 is constituted of an A/D section 614 ; a video encoder 616 ; an audio encoder 617 including a dual-monaural header setter 617 a; a subpicture (SP) encoder 618 ; a formatter 619 ; and a buffer memory 620 . Moreover, the decoder section 602 is constituted of a separator 625 including a memory 626 , a video decoder 628 including a reduced image (thumb nail) generator 628 a, a subpicture (SP) decoder 627 , an audio decoder 630 , and a video processor (V-PRO) 638 .
[0031] Recording (recording of AV information) is performed by the disc drive (DVD-RAM drive) 609 , in which the removable DVD-RAM (or DVD-R/DVD-RW) disc 100 is used, via the encoder section 601 . The disc drive 609 can play back not only the DVD-RAM (or DVD-R/DVD-RW) disc 100 but also the DVD video (or DVD-ROM) disc 100 . That is, reproducing is performed using the disc drive 609 via the decoder section 602 . The function of playing back the DVD video is basically the same as a DVD video player generally on the market.
[0032] A flow of an actual video signal in the apparatus of FIG. 1 is as follows. First, an analog AV signal inputted via the A/V input 612 or an analog TV signal obtained from the TV tuner 613 is converted to a digital signal in A/D section 614 of the encoder section 601 . The video signal subjected to digital conversion is inputted to the video encoder 616 , and the audio signal subjected to digital conversion is inputted to the audio encoder 617 . Moreover, character broadcast data and other character data obtained from the TV tuner 613 are inputted to the subpicture (SP) encoder 618 . The inputted video signal is MPEG compressed in the video (main picture) encoder 616 . The inputted audio signal is subjected to the AC3 or MPEG audio compression in the audio (sound) encoder 617 . Moreover, the inputted character data is subjected to run length compression in the SP encoder 618 .
[0033] For the respective encoders 616 to 618 , the data is packeted to indicate 2048 bytes when the compressed Ad data is packed, and the packeted video data, audio data and subpicture data are inputted to the formatter 619 . The formatter 619 appropriately uses the buffer memory 620 , packs and multiplexes the inputted packet data, and sends the multiplexed video pack, audio pack and subpicture pack to the D-PRO 610 .
[0034] The D-PRO 610 forms an ECC block for every 16 packs (32 or more packs in a next-generation DVD video) in the present DVD video, and attaches error correction data to the block. A data stream obtained in this manner is recorded in the optical disc (DVD-RAM, DVD-RW or DVD-R) 100 by the disc drive 609 . Here, with the disc drive 109 in a busy state for seeking or track jump, the recorded data is stored in the temporary storage 700 (IC memory and/or HDD recorder unit), until the disc drive 609 is prepared for recording the data.
[0035] Furthermore, the formatter 619 prepares respective segmenting information during recording (by interrupt in a top of GOP), and periodically sends the prepared segmenting information to the MPU section 604 . Examples of the segmenting information include the number of packs of a video object unit (VOBU), end address of one picture from the top of VOBU, reproducing time of VOBU, and the like. Each VOBU includes the video pack, and audio pack and/or subpicture pack. The information can be accessed by the unit of the VOBU. Additionally, one video file is disposed in one disc in DVD-RTR (recording/reproducing DVD).
[0036] The TV broadcast signal is received by the TV tuner 613 . The sound signal of the TV broadcast signal can have a plurality of sound modes. The sound signal received by the TV tuner 613 is, for example, monaural (L=R), stereo (L&R), or bilingual (multilingual), that is, dual-monaural (L=main sound/Japanese), R=sub sound/foreign languages, and the like). The bilingual broadcast detector (multilingual detector) 900 detects whether or not the received sound signal is bilingual (multilingual), that is, dual-monaural. The information detected by the bilingual broadcast detector 900 is inputted to the encoder section 601 and main MPU section, and subjected to various settings (described later with reference to flowcharts of and after FIG. 7).
[0037] [0037]FIG. 2 shows one example of a directory structure of an information file recorded by the apparatus of FIG. 1 (universal DVD-RTR recorder compatible with DVD video and other DVD family in reproducing). The video files of air check recording of TV broadcast is managed by a sub directory called DVD-RTAV. The directory DVD-RTAV includes a VMG file for storing management information (VR_MANGR.IFO), a movie video file for storing dynamic image information (VR_MOVIE.VRO), a still picture video file for storing still picture information (VR_STILL.VRO), a still picture audio file for storing additional audio information (VR_AUDIO.VRO) for a still picture, and a VMG backup file storing backup information (VR_MANGR.BUP) of management information. Moreover, in DVD-RTR, one video file is stored in one disc. Furthermore, other audio files can be managed by a sub directory called AUDIO-TS.
[0038] [0038]FIG. 3 shows one example of a data structure of information (video object VOB) recorded by the apparatus of FIG. 1. A content of the file stored in the movie video file VR_MOVIE.VRO of FIG. 2 is recorded as a group of one or more video objects VOB (video object set VOBS). Each VOB can be specified by a corresponding ID number (VOB_IDNi). Each VOB is constituted of a group of one or more video object units VOBU. Each VOBU includes video data constituted of one or more groups of pictures of MPEG (GOP), and is constituted of real time data information (RDI) pack, video (V) pack, audio (A) pack, and the like. The V or RDI pack is disposed in the top of each VOBU, and the top pack includes a system header (not shown). The system header is disposed only in the top pack in one VOBU.
[0039] Additionally, as not shown, each VOBU is constituted of a video part and audio part. The video part includes a V pack group and subpicture (SP) pack. The audio part includes an A pack group. The V pack group can include a sequence header, GOP header, I-picture, sequence end code, and subpicture unit. Moreover, A pack group can include a plurality of audio frames.
[0040] [0040]FIG. 4 shows one example of a data structure of management information (M_VOB_STI, and the like) recorded by the apparatus of FIG. 1. As shown in FIG. 4, the management information stored in the VMG file includes RTR video manager information RTR_VMGI, movie AV file information table M_AVFIT, still picture AV file information table S_AVFIT, original program chain information ORG_PGCI, user-defined program chain information table UD_PGCIT, text data manager TXTDT_MG, and manufacturer information MNFIT.
[0041] The table M_AVFIT includes movie AV file information table information M_AVFITI, one or more pieces of movie VOB stream information M_VOB_STI#1 to M_VOB_STI#n, and movie AV file information M_AVFI.
[0042] Each M_VOB_STI (each of #1 to #n) includes a video attribute V_ART, number of audio stream AST_Ns, number of subpicture stream SPST_Ns, audio attribute A_ARTO of stream #0, audio attribute A_ART1 of stream #1, reserved area, and subpicture color pallet SP_PLT.
[0043] The audio attribute A_ART (each of A_ARTO and A_ART1) includes an audio coding mode (audio compression mode), application flag, quantizing DRC, sampling frequency fs, number of audio channels, bit rate information, and the like.
[0044] For the audio coding mode (audio compression mode), (a) “000b” indicates Dolby AC3 (R), (b) “010b” indicates MPEG1 or MPEG2 having no extension bit stream, (c) “011b” indicates MPEG2 having the extension bit stream, and (d) “100b” indicates linear PCM. Eight modes can be identified by three-bit audio coding mode, but modes other than (a) to (d) are reserved for the future.
[0045] An application flag “00b” indicates that the corresponding audio stream includes audio data of a channel mode defined by “audio channel number”, and “01b” indicates that the corresponding audio stream can include the audio data of a multi-channel mode (monaural, dual-monaural, and stereo). In the application flag “01b”, “audio channel number” defines each mode of the corresponding audio stream.
[0046] In the audio coding mode “000b”, quantization/DRC is set to “11b”. In the audio coding mode “010b” or “011b”, quantization/DRC is set to “00b (no dynamic range control data in the MPEG audio stream)” or “01b (there is dynamic range control data in the MPEG audio stream)”. In the audio coding mode “100b”, quantization/DRC is set to “00b (16 bits)”. Other audio coding modes are reserved.
[0047] For the sampling frequency fs, “00b” indicates 48 kHz. Other sampling frequencies are reserved.
[0048] For the audio channel number, “0000b” indicates one channel (monaural), “0001b” indicates two channels (stereo), and “1001b” indicates two channels (dual-monaural). Moreover, “0010b” to “0111b” indicate multi-stereo (surround) or multi-monaural with three to eight channels. Here, when the audio coding mode (audio compression mode) is “100b (linear PCM)”, two or less channel is set (“0000b”, “0001b”, or “1001b”).
[0049] For the bit rate, 64 kbps to 384 kbps are set by “0000 0001b” to “0000 1011b” (for AC3 and MPEG1 audio). When the bit rate is “0000 1100b”, 384 kbps is designated (for AC3). Moreover, with the bit rates “0000 1101b” and “0000 1110b”, 768 kbps and 1536 kbps are designated, respectively (for linear PCM).
[0050] In summary, when the application flag is “00b”, the corresponding audio stream is defined by the channel mode described in “audio channel number”. When the application flag is “01b”, the representative mode (monaural, dual-monaural, or stereo) of the corresponding audio stream is defined.
[0051] The same information as that of the “audio channel number” (monaural=“0000b”, two channel stereo=“0001b”, dual-monaural=“1101b”) can be recorded in the data (header) of each audio stream. The audio channel number information is set in the audio decoder 630 of FIG. 1 at the start of reproducing. The audio decoder 630 decodes the audio stream reproduced with the set sound mode (monaural, stereo, or dual-monaural).
[0052] [0052]FIG. 5 shows a pack structure of audio information (linear PCM audio) recorded by the apparatus of FIG. 1. As shown in FIG. 5, one pack (2048 bytes) of the linear PCM (LPCM) is constituted of a pack header, packet header, sub stream ID, and LPCM data. The packet header includes stream ID=0xbd (or “1011 1101b”) indicating a private stream 1 . Moreover, sub stream ID is “1010 000*b” indicating the linear PCM. Here, * denotes an audio stream number (0 or 1).
[0053] The LPCM data subsequent to the sub stream ID includes audio frame information, audio data information, and data main body of LPCM. Moreover, the audio data information can store “audio channel number” information (monaural=“0000b”, two-channel stereo=“0001b”, dual-monaural=“1001b”). TV broadcast recording of bilingual broadcast can be indicated by “audio channel number”=“1001b” indicating the dual-monaural mode.
[0054] [0054]FIG. 6 illustrates a pack structure of audio information (MPEG audio) recorded by the apparatus of FIG. 1. As shown in FIG. 6, one pack (2048 bytes) of MPEG audio is constituted of a pack header, packet header, and MPEG audio data. This packet header includes stream ID=0(c0 (or “1100 000*b”) indicating MPEG audio or 0(d0 (or “1101 000*b”). Here, * indicates audio stream number (0 or 1). For the MPEG audio, there is no sub stream ID.
[0055] The MPEG audio data subsequent to the packet header includes a plurality of audio access units (AAU) as a unit of audio decode. Here, AAU is a minimum unit which can individually be decoded to the audio signal), and constantly includes data having a constant sample number. Each AAU includes an error check code and audio data. The header includes a synchronous word, ID information, layer information, . . . , mode information, and the like. (Other information such as a protection bit, bit rate index, sampling frequency, padding bit, and private bit are disposed before the mode information. Moreover, mode expansion information, copyrights information, original or copy information, and emphasis information are disposed after the mode information.) The mode information is constituted of two bits, “00b” indicates stereo, “01b” indicates joint stereo, “10b” indicates dual channel (dual-monaural), and “11b” indicates single channel (monaural). The mode information is “10b” indicating dual-monaural in bilingual broadcast recording. During playback (or reproduction) of the disc after recording, the audio decoder 630 of FIG. 1 reads the mode information, and the mode is automatically changed to a mode (dual-monaural decode mode designated by “10b”) designated by the content of the read mode information.
[0056] Various operations of the apparatus of FIG. 1 will next be described with reference to a flowchart. FIG. 7 is the flowchart showing the whole operation of the apparatus of FIG. 1. Each processing of the flowchart is controlled by the main MPU section 604 of FIG. 1. The main MPU section 604 executes a predetermined initial setting (step ST 10 ) after starting the apparatus. Thereafter, key input from a user (key input from a remote controller (not shown) or operation command from reserving/recording program) is waited for. When there is a key input (step ST 20 ), the input key is interpreted (changeover command of TV received channel, recording start command, reproducing start command, and the like) (step ST 30 ).
[0057] When the input key is interpreted as “the changeover command of TV received channel”, a processing of changing the received channel of the TV tuner 613 is performed (step ST 40 ). The processing of changing the received channel includes not only a channel changing in the same broadcast band (e.g., 1 to 12 ch of VHF band) but also a channel changing over different broadcast bands (e.g., VHF 1 ch to BS digital 103 ch).
[0058] When the input key is interpreted as “recording start command”, the recordable optical disc (DVD-RAM disc, and the like) 100 inserted to the disc drive 609 is subjected to a recording processing (step ST 50 ).
[0059] When the input key is interpreted as “reproducing start command”, a reproducing processing from the optical disc (DVD-RAM disc, DVD-RW disc, DVD-R disc, or DVD video disc) is performed (step ST 60 ).
[0060] [0060]FIG. 8 is a flowchart of an operation for selecting a broadcast program in the apparatus of FIG. 1. Here, it is assumed that a sound language for use in default is stored beforehand in the work RAM 604 a (or a not-shown data storing memory) regarding playback of DVD video by the apparatus of FIG. 1.
[0061] First, a channel change command from the user (or reserving/recording program) is issued to the TV tuner 613 (step ST 400 ). The TV received channel is changed in accordance with the received command in the TV tuner 613 (e.g., the present TV received channel VHF 1 ch is changed to VHF 3 ch).
[0062] The sound mode of TV broadcast received by the TV tuner 613 after changing of the received channel is, for example, monaural broadcast, bilingual broadcast (dual-monaural broadcast: for example, for a content, main sound is Japanese, and sub sound is English), or stereo broadcast. The sound mode of the TV broadcast received by the TV tuner 613 is detected by the bilingual broadcast detector 900 (step ST 402 ).
[0063] When the detected sound mode is not bilingual (dual-monaural) (no in step ST 404 ), the TV tuner 613 outputs the sound of the received TV broadcast as two-channel stereo (step ST 406 ). Additionally, when the detected sound mode is monaural, the same monaural signal is distributed and outputted to two channels (L=R).
[0064] When the detected sound mode is bilingual (dual-monaural) (yes in step ST 404 ), the main MPU section 604 judges whether or not the sound mode of the TV broadcast is set in accordance with the audio language code set for the DVD video (step ST 408 ). The user designates whether or not the sound mode is tuned to the audio language code set for the DVD video.
[0065] The user judges that the sound mode of the TV broadcast is not to be tuned to the audio language for the DVD video (no in step ST 408 ). In this case, for example, a graphic user interface GUI (not shown) outputted to the display 608 or the external TV 637 is used to output the sound (dual-monaural: the main sound is Japanese and sub sound is English) of the received channel (subjected to changing designation) to two channels (L/R) as it is) (step ST 410 ).
[0066] The user judges that the sound mode of the TV broadcast is to be tuned to the audio language (e.g., English) for the DVD video (yes in step ST 408 ). In this case, the main MPU section 604 checks the language code for use in the DVD video from a parameter table (not shown) for the DVD video stored in the work RAM 604 a. When the language code is, for example, English, the sub sound (English) of the received TV channel is distributed and outputted to two channels (L=R) (step ST 412 ). Alternatively, when the language code is Japanese, the main sound (Japanese) of the received TV channel is distributed and outputted to the two channels (L=R) (step ST 412 ).
[0067] Subsequently, the sound outputted in step ST 406 , ST 410 or ST 412 is recorded, for example, in the DVD-RAM disc 100 .
[0068] Additionally, a case in which the language code for present use in the DVD video is the same as the language of the subsound of bilingual broadcast has been described above. However, when the language code for present use in the DVD video is different from the language of the subsound of bilingual broadcast, several variations are considered in processing methods of steps ST 408 and ST 412 .
[0069] That is, when the present language setting of the DVD video is other than Japanese (e.g., German), and even when the language of the subsound is any language (e.g., English, German, or French), there is a method of distributing and outputting the subsound to two channels (L=R). This method is not suitable for a case in which the MPU section 604 cannot obtain the information for specifying the type of the subsound language of the received bilingual broadcast.
[0070] Alternatively, when the language setting of the DVD video is English, there is a method of distributing and outputting the subsound (any language) to two channels (L=R). This method is suitable for distributing and outputting the subsound of any foreign language (there is usually a highest possibility of English) to two channels (L=R).
[0071] As described above, when the sound language setting of the DVD video is reflected in setting of recording/reproducing of DVD-RTR, a digital recording/reproducing apparatus (DVD-RTR recorder) can be realized without intricacy of setting.
[0072] [0072]FIG. 9 is a flowchart of a recording operation in the apparatus of FIG. 1. The main MPU section 604 reads each file system data from the disc 100 inserted in the disc drive 609 (step ST 500 ). A used capacity is calculated from the read data, and it is checked whether or not there is a free space (or a vacant capacity) in the disc 100 . When there is no free space (no in step ST 502 ), a warning indicating that “there is no recording space” is displayed in the display 608 or TV 637 (step ST 504 ), and the processing is ended. When there is a free space (yes in step ST 502 ), a managing file (VMG file) is read from the disc 100 . When there is not managing file, a new VMG file is prepared and developed in the RAM 604 a (step ST 506 ).
[0073] After recording preprocessing is performed (step ST 506 ), setting shifts to a recording initial setting (step ST 508 ). In the recording initial setting, the STC 650 is reset, a writing start address and writing command are set to each drive (disc drive 609 , and the like), and the formatter 619 is subjected to initial setting (setting of divisions of cell CELL, video object unit VOBU, program PG, and program chain PGC), and the like. Subsequent to the initial setting, recording start setting is performed (step ST 510 ). In the recording start setting, the recording start command is set to the encoder section 601 , and segmenting information (division set in step ST 508 ) is registered as the video object VOB.
[0074] When recorded data for “one contiguous data area (DCA)” is stored in the temporary storage 700 (yes in step ST 512 ), the writing address and writing length are determined in the disc drive 609 , and writing command is issued to the disc drive 609 (step ST 514 ). When there is an interrupt for taking the segmenting information (yes in step ST 516 ), the segmenting information is extracted from the formatter 619 (step ST 518 ). In other words, the image and sound signals taken into the encoder section 601 is A/D converted, respectively, and compressed by the encoders 616 , 617 . When a constant amount (one CDA) of compressed data is accumulated (yes in step ST 512 ), the data is recorded in the disc 100 . In this case, the segmenting information of the compressed data is taken into the work RAM 604 a (step ST 518 ). During recording (no in step ST 520 ), the processing of steps ST 512 to ST 518 is repeated.
[0075] When the recording ends (yes in step ST 520 ), a recording end processing is executed (step ST 530 ). In the recording end processing, the remaining segmenting information is taken from the formatter 619 and initialized, and setting of program chain information PGCI (segmenting information, I-picture information, and the like) is written into the management information VMG. In other words, the remaining segmenting information is taken into the work RAM 604 a, and the management information VMG is updated based on the taken segmenting information. In this case, the sound mode having a largest number of packs in recording is recorded in stream information STI (M_VOB_STI# of FIG. 4) in accordance with the sound mode (monaural, dual-monaural, or stereo) of the segmenting information (STI setting processing described later with reference to FIG. 11). Generally speaking, the stereo sound mode is most in TV recording of a music program, and the dual-monaural mode is mot in TV recording of foreign movie with Japanese subtitles.
[0076] [0076]FIG. 10 is a flowchart of an interrupt processing in the apparatus of FIG. 1. In the interrupt processing, there are various factors for an interrupt, and first the interrupt factors are checked (step ST 70 ). When the interrupt factor is, for example, “interrupt processing at the end of transfer of one pack to D-PRO 610”, an interrupt processing Recpack++ for counting up the number of recording packs is executed (step ST 72 ). Moreover, when the interrupt factor is, for example, “interrupt processing during extracting of segmenting information from formatter 619 ”, an interrupt flag for extracting segmenting information 1 is set (step ST 74 ). As not shown, an interrupt flag for extracting segmenting information×(x=1, 2, 3, . . . ) is appropriately performed. After the interrupt processing for each interrupt factor is performed as described above, the processing returns to another flow of processing.
[0077] [0077]FIG. 11 is a flowchart of a setting processing of stream information (STI) in the apparatus of FIG. 1. This processing is executed as a part of step ST 530 of FIG. 9. First, a state (monaural, dual-monaural, or stereo) of the sound mode during recording is checked from the segmenting information taken into the work RAM 604 a (step ST 5300 ). The sound mode having a largest number of recordings is checked among the checked sound modes (step ST 5302 ). When the monaural sound mode has the largest number of recordings, the “audio channel number” of the stream information STI (M_VOB_STI# of FIG. 4) is set to “monaural: 0000b” (step ST 5304 ). When the dual-monaural sound mode has the largest number of recordings, the “audio channel number” of the stream information STI is set to “dual-monaural: 1001b” (step ST 5306 ). When the stereo sound mode has the largest number of recordings, the “audio channel number” of the stream information STI is set to “2 ch stereo: 0001b” (step ST 5308 ).
[0078] [0078]FIG. 12 is a flowchart of an encoding processing of audio data in the apparatus of FIG. 1. First, the main MPU section 604 reads attribute information (A_ATR of FIG. 4) of a sound A/D converted and taken into the encoder section 601 from the TV tuner 613 (step ST 5400 ). The sound mode is checked from the content of the read attribute information (“audio channel number”) (step ST 5402 ). When the sound mode is monaural, monaural is set in the header of a sound stream (FIG. 6) (step ST 5404 ). When the sound mode is dual-monaural, dual-monaural is set in the header of the sound stream (step ST 5406 ). When the sound mode is stereo, stereo is set in the header of the sound stream (step ST 5408 ). After the information of the sound mode is set in the header of the sound stream, a compression processing of the sound data (e.g., compression processing of MPEG audio) is executed (step ST 5410 ). Additionally, when the sound data is recorded as linear PCM, setting of steps ST 5404 to ST 5408 is performed with respect to the “audio channel number” of FIG. 5, and the processing of step ST 5410 corresponds to linear PCM encoding.
[0079] [0079]FIGS. 13 and 14 are flowcharts showing the whole reproducing operation in the apparatus of FIG. 1. First, reading is started from lead-in of the disc 100 inserted in the disc drive 609 , and it is checked whether or not the disc is normally read (step ST 600 ). The disc is not normally read and it is judged that the disc 100 has a problem (NG in step ST 600 ). Then, an error processing (displaying of error in the display 608 and/or the TV 637 ) is performed (step ST 602 ), and the reproducing processing ends. On the other hand, the disc 100 can normally be read (OK in step ST 600 ), and it is then checked whether or not the information of a volume structure is recorded in the disc 100 (step ST 604 ). When the volume structure is not recorded (no in step ST 604 ), “not recorded” is displayed in the display 608 and/or the TV 637 (step ST 606 ), and the reproducing processing ends.
[0080] When the volume structure is recorded (yes in step ST 604 ), presence/absence of the directory of DVD-RTR (DVD-RTAV in FIG. 2) is checked in a recorded hierarchy file (step ST 608 ). If there is no DVD-RTR (DVD-RTAV) directory (no in step ST 608 ), “not recorded” is displayed (step ST 606 ), and the reproducing processing ends. If there is DVD-RTR (DVD-RTAV) directory (yes in step ST 608 ), the presence/absence of the error is checked (step ST 610 ). If there is an error (yes in step ST 610 ), “error has been found in file system” is displayed in the display 608 and/or the TV 637 (step ST 612 ) and the reproducing processing ends.
[0081] If there is no error (no in step ST 610 ), recording of management information VMG (VR_MANGR.IFO of FIG. 2) is checked (step ST 614 ). When VMG is not recorded (no in step ST 614 ), “not recorded” is displayed (step ST 616 ) and the reproducing processing ends. When the VMG is recorded (yes in step ST 614 ), VMG file is read (step ST 618 ), and preparation for reproducing is performed. Here, the main MPU section 604 reads the stream information STI which belongs to the VOB to be reproduced, and sets the respective decoders ( 627 to 630 ) in the decoder section 602 in accordance with the information in STI.
[0082] When VRO file (VR_MOVIE.VOR of FIG. 2, and the like) is not recorded in the read VMG directory (no in step ST 620 ), “not recorded” is displayed (step ST 616 ) and the reproducing processing ends. when the VRO file is recorded in the read VMG directory (yes in step ST 620 ), a program chain to be reproduced (original PGC, user-defined PGC#1, user-defined PGC#2, and the like) is determined (step ST 622 ). Subsequently, the content of the stream information STI (any one of M_VOB_STI#1 to #n) in VMG read in step ST 618 is read, and the MPEG video decoder 628 , subpicture decoder 627 , and audio decoder 630 of FIG. 1 are subjected to the initial setting (step ST 624 ). This continues to <node A> of FIG. 14.
[0083] The stream information STI read in step ST 624 includes the audio attribute information A_ATR (see FIG. 4) which has the “audio channel number”. The main MPU section 604 of FIG. 1 checks whether or not the sound mode of the title to be reproduced is “bilingual” (i.e., whether or not “audio channel number” is “1001b” indicating the dual-monaural mode) based on the content (“audio channel number”) of the stream information STI (step ST 626 ). With the bilingual mode (yes in step ST 626 ), it is further checked whether or not the audio language code of the DVD video is to be followed (step ST 628 ).
[0084] When the code is followed (yes in step ST 628 ), the audio language code of the DVD video (set by the user during initial setting, e.g., English) is read from the work RAM 604 a , and the subsound (English) of the bilingual mode is selected in accordance with sound language code (English). The audio decoder 630 is set so that the selected subsound is outputted via both channels (L/R) (step ST 630 ). When the code is not followed (no in step ST 628 ), the sound (e.g., Japanese main sound or English sub sound) designated for reproducing of DVD-RTR by the user via GUI is selected from the sound of the recorded TV channel. The audio decoder 630 is set so that the selected subsound is outputted via the both channels (L/R) (step ST 632 ). When the sound mode of the title to be reproduced is stereo (no in step ST 626 ), the processing of steps ST 628 to ST 632 is slipped. Then, the audio decoder 630 is set so that the recorded stereo sound is outputted via the both channels (L/R).
[0085] After the audio decoder 630 is set as described above, a cell reproducing processing (step ST 640 ) is performed. During reproducing (no in step ST 642 ), the next cell is set in accordance with the program chain information PGCI (original PGCI or user-defined PGCI) in the VMG file (step ST 644 ). In this case, when the sound mode changes (to the stereo mode from the dual-monaural mode), and the setting of audio decoding is changed (yes in step ST 646 ), the setting of the audio decoder 630 is changed by the next sequence end code (step ST 648 ). When the setting of the audio decoding is not changed (no in step ST 646 ), the setting of step ST 648 is not changed. When the reproducing continues to the next cell in a seamless mode (yes in step ST 650 ), the processing returns to the cell reproducing processing of step ST 640 . When the reproducing continues to the next cell in a non-seamless mode (no in step ST 650 ), the MPEG decoder is set to a free run mode, a seamless connection flag (not shown) is set (step ST 652 ), and the processing returns to the cell reproducing processing (step ST 640 ).
[0086] After the cell reproducing ends (yes in step ST 642 ), the error is checked (step ST 660 ). When there is no error (no in step ST 660 ), the other processing for ending the reproducing is executed (step ST 662 ), and the reproducing processing of FIGS. 13 and 14 ends. When the error occurs at the end of reproducing (yes in step ST 660 ), “read error occurs” is displayed in the display 608 and/or the TV637 (step ST 664 ), the reproducing end processing (step ST 666 ) is executed, and the processing returns to other processing state (e.g., the key input waiting state of step ST 20 of FIG. 7).
[0087] Additionally, the processing of steps the ST 626 , ST 628 , ST 630 and ST 632 of FIG. 14 corresponds to the processing of steps ST 404 , ST 408 , ST 412 and ST 410 of FIG. 8.
[0088] [0088]FIGS. 15 and 16 are flowcharts showing one example of a concrete content of a cell reproducing processing (step ST 640 ) in the apparatus of FIG. 1. First, a cell start position FP (logic block number LBN) and end FP (LBN) are determined based on the program chain information PGCI and time map information TMAPI included in the management information VMG. Subsequently, read FP is set as cell start FP, and “end address—start address” is set as a remaining cell length (step ST 6400 ). A start address and read length of contiguous data area CDA to be read are set (step ST 6402 ). When the read CDA length is smaller than a remaining cell length (yes in step ST 6404 ), “remaining cell length-length of the CDA to be read” is set as the remaining cell length, and the read length is set as CDA length (step ST 6406 ). On the other hand, when the length of the CDA to be read is not less than the remaining cell length (no in step ST 6406 ), the read length is set as the remaining cell length, and the remaining cell length is set to 0 (step ST 6408 ).
[0089] Subsequently, the data read command is set to the disc drive 609 (step ST 6410 ), and transfer start of the read data is waited for. The transfer starts (yes in step ST 6412 ), and one VOBU of the read data is accumulated in the buffer memory (not shown). When the one VOBU of data is accumulated in the buffer memory (yes in step ST 6414 ), one VOBU of data is read from the buffer memory (step ST 6416 ), and the pack constituting the VOBU is checked. When there is RDI pack (FIG. 3) in the top of VOBU (yes in step ST 6418 ), and there is a change in aspect ratio (yes in step ST 6420 ), a direct-current component of a chromatic signal (C signal) outputted via video terminal S after decoding is appropriately changed (step ST 6422 ). This continues to <node B> of FIG. 16.
[0090] When the seamless connection flag (set in step ST 652 of FIG. 14) in the VOBU data read in step ST 6416 is set (yes in step ST 6424 ), “read FP+read length” is set as read FP, and MPEG decoder is set to a normal mode. Moreover, a system clock reference SCR is appropriately read and set, and the seamless connection flag is reset (step ST 6426 ).
[0091] When the transfer started in step ST 6412 of FIG. 15 does not end (no in step ST 6428 ), there is a key input in step ST 20 of FIG. 7 (yes in step ST 6430 ), and a special reproducing mode is fast forward FF (yes in step ST 6432 ), a jump direction for the fast forward is set to a positive direction, and a read position read_fp is set in accordance with the jump amount (step ST 6434 ). On the other hand, when a special reproducing mode is not the fast forward FF but a fast rewind FR (no in step ST 6432 , yes in step ST 6436 ), the jump direction for the fast rewind is set to a negative direction, and the read position read_fp is set in accordance with the jump amount (step ST 6438 ). When the read position read_fp during FF or FR operation, a processing of contiguous data area DCA for the special reproducing (FF or FR) is performed (step ST 6440 ), and the processing returns to step ST 642 of FIG. 14.
[0092] Additionally, in DCA processing of step ST 6440 , the read position read_fp can be determined based on the time map information TMAPI referred to in step ST 6400 of FIG. 15 in consideration of the jump amount. Moreover, if there is no key input (no in step ST 6430 ), or even if the key input is neither FF key nor FR key (no in step ST 6432 , no in step ST 6436 ), the processing returns to step ST 6414 of FIG. 15 via <node C>.
[0093] When the transfer started in step ST 6412 of FIG. 15 ends (yes in step ST 6428 ), and the remaining cell length is zero (yes in step ST 6450 ), this is an end of the cell. Therefore, the processing of FIGS. 15 and 16 ends, and the processing returns to step ST 642 of FIG. 14. When the remaining cell length is not zero (no in step ST 6450 ), the processing returns to step ST 6420 of FIG. 15 via <node D>.
[0094] Additionally, in the aforementioned embodiment, “the setting which is associated with the language of the sound already set in DVD video reproducing” is automatically reflected in setting of DVD video recording. As expansion/modification, “the setting which is associated with the language of the set sound” can automatically be reflected in setting a received sound of the TV tuner 613 of FIG. 1 (or a single TV tuner unit connected in i link (R) via IEEE 1394 interface (not shown)). Concretely, the tuner received sound having the content set in step ST 412 of FIG. 8 can not only be recorded in the disc 100 of FIG. 1 but also be outputted via the speaker 633 of FIG. 1 (without being recorded in the disc 100 ).
[0095] Furthermore, similarly as the method of automatically reflecting the setting associated with the set language in the setting of video recording”, “the setting associated with the language of the subpicture already set in the DVD video reproducing” can automatically be reflected in selecting the language displayed in the monitor during reception of character broadcast.
[0096] [0096]FIG. 17 is a diagram showing contents of management information to be recorded by the apparatus of FIG. 1. Here, explanation will be given to a case where information of the volume space shown in FIG. 17( b ) is recorded in the information recording area of a DVD-RAM disc ( 100 ) shown in FIG. 17( a ). (Note that the data structure of information to be recorded on storage unit (such as an HDD) 700 may be the same.) The volume space of the disc ( 100 ) includes, as shown in FIG. 17( b ), a recording area of a volume & file management information and a data area of user data (AV information or the like). As shown in FIG. 17( c ), the data area can record management information RTR_VMG and contents (video object VOB constituting the AV information, or the like) of the user data. Management information RTR_VMG is stored as a file of video manager VMG.
[0097] Management information RTR_VMG includes, as shown in FIG. 17( d ), RTR video manager information RTR_VMGI, movie AV file information table M_AVFIT, still picture AV file information table S_AVFIT, original program chain information ORG_PGCI, user-defined program chain information table UD_PGCIT, text data manager TXTDT_MG, and manufacturer's information MNFIT.
[0098] Incidentally, program chain information PGCI has a data structure representing a whole reproduction of program chain PGC, and the PGC represents a sequence of program PG (or a program set). The PG is a logical unit of the recorded contents. The PG is recognized or defined by a user. The PG in a program set is formed of one or more original cells (which are reproduction units of the initial recorded contents), and the PG is defined only within the ORG_PGCI. In other words, the ORG_PGCI is the information by which an order of reproduction of cells corresponding to the initial recorded contents is described. On the other hand, the UD_PGCIT denotes a table which describes one or more PGCI's being subjected to a user's edition after recording.
[0099] The M_AVFIT includes, as shown in FIG. 17( e ), movie AV file information table information M_AVFITI, one or more pieces of movie VOB stream information M_VOB_STI#1 to M_VOB_STI#n, and movie AV file information M_AVFI. The M_AVFI includes, as shown in FIG. 17( f ), movie AV file information general information M_AVFI_GI, one or more movie VOB information search pointers M_VOBI_SRP#1 to M_VOBI_SRP#n, and pieces of movie VOB information M_VOBI#1 to M_VOBI#n corresponding in number to the number of the search pointers.
[0100] Each of the M_VOBI#'s includes, as shown in FIG. 17( g ), movie VOB general information M_VOBI_GI, seamless information SMLI, audio gap information AGAP, and time map information TMAPI. The TMAPI may be utilized when a special playback (e.g., a playback of cells in a special order defined by an independent user using the user-defined PGC) or a time search is to be performed.
[0101] The TMAPI includes, as shown in FIG. 17( h ), time map general information TMAP_GI, one or more time entries TM_ENT#1 to TM_ENT#r, and one or more VOBU_ENT#1 to VOBU_ENT#q.
[0102] Each TM_ENT includes, as shown in FIG. 17( i ), VOBU_ENTN indicating the corresponding VOBU entry number, TM_DIFF indicating a time difference between the playback start time of the VOBU being designated by the time entry and the calculated playback time, and VOBU_ADR indicating the address of the target VOBU. In the NTSC, when a time unit TMU is represented by 600 fields (or in the PAL, when the time unit TMU is represented by 500 fields), the above-mentioned “calculated playback time” with respect to the time entry #j can be represented by TMU x (j-1)+TM_OSF. The VOBU_ADR represents the target VOBU address by the total size of the preceding VOBU's of the VOB wherein the size of the VOBU is expressed in unit of a sector.
[0103] According to the data structure as exemplified above, when a playback has to be started from an intermediate point of a VOBU, it is necessary to determine its access point. This access point is called a time entry point. The time entry point is located at a place being deviated from the position, indicated by the movie address information of the VOBU, by the time difference, indicated by the time difference information TM_DIFF in the time entry TM_ENT. This time entry point is a specific playback start point (or time search point) indicated by the time map information TMAPI.
[0104] Each VOBU entry includes, as shown in FIG. 17( i ), reference picture size information 1STREF_SZ, VOBU playback time information VOBU_PB_TM, and VOBU size information VOBU_SZ. Here, the VOBU_PB_TM indicates the playback time of the corresponding VOBU in unit of a video field. The reference picture size information 1STREF_SZ indicates the size of the first reference picture (corresponding to an I-picture of the MPEG) in the corresponding VOBU in unit of a sector.
[0105] Incidentally, in the VOBU entry, the “time interval of VOBU's” is represented by the number of fields. However, as another method, the “time interval of VOBU's” may be represented by the count value of a clock counter, the count value indicating the interval from one VOBU to the next VOBU. More specifically, the “time interval of VOBU's” may be represented by the differential value of the “presentation time stamp PTS at the leading point of one VOBU” and the “PTS value at the leading point of the immediately followed VOBU.” In other words, it is possible to represent the time interval in a specific unit by the differential value of clock counts within that unit.
[0106] As described above, according to the digital recording/reproducing apparatus of the present invention, the setting associated with the language of the sound (already completed) is reflected in setting of recording/reproducing of DVD-RTR, and setting intricacy can be solved.
[0107] 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 invention concept as defined by the appended claims and their equivalents. | A digital recording/reproducing apparatus uses an information medium for storing audio-visual information corresponding to a plurality of types of audio languages and sound mode information associated with these audio languages. The apparatus is configured to record the audio-visual information on the information medium or to reproduce the audio-visual information from the information medium based on at least one of a plurality of different formats. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of and claims priority to pending U.S. application Ser. No. 11/812,300 filed on Jun. 18, 2007, and entitled RADIO FREQUENCY SHIELDING APPARATUS SYSTEM AND METHOD, the entire contents of which is expressly incorporated by reference herein.
BACKGROUND
[0002] The present disclosure generally relates to radio frequency shielding for a commercial aircraft. More particularly, the disclosure pertains to a method and system that assists in attenuating electromagnetic propagation through commercial aircraft passenger windows, aircraft doors or the like.
BACKGROUND
[0003] Generally, the fuselage of commercial aircraft are extremely efficient at attenuating electromagnetic radiation or energy such as radio frequency (RF) energy. Conventional aircraft typically include an outer skin of aluminum or include a conductive mesh or coating to dissipate lightning strikes. This conductive skin reflects and attenuates RF energy to a high degree. However, commercial aircraft generally also include a number of electromagnetic apertures. Aircraft windows and doors are two of the most common electromagnetic apertures inherent to most commercial aircraft designs. During operation of commercial aircraft, these apertures allow RF energy to enter and exit the aircraft.
[0004] This property of aircraft windows and doors is undesirable for several reasons. For example, externally generated RF transmissions may interfere with on-board systems. In another example, internally generated RF transmissions may interfere with on-board systems and/or may violate the rules of the United States Federal Communications Commission (FCC) and other such regulatory institutions.
[0005] Accordingly, it is desirable to provide a cost effective method and apparatus for attenuating electromagnetic propagation through aircraft passenger windows or the like at least to some extent.
SUMMARY
[0006] The foregoing needs are met, at least to some extent, by the present disclosure, wherein in one respect a system, assembly, and method is provided that in some embodiments attenuates electromagnetic propagation through an aperture in an aircraft.
[0007] An embodiment relates to a system for shielding an aircraft from electromagnetic energy. The system includes a fuselage, aperture, window mounting, and window plug. The fuselage provides an electrically conductive envelope. The aperture is disposed in the fuselage. The window mounting spans the aperture. The window plug spans the aperture. The window mounting and the window plug are electrically coupled to the fuselage and provide an electrical path spanning the aperture.
[0008] Another embodiment pertains to an assembly for shielding an aperture in a fuselage of an aircraft from electromagnetic energy. The assembly includes a window mounting and a window plug. The window mounting spans the aperture. The window plug spans the aperture. The window mounting and the window plug are electrically coupled to the fuselage and provide an electrical path spanning the aperture.
[0009] Yet another embodiment relates to a method of shielding an aperture in a fuselage of an aircraft from electromagnetic energy. In this method, a window mounting is conductively connected to the fuselage and a window plug is conductively connected to the window mounting.
[0010] There has thus been outlined, rather broadly, certain embodiments that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments that will be described below and which will form the subject matter of the claims appended hereto.
[0011] In this respect, before explaining at least one embodiment in detail, it is to be understood that embodiments are not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. In addition to the embodiments described, the various embodiments are capable of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0012] 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 disclosure. 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 various embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an exploded view of a system for shielding an aperture according to an embodiment.
[0014] FIG. 2 is a cross-sectional perspective view of a window mounting suitable for use with the system according to FIG. 1 .
[0015] FIG. 3 is a cross-sectional view of a capacitive gasket suitable for use with the window mounting according to FIG. 2 .
[0016] FIG. 4 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of coated windows suitable for use with the system according to FIG. 1 .
[0017] FIG. 5 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of coated windows and electronically dimmable windows suitable for use with the system according to FIG. 1 .
[0018] FIG. 6 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of coated windows and grounded electronically dimmable windows suitable for use with the system according to FIG. 1 .
[0019] FIG. 7 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of coated windows and circumferentially bonded electronically dimmable windows suitable for use with the system according to FIG. 1 .
[0020] FIG. 8 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of a coated bellows suitable for use with the system according to FIG. 1 .
DETAILED DESCRIPTION
[0021] Various embodiments will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. An embodiment in accordance with the present disclosure provides a method and system that assists in attenuating electromagnetic propagation, for example RF energy, through commercial aircraft apertures such as passenger windows, aircraft doors or the like. More particularly, an embodiment provides an aircraft aperture assembly or system having a plurality of components that, when assembled in an aircraft frame or fuselage, assists in the attenuation of the transmission of RF energy therethrough.
[0022] Referring now to FIG. 1 , a window system 10 includes a window mounting 14 and window plug 16 . The window mounting 14 is configured to be mounted in or mated with a window opening 18 in an outer skin 20 of an aircraft (not shown). The window plug 16 is configured to be mounted in or mated with a plug opening 22 in an inner skin 24 of the aircraft. The window mounting 14 includes a capacitive gasket 28 , outer window 30 , inner window 32 , and window forging 34 . The window mounting 14 is further described in FIGS. 2 and 3 . The window plug 16 includes a bellows seal 40 , outer reveal 42 , electronically dimmable window (EDW) 44 , inner reveal 46 , dust cover 48 , and window plug molding 50 .
[0023] In general, some or all of the various components of the window system 10 are configured to conduct electricity sufficiently well enough to reflect and/or attenuate electromagnetic energy such as RF energy. More particularly, when installed in an electrically conductive envelope such as a fuselage of an aircraft, the assembled components of the window system 10 provide a conductive path spanning the window opening 18 in the outer skin 20 of the fuselage. In this manner, electromagnetic energy such as RF energy generated within the fuselage may be attenuated or essentially prevented, to a large extent, from entering or exiting the fuselage. It is an advantage of various embodiments that RF energy may be attenuated to such an extent that signals emanating from within the fuselage can not reasonably be detected outside the fuselage. It is another advantage of various embodiments that, for the purposes of the United States Federal Communications Commission (FCC) and other such regulatory institutions, the interior of an aircraft outfitted with the window system 10 may be classified an indoor environment due to the attenuation of RF energy provided by the window system 10 .
[0024] In FIG. 2 , a particular embodiment of the commercial aircraft window mounting, generally designated 14 , is illustrated. The commercial aircraft window mounting 14 includes the capacitive gasket 28 positioned between and/or partially surrounding the outer window 30 and the inner window 32 . The commercial aircraft mounting 14 additionally includes the window forging 34 that is configured to mate with the airframe or outer skin 20 of the aircraft. The window forging 34 includes a radial flange 56 and an axial flange 58 . The window forging 18 also includes a base portion 60 that extends in opposing relationship to the radial flange 56 . That is, the base portion 60 extends generally inwardly or opposite the radial flange 56 as previously discussed, and provides an inwardly and downwardly sloping surface 62 .
[0025] As illustrated in FIG. 2 , the commercial aircraft window mounting 14 further includes a series of spring clips 64 positioned about the periphery of the window forging 34 . The commercial aircraft window mounting 14 also has a series of mounting flanges 66 and a series of bolts 68 , or other such mechanical attachments or fasteners, also positioned about the periphery of the forging 34 . The mounting flanges 66 are connected to, and extend from, the axial flange 58 of the window forging 34 . The mounting flanges 66 are positioned about the periphery of the window forging 34 as illustrated in FIG. 1 , and combine with the spring clips 64 and the bolts 34 to mount the gasket 28 and outer and inner windows 30 , 32 to the window forging 34 .
[0026] Referring now to FIGS. 2 and 3 , a cross-sectional view of the gasket 28 is illustrated. As depicted in FIGS. 2 and 3 , the gasket 28 encircles the outer window 30 and inner window 32 and provides a circumferential bond between the outer and inner windows 30 , 32 and the window forging 34 . The gasket 28 is a capacitive gasket that provides a capacitive bond between the windows 30 , 32 and the window forging 34 . The gasket 28 includes a lower portion or section 70 , a mid-section or portion 72 and an upper portion or section 74 .
[0027] As illustrated in FIGS. 2 and 3 , the lower section 70 of the gasket 28 extends from the mid-section 72 of the gasket 28 at an angle in a downwardly direction, away for the window forging 34 . The aforementioned geometry of the lower section 70 of the gasket 28 generally mirrors or compliments the downwardly sloping surface 62 of the base portion 60 . The lower section 70 includes a series of ridges, generally designated 78 , that extend outwardly from the lower section 70 . As depicted in FIGS. 2 and 3 , the mid-section 72 , as the name suggests, occupies the middle portion of the gasket 28 and functions as a spacer between the outer window 30 and inner window 32 . The upper portion 74 extends upwardly from the mid-section 72 , generally parallel to the axial flange 58 of the window forging 34 .
[0028] In various embodiments, the gasket 28 includes a conductive media that is bound by an elastomeric matrix. The conductive media includes any suitable strongly, weakly, and/or semi-conductive materials. Specific examples of conductive materials include conductive carbon black, aluminum, silver, and the like. The elastomeric matrix includes ethylene propylene diene monomer (EPDM) and the like. In one embodiment, the capacitive gasket 28 includes a carbon black media in an EPDM or other such elastomeric matrix. Alternatively, the gasket 28 may include silver and/or aluminum flakes in an EPDM or other such elastomeric matrix. The carbon black media provides greater than 20 dB to about 45 dB of RF energy shielding in the range of from about 80 MHz to approximately 18 GHz of the electromagnetic spectrum. The silver and/or aluminum flake media provides approximately 10 dB to about 47 dB of RF energy shielding in the range of from about 80 MHz to approximately 18 GHz of the electromagnetic spectrum.
[0029] As previously discussed, during operation of commercial aircraft for example, the aircraft encounters electromagnetic energy in the form of RF radiation from external sources. This RF radiation can interfere with the operation of the commercial aircraft systems such as the communication system and the navigation system. Accordingly, in order to attenuate the propagation of RF radiation through the commercial aircraft passenger windows, techniques such as shielding are implemented to reduce electromagnetic propagation. During the shielding process and, prior to assembly of the window system 10 the windows are treated with a film or material that reflects electromagnetic energy. As illustrated in FIG. 1 , the inner window 32 has been shielded or treated, as generally designated by reference numeral 76 , with a film or other material that reduces or attenuates the propagation of electromagnetic radiation. The shielding 76 includes any suitable film, layer, and/or treatment operable to reflect, attenuate, or otherwise reduce the propagation of electromagnetic energy. Suitable examples of the shielding 76 include conductive films, meshes, and the like.
[0030] The shielded inner window 32 combines with the gasket 28 to reduce electromagnetic propagation through the passenger windows of a commercial aircraft. As previously discussed, the shielded window 32 reflects electromagnetic radiation, however as the frequency of electromagnetic energy increases, for example, to approximately 1 GHz to approximately 2 GHz, the window may begin to lose its attenuation characteristics and begin to resonate and retransmit the electromagnetic energy. To avoid such instances, the gasket 28 provides a capacitive coupling between the inner window 32 and the commercial aircraft frame, dissipating the electromagnetic energy onto the aircraft frame or outer skin 20 . In this regard, the gasket 28 includes a material having a dielectric constant, permittivity, and/or resistance such that the gasket 28 is configured to discharge electromagnetic energy from the window 32 to the window forging 34 prior to resonance of the window 32 . That is, the window 32 is configured to reflect electromagnetic energy until the energy exceeds a predetermined maximum amount of energy. If the window 32 were to remain electrically isolated past this predetermined maximum amount of energy, the window 32 may transmit RF energy. The gasket 28 is configured to conduct electromagnetic energy or electricity from the window 32 to the window forging 34 prior to the amount of energy in the window 32 exceeding the predetermined maximum. The gasket 28 further assists the attenuation electromagnetic radiation by absorbing some of the electromagnetic energy as heat.
[0031] FIGS. 4-7 are examples of graphs showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of components suitable for use with the system according to FIG. 1 . As shown in FIG. 4 , the window 30 and/or 32 , when coated with a thin, essentially transparent, coating of gold, attenuates approximately 20 decibels (dB) of electromagnetic (EM) energy within a frequency range of about 300 megahertz (MHz) to about 11,000 MHz. As shown in FIG. 5 , when the coated window 30 and/or 32 is combined with the EDW 44 , approximately 25 dB of EM energy is attenuated within a frequency range of about 300 MHz to about 11,000 MHz. That is, assembling these two components increases the attenuation. Similarly, as shown in FIG. 6 , by grounding the EDW 44 , approximately 35 dB of EM energy is attenuated within a frequency range of about 300 MHz to about 11,000 MHz. The attenuation is further again increased by circumferentially bonding the EDW 44 within the window system 10 . In a particular embodiment, the EDW 44 is circumferentially bonded to the window system 10 via the bellows seal 40 . For example the bellows seal 40 is conductively coated or otherwise configured to conduct EM energy. In a particular example, the bellows seal 40 is coated with an electrically conductive silicone-based ink. This ink may include any suitable conductive material such as, for example, aluminum, silver, gold, carbon, and the like. While in general, any suitable coating material that exhibits good adhesion to the bellows seal 40 , flexibility, and conductivity may be utilized in various embodiments, specific examples of coating materials may be manufactured by Creative Materials, Inc. of Tyngsboro, Mass. 01879, U.S.A. In particular, product number 115-08, electrically conductive silicone ink with 87% silver (cured) is suitable for use with various embodiments. It is to be understood that the graphs illustrated in FIGS. 4-7 are for illustrative purposes only, and thus, the respective curvatures, slopes and y-intercepts may be the same or different depending on the response of the various EM energy attenuators.
[0032] FIG. 8 is an example of a graph showing frequency in MHz (abscissa) as it affects the shielding effectiveness in dB (ordinate) of a coated bellows suitable for use with the system according to FIG. 1 . As shown in FIG. 8 , when coated with electrically conductive silicone ink with 87% silver (cured), the bellows seal 40 attenuates approximately 20 dB. It is to be understood that the graph illustrated in FIG. 8 is for illustrative purposes only, and thus, the respective curvatures, slopes and y-intercepts may be the same or different depending on the response of the various EM energy attenuators.
[0033] The many features and advantages of the various embodiments are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages that fall within the true spirit and scope of the embodiments. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the embodiments to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the various embodiments. | An assembly for shielding an aircraft from electromagnetic energy may include a window mounting configured to be conductively coupled to an aperture in a fuselage of an aircraft. The window mounting may include a window pane having an electromagnetically-reflective coating for reflecting electromagnetic energy. The window pane may remain electrically isolated from the fuselage prior to the electromagnetic energy exceeding a frequency of approximately 1 GHz. The window mounting may further include a capacitive gasket capcaitively coupling the window pane to the fuselage after the frequency of the electromagnetic energy reflected by the window pane exceeds approximately 1 GHz. | 1 |
BACKGROUND OF THE INVENTION
The present invention pertains generally to strengthening solid propellants for rocket motors and recoilless guns and in particular to improving the structural integrity of reinforced high-thrust rocket motors and other recoilless systems.
The high thrust, high mass flow, and short burning times of high-acceleration recoilless gun systems and rocket motors, such as those used in tube-launched weapon systems, place the propellant under severe shock or stress conditions which can destroy the physical integrity of the gun or rocket motor. Resulting from the cracks and the break-up of the propellant is an uncontrolled increase in the burning-surface area and thus the supply of gas. These problems plus the total impulse requirements from a system of highly constrained dimensions and weight mitigate against the use of double-base propellants in high-thrust rockets, such as tube-launched rockets, even though double-base propellants are less smokey, corrosive, expensive, and toxic than the presently used case-bonded composite propellants. The problems of smoke and toxicity are especially serious for tube-launched rockets and recoilless guns because of the close proximity of people to their use. An additional problem with presently used composite propellants is the excessive noise during combustion of the high thrust, very short-burning rockets.
Previous attempts at strengthening a double-base propellant with a reinforcing substrate involved bonding one or two thin sheets of propellant to a flexible metallic or non-metallic sheet or screen by pressure, adhesive, or curing the propellant around the substrate. All of these attempts had the problem of not producing a sufficiently strong and complete bond between the substrate and propellant as well as problems arising from the choice of substrate. Since the propellant was not securely bonded, combustion flashed into the unbonded propellant areas and caused catastrophic failure of the rocket motor and recoilless guns. Further, adhesives, when used, interfered with the propellant's combustion. The effectiveness of these previous attempts to utilize smokeless propellants was so poor that the very objectionable case-bonded composite propellants continued to be used.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a method for reinforcing double-base propellants sufficiently to permit their use in high-thrust, short-burning applications.
Another object of the present invention is to increase the strength of the bond between propellant and a reinforcing substrate.
A further object of the present invention is to maximize the controlled burning surface of a reinforced propellant.
These and other objects are achieved by slowly coating a flexible non-metallic screen with a propellant lacquer so that the propellant dries quickly and shrinks perpendicularly to the surface of the screen.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention is suitable for any propellant which can be made into a lacquer. While this method is applicable to composite propellants, the advantages of this invention are best realized with double-base propellants since this method permits their effective use in high-thrust rockets and recoilless guns.
The reinforcing substrate may be a screen or a perforated sheet or any other form so long as the substrate is permeable to propellant decomposition gases which evolve during storage, is sufficiently strong to withstand the severe stress and shock of a firing, and has a low density. For tube-launched rockets, it is preferred that the substrate has a mesh size from 4 to 9 meshes per centimeter.
The material of the substrate must be flexible so that the substrate can adapt to the physical behaviour of the propellant as it shrinks during drying and as the charge is stressed during a firing. It is, of course, necessary that the material be chemically compatible with the solid propellant, have a low solubility in the components of the propellant lacquer especially for nitroglycerine and other energetic plasticizers, be relatively non-combustible in a reducing atmosphere, resistant to erosion by the propellant combustion gases, have coefficients of expansion and thermal conductivity close enough to those of the propellant to be physically compatible, permit the propellant to adhere to its surface and be easily processed and formed. Examples of suitable materials include polypropylene, polyethylene, polyvinylchloride, and silicone rubbers.
The propellant lacquer is prepared by dissolving a propellent, which can be in any form e.g. powder, flake, sheet, etc., in a solvent by any of the standard techniques and preferably by those which minimize the amount of water in the propellant which is detrimental to the uniformity of the resulting propellant coating on the substrate. If a surfactant is added to prevent the water from forming discrete globules in the lacquer, a greater tolerance of water is possible. One commonly used solvent in lacquer processing is acetone because of its low cost and high soluting power for propellants. For this reason, acetone is the preferred solvent. But any other solvent which is compatible with the propellant and substrate can be used.
The method of the present invention can be practiced in a batch or continuous mode but the continuous mode is preferred because of reduced labor costs. With either technique care must be taken to ensure uniformity of propellant thickness and to prevent voids, bubbles, and other defects in the propellant. It is preferred that the resulting reinforced propellant have a waffle appearance imparted by the substrate because of the desirably increased surface area.
With either mode, a lacquer having a concentration up to about saturation, a uniform consistency, and in absence of air bubbles is prepared. Preferably, the lacquer has a concentration from about 10 to about 35 weight percent of total solution. Concentrations below 10 weight percent would require the subject method to be repeated many times in order to obtain a sufficiently thick coat on a reinforcing substrate. However, if the screen is thin and lacks stiffness, a solution below ten percent might be necessary. Concentration above 30 weight percent would increase the difficulties of maintaining uniformity in the propellant coating and of traversing the substrate through the lacquer. The most preferred concentration is from 15 to 25 weight percent of total solution.
The preferred batch technique of traversing the substrate through the propellant lacquer is by vertically dipping the substrate into the lacquer and gradually withdrawing the substrate at a rate up to about the drain rate of the lacquer, i.e. at a rate which avoids dripping. Dripping is to be avoided because of its detrimental effect on the coating. After each coating, the substrate is hung to dry. For repeated coatings, the substrate, upon removal from the lacquer, is allowed to dry until the propellant surface is no more than slightly tacky before another application is made.
The preferred continuous technique of traversing a substrate through a propellant lacquer comprises passing the substrate from a continuous roll through the propellant lacquer whereby the substrate exits without dripping from the lacquer substantially vertical to it and proceeds through an oven or similar drying means. If several coats are desired, the apparatus is modified to permit several sequential dippings and dryings.
The method of the present invention is suitable for the preparation of a continuous propellant charge or of propellant discs which are stacked to form a propellant charge. The continuous propellant charge is formed by winding laminated sheets of substrate and propellant into the desired configuration, e.g., a cylinder. Spacing among the windings, which provides increased burning surface and good control of port area for the combustion gases is most easily achieved with a corrugated screen.
the following examples are given by way of explanation and are not meant to limit this disclosure or the claims to follow.
EXPERIMENTAL SECTION I
Preparation of Propellant Charge
A 20 weight percent lacquer was prepared by dissolving and mixing, in acetone, a propellant consisting of nitrocellulose (49%), nitroglycerine (42%), 2-nitrodiphenylamine (2%), di-normal propyl adipate (1.5%), normal lead betaresorcylate (2.5%) monobasic cupric betaresorcylate (2.5%), and carbon black (0.5%). The mixing was accomplished by a slow horizontal rolling of the lacquer container at a temperature from about 15° to about 27° C. for several days. Rectangles (21.6 cm by 15.2 cm) were cut from screens consisting of 11 mil polypropylene fiber with carbon black filter, woven with 5.5 by 7 meshes per centimeter.
Just prior to use, a vacuum (380 mm Hg) was placed on the lacquer container for 10 to 20 seconds and this was repeated three times in order to bring air bubbles to the surface of the lacquer. Each screen was lowered into the lacquer vertically until the screen rectangle was just fully covered, followed by a gradual withdrawal from the lacquer at a rate not exceeding about 2.5 cm/sec. A brief pause of about five to ten seconds when the screen was half removed and another pause of about three minutes when the screen was just touching the lacquer were made during the withdrawal in order to drain excess propellant from the screen without dripping. The extra care to avoid any dripping was prompted by the air bubbles formed by dripping. Upon removal from the lacquer the screen was gently brought into contact with a solid surface in order to avoid further dripping and to prevent a build-up of excess thickness at the bottom of the screen.
The screens were individually hung on a drying rack under a hood over night and were dipped a second time in the opposite direction the following day. The second dip was done exactly as the first dip although it was easier because of the increased weight and density of the coated screen. After four hours of drying under a hood at room temperature (22° C.), the screens were trimmed with a photographic-type trimmer by successively cutting strips of approximately 0.3 cm width from all sides of the dried screens. The strips were later used as spacer strips to separate the discs cut from the coated screen rectangles.
Two full-length spacer strips were placed lengthwise on each screen rectangle so that they were 3.3 cm in from each side. The ends tacked to the screen with acetone from a dropper. Three shorter strips across the full-length strips, one exactly centered and the others 3.3 cm in from the ends. The strips were bonded at the six intersecting locations with a few drops of acetone, followed by pressing until the bond was formed. To completely bond the strips, acetone was sparingly injected along the full length of each stopper and the strips were pressed until bonding was achieved throughout the lengths of all spacer strips except in the six regions of intersection.
Discs were then cut out using a concentric cutter. The resulting discs were 0.08 to 0.1 cm in thickness and weighed 2.9 to 3.6 grams. All discs were dipped in acetone for about ten seconds each to seal cut edges. Discs weighing from about 3.3 to 3.6 grams were stacked on igniter spindles to form three propellant charges having 130 discs each and weighing approximately 450 grams. Other discs weighing from about 2.9 to 3.2 grams were stacked on an igniter spindle to form a propellant charge having 150 discs and weighing approximately 450 grams.
EXPERIMENTAL SECTION II
Testing the Propellant Charge
The above propellant charges designated as "1", "2", and "3" for the 130 disc charges and "4" for 150 disc charge were tested by firing a 2.3 kg projectile from an 81 mm recoiless gun with an 80 cm launcher stroke. The results are shown and compared with the performance of a standard tube-launched, anti-tank rocket, "5", which has a composite propellant, in Table I. The anti-tank rocket differs further from the charge tests in that the propellant weight of the anti-tank rocket was 150 grams and the projectile was about 1.2 kg.
TABLE I__________________________________________________________________________ Head Temp. Burn Muzzle Level Maximum Breech of Temp. Time, Sec.Test Velocity Noise,* Pressure Pressure, Round Coeff., (10% to 10%)No. Ft/Sec. (Decibles) psi psi °F. %/°F. Pressure__________________________________________________________________________1 765 176.5 2378 2335 140° 0.00872 715 173.5 2243 2186 70° 0.055 0.01193 705 176.5 2108 2006 -40° 0.01154 888 182 3000 70° 0.01155 835 186 ˜7000 70° 0.16 estim. 0.006__________________________________________________________________________
The results in Table I show a significant reduction in noise and a substantial improvement in the temperature coefficient, which is an excellent indicator of the constancy of a propellant's performance. Further, the results indicate an excellent temperature independence in performance over a temperature range from -40° F. to 140° F.
EXPERIMENTAL SECTION III
Additional Tests
The charges for Tests Nos. 6-13 were prepared by the method described in I. Each test charge had 150 discs and the total weight of each test charge for Test Nos. 6 to 10 was about 425 gm, for Test Nos. 11 and 12 was about 405 gm, and for Test No. 13 was about 365 gm. An 81 mm MOUT Assault Weapon was used to fire the test charges. The chamber pressures were measured with a Bourdon gauge and the noise level was measured with Kistler gauges at these points: (1) about one foot from center line towards the nozzle end, (2) at about the nozzle end, and (3) about two feet above center of gun at the nozzle end.
TABLE II______________________________________Amb. Mc/ In GunTest Temp Chamber Av. Chamber Firing Time Vel.No. °F. Pr, psi Pr, psi millisec FPS______________________________________6 70 2712 1667 10.8 8807 70 2680 1645 10.6 8758 70 2980 1716 10.9 9169 70 2555 1587 10.8 89210 -40 2320 1292 13.6 84411 140 2965 1584 8.5 84612 140 3000 1600 8.3 83113 140 2905 1698 7.9 794______________________________________
TABLE III______________________________________ Noise levelTest Gauge 1 Gauge 2 Gauge 3No. db db db______________________________________6 170 165 1797 169.5 165.5 1788 169.7 164.5 1809 171.5 177 16910 169.5 165.5 177.711 169 170 16412 166 164 18213 142 130 168______________________________________
The results shown in Tables II and III again show excellent temperature independence in performance. The pressure and noise-level results demonstrate that the use of double-base propellants in recoilless guns is now possible. A blow-out plug was not needed for the tests because of the propellant's ease of ignition, a property resulting from both the chemistry of the propellant and the configuration of the propellant. Thus, the method of the present invention permits the elimination of the hazardous and noise-generating end plug.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein. | A method for strengthening a propellant charge by incorporating a support ructure in the propellant charge comprises slowly traversing a flexible perforated material through a propellant lacquer until the desired loading is obtained. Reinforcement by this technique makes possible the use of a double base propellant in high-thrust, short-burning applications. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of and claims the benefit of currently pending U.S. patent application Ser. No. 13/291,145, entitled “HUMAN ANTIBODIES TO HUMAN TNF-LIKE LIGAND 1A (TL1A)”, filed Nov. 8, 2011, which application claims the benefit under 35 U.S.C §119(e) of U.S. provisional application Nos. 61/411,276 filed Nov. 8, 2010; and 61/478,309 filed Apr. 22, 2011, both of which are herein specifically incorporated by reference in their entireties.
FIELD OF THE INVENTION
The present invention is related to human antibodies and antigen-binding fragments of human antibodies that specifically bind human TNF-like ligand 1A (hTL1A), and therapeutic methods of using those antibodies.
STATEMENT OF RELATED ART
TL1A is a type II cell membrane protein of the tumor necrosis factor superfamily (TNFSF) and also designated as TNFSF15. It is expressed on the surface of endothelial cells, and activated cells of the hematopoietic lineage, including monocytes, macrophages, lymphocytes, lamina propria mononuclear cells, dendritic cells and plasma cells (Tan, K. B. et al., 1997, Gene 204:35-46; Prehn, J. L. et al., 2007, J Immunol 178:4033-4038). It is also expressed in kidney, lung, prostate and thymus (Tan et al., 1997, supra). In endothelial cells, expression of TL1A is upregulated by IL-1α and TNFα (Migone, T. S. et al., 2002, Immunity 16:479-492). In human fresh blood monocytes and monocyte-derived dendritic cells, TL1A expression is upregulated by FcγR-mediated or Toll-like receptor (TLR) signaling (Prehn et al., 2007, supra; Meylan, F. et al., 2008 , Immunity 29:79-89). TL1A can be cleaved from the cell membrane via a mechanism analogous to TNFα and a soluble ectodomain form of TL1A has been reported (Migone et al., 2002, supra; Kim, S. et al., 2005, J Immunol Methods 298:1-8; Yang, C. R. et al., 2004, Cancer Res 64:1122-1129). Protein sequencing has confirmed that this form of TL1A is liberated following cleavage of the membrane-anchored precursor between residues Ala-71 and Leu-72 (Migone et al., 2002, supra). Two variant cDNAs that potentially encode N-terminally truncated versions of TL1A have been identified: VEGI-174 (or TL1) (Zhai, Y. et al., 1999, FASEB J 13:181-189) and VEGI-192 (Chew, L. J. et al., 2002, FASEB J 16:742-744). The published data suggest the biologically active products of the TL1A gene are the full-length type II transmembrane protein (residues 1-251) and its proteolytically cleaved ectodomain (residues 72-251) (Migone et al., 2002, supra; Jin et al., 2007, Biochem Biophys Res Commun 364:1-6). A variant of hTL1A, designated as “Fhm”, containing a single amino acid substitution of Gln-167 with Arg, is disclosed in U.S. Pat. No. 6,521,422.
TL1A mediates signals via its cognate receptor Death Receptor 3 (DR3; also known as TNFRSF25; the nucleic acid and amino acid sequences of SEQ ID NO:251 and 252, respectively), resulting in promoting cell survival and secretion of pro-inflammatory cytokines, or promoting apoptosis, in a context-dependent manner. TL1A is one of three known ligands (in addition to FasL and LIGHT) that are bound by the endogenous soluble decoy receptor, DcR3 (also known as TR6, NTR3 or TNFRSF21; the nucleic acid and amino acid sequences of SEQ ID NO:253 and 254, respectively) (Migone et al., 2002, supra; Yang C. R. et al., 2004, Cancer Res 64:1122-1129).
DR3 is a TNF receptor-related death-domain receptor expressed on the majority of activated T lymphocytes and NK cells (Migone et al., 2002, supra; Screaton G. R. et al., 1997, Proc Natl Acad Sci ( USA ) 94:4615-4619). TL1A engages DR3 on T cells, enhancing their responsiveness to IL-2 (Migone et al., 2002, supra), potentiating T cell proliferation and release of IFNγ and GM-CSF under conditions of suboptimal costimulation (Migone et al., 2002, supra; Meylan et al., 2008, supra). TL1A has also been shown to synergize with suboptimal levels of IL-12/IL-18 to induce IFNγ production by CD4 + T cells (Papadakis, K. A. et al., 2004, J Immunol 172:7002-7007; Prehn, J. L. et al., 2004, Clin Immunol 112:66-77; Papadakis, K. A. et al., 2005, J Immunol 174:4985-4990; Cassatella, M. A. et al., 2007, J Immunol 178:7325-7333).
TL1A has been implicated in various inflammatory diseases and/or auto immune diseases, including inflammatory bowel diseases [e.g., ulcerative colitis (UC) and Crohn's disease (CD)], rheumatoid arthritis, multiple sclerosis (MS), atherosclerosis, and the like (see Bayry, J., 2010 , Nature Reviews/Rheumatology 6:67-68; Takedatsu, H. et al., 2008, Gastroenterology 135:552-567; Prehn et al., 2004, supra; Bamias, G. et al., 2008, Clin Immunol 129:249-255; Bull, M. J. et al., 2008, J Exp Med 205:2457-2464; Pappu, B. P. et al., 2008, J Exp Med 205:1049-1062; Bamias, G. et al., 2003, J Immunol 171:4868-4874; Kang, Y. et al., 2005, Cytokine 29:229-235). Although the majority of the published data are consistent with a pivotal role for TL1A in driving differentiation of T H 1 and T H 17 effector function, a recent study has proposed a role for the TL1A/DR3 interaction in development of T H 2 T cell responses in asthma models (Fang, L. et al., 2008, J Exp Med 205:1037-1048). Thus, the use of TL1A inhibitors, such as fully human antibodies against TL1A with high affinities and neutralizing activity, alone or in combination with currently available anti-inflammatory agents, immunosuppresants (e.g., TNF-α antagonists, cortisone or steroids, and the like), and/or anti-allergy agents, provides effective treatment for these diseases and disorders.
The nucleic acid and the amino acid sequences of human TL1A are shown in SEQ ID NOS: 243 and 244, respectively, and those of Fhm are shown in SEQ ID NOS:245 and 246, respectively. Antibodies to TL1A are disclosed in, for example, U.S. Pat. No. 7,597,886, U.S. Pat. No. 7,820,798 and US 2009/0280116.
BRIEF SUMMARY OF THE INVENTION
In a first aspect, the invention provides fully human monoclonal antibodies (mAbs) and antigen-binding fragments thereof that specifically bind and neutralize human TL1A (hTL1A) activity.
The antibodies can be full-length (for example, an IgG1 or IgG4 antibody) or may comprise only an antigen-binding portion (for example, a Fab, F(ab′) 2 or scFv fragment), and may be modified to affect functionality, e.g., to eliminate residual effector functions (Reddy et al., 2000, J. Immunol. 164:1925-1933).
In one embodiment, the invention features an antibody or antigen-binding fragment of an antibody comprising a heavy chain variable region (HCVR) selected from the group consisting of SEQ ID NO:2, 18, 34, 50, 66, 82, 98, 114, 118, 134, 138, 154, 158, 174, 178, 194, 198, 214, 218 and 234, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity. In another embodiment, the antibody or an antigen-binding fragment thereof comprises a HCVR having an amino acid sequence selected from the group consisting of SEQ ID NO:2, 18, 34, 50, 66, 134, 174 and 234. In yet another embodiment, the antibody or fragment thereof comprises a HCVR comprising SEQ ID NO:2, 18, 174 or 234.
In one embodiment, the antibody or fragment thereof further comprises a light chain variable region (LCVR) selected from the group consisting of SEQ ID NO:10, 26, 42, 58, 74, 90, 106, 116, 126, 136, 146, 156, 166, 176, 186, 196, 206, 216, 226 and 236, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity. In another embodiment, the antibody or antigen-binding portion of an antibody comprises a LCVR having an amino acid sequence selected from the group consisting of SEQ ID NO:10, 26, 42, 58, 74, 136, 176 and 236. In yet another embodiment, the antibody or fragment thereof comprises a LCVR comprising SEQ ID NO:10, 26, 176 or 236.
In further embodiments, the antibody or fragment thereof comprises a HCVR and LCVR (HCVR/LCVR) sequence pair selected from the group consisting of SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 82/90, 98/106, 114/116, 118/126, 134/136, 138/146, 154/156, 158/166, 174/176, 178/186, 194/196, 198/206, 214/216, 218/226 and 234/236. In one embodiment, the antibody or fragment thereof comprises a HCVR and LCVR selected from the amino acid sequence pairs of SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 134/136, 174/176 and 234/236. In another embodiment, the antibody or fragment thereof comprises a HCVR/LCVR pair comprising SEQ ID NO:2/10, 18/26, 174/176 or 234/236.
In a second aspect, the invention features an antibody or antigen-binding fragment of an antibody comprising a heavy chain complementarity determining region 3 (HCDR3) amino acid sequence selected from the group consisting of SEQ ID NO:8, 24, 40, 56, 72, 88, 104, 124, 144, 164, 184, 204 and 224, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity; and a light chain CDR3 (LCDR3) amino acid sequence selected from the group consisting of SEQ ID NO:16, 32, 48, 64, 80, 96, 112, 132, 152, 172, 192, 212 and 232, or substantially similar sequences thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity. In one embodiment, the antibody or fragment thereof comprises a HCDR3/LCDR3 amino acid sequence pair comprising SEQ ID NO:8/16, 24/32, 40/48, 56/64, 72/80, 88/96, 104/112, 124/132, 144/152, 164/172, 184/192, 204/212 or 224/232. In another embodiment, the antibody or fragment thereof comprises a HCDR3/LCDR3 amino acid sequence pair comprising SEQ ID NO: 8/16, 24/32, 40/48, 56/64, 72/80, 124/132, 164/172 or 224/232. In yet another embodiment, the antibody or fragment thereof comprises a HCDR3/LCDR3 amino acid sequence pair comprising SEQ ID NO:8/16, 24/32, 164/172 or 224/232.
In a further embodiment, the invention features an antibody or fragment thereof further comprising a heavy chain CDR1 (HCDR1) amino acid sequence selected from the group consisting of SEQ ID NO:4, 20, 36, 52, 68, 84, 100, 120, 140, 160, 180, 200 and 220, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity; a heavy chain CDR2 (HCDR2) amino acid sequence selected from the group consisting of SEQ ID NO:6, 22, 38, 54, 70, 86, 102, 122, 142, 162, 182, 202 and 222, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity; and/or a light chain CDR1 (LCDR1) amino acid sequence selected from the group consisting of SEQ ID NO:12, 28, 44, 60, 76, 92, 108, 128, 148, 168, 188, 208 and 228, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity; and/or a light chain CDR2 (LCDR2) amino acid sequence selected from the group consisting of SEQ ID NO:14, 30, 46, 62, 78, 94, 110, 130, 150, 170, 190, 210 and 230, or a substantially similar sequence thereof having at least 90%, at least 95%, at least 98% or at least 99% sequence identity. In one embodiment, the antibody or fragment thereof comprises a combination of HCDR1/HCDR2/HCDR3 selected from the group consisting of SEQ ID NO:4/6/8, 20/22/24, 36/38/40, 52/54/56, 68/70/72, 84/86/88, 100/102/104, 120/122/124, 140/142/144, 160/162/164, 180/182/184, 200/202/204 and 220/222/224; and/or a combination of LCDR1/LCDR2/LCDR3 selected from the group consisting of 6SEQ ID NO:12/14/16, 28/30/32, 44/46/48, 60/62/64, 76/78/80, 92/94/96, 108/110/112, 128/130/132, 148/150/152, 168/170/172, 188/190/192, 208/210/212 and 228/230/232. In another embodiment, the heavy and light chain CDR amino acid sequences comprise a CDR sequence combination selected from the group consisting of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 36/38/40/44/46/48, 52/54/56/60/62/64, 68/70/72/76/78/80, 84/86/88/92/94/96, 100/102/104/108/110/112, 120/122/124/128/130/132, 140/142/144/148/150/152, 160/162/164/168/170/172, 180/182/184/188/190/192, 200/202/204/208/210/212 and 220/222/224/228/230/232. In another embodiment, the antibody or antigen-binding fragment thereof comprises heavy and light chain CDR sequences of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 36/38/40/44/46/48, 52/54/56/60/62/64, 68/70/72/76/78/80, 120/122/124/128/130/132, 160/162/164/168/170/172 or 220/222/224/228/230/232. In yet another embodiment, the heavy and light chain CDR amino acid sequences comprise a CDR sequence combination of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 160/162/164/168/170/172 or 220/222/224/228/230/232.
In a related embodiment, the invention comprises an antibody or antigen-binding fragment of an antibody which specifically binds hTL1A, wherein the antibody or fragment thereof comprises heavy and light chain CDR domains contained within heavy and light chain sequence pairs selected from the group consisting of SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 82/90, 98/106, 114/116, 118/126, 134/136, 138/146, 154/156, 158/166, 174/176, 178/186, 194/196, 198/206, 214/216, 218/226 and 234/236. Methods and techniques for identifying CDRs within HCVR and LCVR amino acid sequences are known in the art and can be applied to identify CDRs within the specified HCVR and/or LCVR amino acid sequences disclosed herein. Conventional definitions that can be applied to identify the boundaries of CDRs include the Kabat definition, the Chothia definition, and the AbM definition. In general terms, the Kabat definition is based on sequence variability, the Chothia definition is based on the location of the structural loop regions, and the AbM definition is a compromise between the Kabat and Chothia approaches. See, e.g., Kabat, “Sequences of Proteins of Immunological Interest,” National Institutes of Health, Bethesda, Md. (1991); Al-Lazikani et al., J. Mol. Biol. 273:927-948 (1997); and Martin et al., Proc. Natl. Acad. Sci. USA 86:9268-9272 (1989). Public databases are also available for identifying CDR sequences within an antibody. In one embodiment, the antibody or fragment thereof comprises CDR sequences contained within a HCVR and LCVR pair selected from the group consisting of the amino acid sequence pairs of SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 134/136, 174/176 and 234/236. In another embodiment, the antibody or fragment thereof comprises CDR sequences contained within the HCVR and LCVR sequence pair of SEQ ID NO: 2/10, 18/26, 174/176 or 234/236.
In another related embodiment, the invention provides an antibody or antigen-binding fragment thereof that competes for specific binding to hTL1A with an antibody or antigen-binding fragment comprising heavy and light chain CDR sequences of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 36/38/40/44/46/48, 52/54/56/60/62/64, 68/70/72/76/78/80, 120/122/124/128/130/132, 160/162/164/168/170/172 or 220/222/224/228/230/232. In one embodiment, the antibody or antigen-binding fragment thereof competes for specific binding to hTL1A with an antibody or antigen-binding fragment comprising heavy and light chain CDR sequences of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 160/162/164/168/170/172 or 220/222/224/228/230/232. In another embodiment, the antibody or antigen-binding fragment of the invention competes for specific binding to hTL1A with an antibody or antigen-binding fragment comprising a HCVR/LCVR sequence pair of SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 134/136, 174/176 or 234/236. In yet another embodiment, the antibody or antigen-binding fragment thereof competes for specific binding to hTL1A with an antibody or antigen-binding fragment comprising a HCVR/LCVR sequence pair of SEQ ID NO:2/10, 18/26, 174/176 or 234/236.
In another related embodiment, the invention provides an antibody or antigen-binding fragment thereof that binds the same epitope on hTL1A that is recognized by an antibody or fragment thereof comprising heavy and light chain CDR sequences of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 36/38/40/44/46/48, 52/54/56/60/62/64, 68/70/72/76/78/80, 120/122/124/128/130/132, 160/162/164/168/170/172 or 220/222/224/228/230/232. In one embodiment, the antibody or antigen-binding fragment thereof binds the same epitope on hTL1A that is recognized by an antibody or antigen-binding fragment thereof comprising heavy and light chain CDR sequences of SEQ ID NO:4/6/8/12/14/16, 20/22/24/28/30/32, 160/162/164/168/170/172 or 220/222/224/228/230/232. In another embodiment, the antibody or antigen-binding fragment of the invention recognizes the same epitope on hTL1A that is recognized by an antibody or antigen-binding fragment thereof comprising a HCVR/LCVR sequence pair of SEQ ID NO: SEQ ID NO:2/10, 18/26, 34/42, 50/58, 66/74, 134/136, 174/176 or 234/236. In yet another embodiment, the antibody or antigen-binding fragment thereof recognizes the same epitope on hTL1A that is recognized by an antibody or antigen-biniding fragment thereof comprising a HCVR/LCVR sequence pair of SEQ ID NO:2/10, 18/26, 174/176 or 234/236.
In a third aspect, the invention provides nucleic acid molecules encoding anti-TL1A antibodies or fragments thereof described above. Recombinant expression vectors carrying the nucleic acids of the invention, and isolated host cells, e.g., bacterial cells, such as E. coli , or mammalian cells, such as CHO cells, into which such vectors have been introduced, are also encompassed by the invention, as are methods of producing the antibodies by culturing the host cells under conditions permitting production of the antibodies, and recovering the antibodies produced.
In one embodiment, the invention provides an antibody or fragment thereof comprising a HCVR encoded by a nucleic acid sequence selected from the group consisting of SEQ ID NO:1, 17, 33, 49, 65, 81, 97, 113, 117, 133, 137, 153, 157, 173, 177, 193, 197, 213, 217 and 233, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof. In another embodiment, the antibody or fragment thereof comprises a HCVR encoded by a nucleic acid sequence selected from the group consisting of SEQ ID NO:1, 17, 33, 49, 65, 133, 173 and 233. In yet another embodiment, the antibody or fragment thereof comprises a HCVR encoded by the nucleic acid sequence of SEQ ID NO:1, 17, 173 or 233.
In one embodiment, the antibody or fragment thereof further comprises a LCVR encoded by a nucleic acid sequence selected from the group consisting of SEQ ID NO:9, 25, 41, 57, 73, 89, 105, 115, 125, 135, 145, 155, 165, 175, 185, 195, 205, 215, 225 and 235, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof. In another embodiment, the antibody or fragment thereof comprises a LCVR encoded by a nucleic acid sequence selected from the group consisting of SEQ ID NO:9, 25, 41, 57, 73, 135, 175 and 235. In yet another embodiment, the antibody or fragment thereof comprises a LCVR encoded by the nucleic acid sequence of SEQ ID NO:9, 25, 175 or 235.
In further embodiments, the antibody or fragment thereof comprises a HCVR and LCVR (HCVR/LCVR) sequence pair encoded by a nucleic acid sequence pair selected from the group consisting of SEQ ID NO:1/9, 17/25, 33/41, 49/57, 65/73, 81/89, 97/105, 113/115, 117/125, 133/135, 137/145, 153/155, 157/165, 173/175, 177/185, 193/195, 197/205, 213/215, 217/225 and 233/235. In one embodiment, the antibody or fragment thereof comprises a HCVR/LCVR sequence pair encoded by a nucleic acid sequence pair selected from the group consisting of SEQ ID NO:1/9, 17/25, 33/41, 49/57, 65/73, 133/135, 173/175 and 233/235. In yet another embodiment, the antibody or fragment thereof comprises a HCVR/LCVR pair encoded by a nucleic acid sequence pair of SEQ ID NO:1/9, 17/25, 173/175 or 233/235.
In one embodiment, the invention features an antibody or antigen-binding fragment of an antibody comprising a HCDR3 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:7, 23, 39, 55, 71, 87, 103, 123, 143, 163, 183, 203 and 223, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof; and a LCDR3 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:15, 31, 47, 63, 79, 95, 111, 131, 151, 171, 191, 211 and 231, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof. In another embodiment, the antibody or fragment thereof comprises a HCDR3 and LCDR3 sequence pair encoded by the nucleic acid sequence pair of SEQ ID NO:7/15, 23/31, 39/47, 55/63, 71/79, 87/95, 103/111, 123/131, 143/151, 163/171, 183/191, 203/211 or 223/231. In another embodiment, the antibody or fragment thereof comprises a HCDR3 and LCDR3 sequence pair encoded by the nucleic acid sequence pair of SEQ ID NO:7/15, 23/31, 39/47, 55/63, 71/79, 123/131, 163/171 or 223/231. In yet another embodiment, the HCDR3/LCDR3 sequence pair is encoded by the nucleic acid sequence pair of SEQ ID NO:7/15, 23/31, 163/171 or 223/231.
In a further embodiment, the antibody or fragment thereof further comprises, a HCDR1 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:3, 19, 35, 51, 67, 83, 99, 119, 139, 159, 179, 199 and 219, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof; a HCDR2 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:5, 21, 37, 53, 69, 85, 101, 121, 141, 161, 181, 201 and 221, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof; a LCDR1 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:11, 27, 43, 59, 75, 91, 107, 127, 147, 167, 187, 207 and 227, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof; and a LCDR2 domain encoded by a nucleotide sequence selected from the group consisting of SEQ ID NO:13, 29, 45, 61, 77, 93, 109, 129, 149, 169, 189, 209 and 229, or a substantially identical sequence having at least 90%, at least 95%, at least 98%, or at least 99% homology thereof. In one embodiment, the antibody or fragment thereof comprises a combination of HCDR1/HCDR2/HCDR3 encoded by SEQ ID NO:3/5/7, 19/21/23, 35/37/39, 51/53/55, 67/69/71, 83/85/87, 99/101/103, 119/121/123, 139/141/143, 159/161/163, 179/181/183, 199/201/203 or 219/221/223; and a combination of LCDR1/LCDR2/LCDR3 encoded by SEQ ID NO:11/13/15, 27/29/31, 43/45/47, 59/61/63, 75/77/79, 91/93/95, 107/109/111, 127/129/131, 147/149/151, 167/169/171, 187/189/191, 207/209/211 or 227/229/231. In one embodiment, the antibody or fragment thereof comprises heavy and light chain CDR sequences encoded by a nucleic acid sequence combination selected from the group consisting of SEQ ID NO:3/5/7/11/13/15, 19/21/23/27/29/31, 35/37/39/43/45/47, 51/53/55/59/61/63, 67/69/71/75/77/79, 83/85/87/91/93/95, 99/101/103/107/109/111, 119/121/123/127/129/131, 139/141/143/147/149/151, 159/161/163/167/169/171, 179/181/183/187/189/191, 199/201/203/207/209/211 and 219/221/223/227/229/231. In another embodiment, the antibody or antigen-binding portion thereof comprises heavy and light chain CDR sequences encoded by a nucleic acid sequence combination of SEQ ID NO:3/5/7/11/13/15, 19/21/23/27/29/31, 35/37/39/43/45/47, 51/53/55/59/61/63, 67/69/71/75/77/79, 119/121/123/127/129/131, 159/161/163/167/169/171 or 219/221/223/227/229/231. In yet another embodiment, the antibody or antigen-binding portion thereof comprises heavy and light chain CDR sequences encoded by a nucleic acid sequence combination of SEQ ID NO: 3/5/7/11/13/15, 19/21/23/27/29/31, 159/161/163/167/169/171 or 219/221/223/227/229/231.
In a fourth aspect, the invention features an isolated antibody or antigen-binding fragment of an antibody that specifically binds hTL1A, comprising a HCDR3 and a LCDR3, wherein the HCDR3 comprises an amino acid sequence of the formula X 1 -X 2 -X 3 -X 4 -X 5 -X 6 -X 7 -X 8 -X 9 -X 10 -X 11 -X 12 -X 13 -X 14 -X 15 -X 16 (SEQ ID NO:239), wherein X 1 is Thr or Ala, X 2 is Lys, Arg or absent, X 3 is Glu, Gly or absent, X 4 is Asp, Pro or absent, X 5 is Leu or absent, X 6 is Arg, Tyr, Glu or absent, X 7 is Gly, Asp, Ala or absent, X 9 is Asp, Ser or Tyr, X 9 is Tyr or Trp, X 10 is Tyr or Asp, X 11 is Tyr, Lys or Ile, X 12 is Gly, Tyr, Asn, or Ser, X 13 is Val, Gly or Ser, X 14 is Phe or Met, X 15 is Asp, and X 16 is Tyr or Val; and the LCDR3 comprises an amino acid sequence of the formula X 1 -X 2 -X 3 -X 4 -X 5 -X 6 -X 7 -X 8 -X 9 (SEQ ID NO:242), wherein X 1 is Gln, X 2 is Gln, X 3 is Tyr, Leu or Phe, X 4 is His, Tyr or Asn, X 5 is Arg or Ser, X 6 is Ser, Thr or Tyr, X 7 is Trp or Pro, X 9 is Phe, Leu or absent, and X 9 is Thr.
In a further embodiment, the antibody or fragment thereof further comprises a HCDR1 sequence comprising an amino acid sequence of the formula X 1 -X 2 -X 3 -X 4 -X 5 -X 6 -X 7 -X 8 (SEQ ID NO:237), wherein X 1 is Gly, X 2 is Phe, X 3 is Thr, X 4 is Phe, X 5 is Ser, X 6 is Thr, Ser or Asn, X 7 is Tyr, and X 8 is Gly, Trp, Val or Ala; a HCDR2 sequence comprising an amino acid sequence of the formula X 1 -X 2 -X 3 -X 4 -X 5 -X 6 -X 7 -X 8 (SEQ ID NO:238), wherein X 1 is Ile or Val, X 2 is Ser or Lys, X 3 is Gly or Glu, X 4 is Thr, Asp, Ser or Arg, X 5 is Gly, X 6 is Arg, Ser or Gly, X 7 is Thr, Glu or Ser, and X 8 is Thr or Lys; a LCDR1 sequence comprising an amino acid sequence of the formula X 1 -X 2 -X 3 -X 4 -X 5 -X 6 -X 7 -X 8 -X 9 -X 10 -X 11 -X 12 (SEQ ID NO:240), wherein X 1 is Gln, X 2 is Thr, Ser, Ala or Gly, X 3 is Ile, X 4 is Ser or Leu, X 5 is Tyr or absent, X 6 is Ser or absent, X 7 is Ser or absent, X 8 is Asn or absent, X 9 is Asn or absent, X 10 is Lys or absent, X 11 is Ser, Asn or Thr, and X 12 is Trp or Tyr; and a LCDR2 sequence comprising an amino acid sequence of the formula X 1 -X 2 -X 3 (SEQ ID NO:241) wherein X 1 is Ala, Trp or Ser, X 2 is Ala or Thr, and X 3 is Ser.
In a fifth aspect, the invention features a human anti-TL1A antibody or antigen-binding fragment thereof comprising a heavy chain variable region (HCVR) encoded by nucleotide sequence segments derived from V H , D H and J H germline sequences, and a light chain variable region (LCVR) encoded by nucleotide sequence segments derived from V K and J K germline sequences. In certain embodiments, the antibody or antigen-binding fragment thereof comprises the HCVR and the LCVR encoded by nucleotide sequence segments derived from a germline gene combination selected from the group consisting of: (i) V H 3-23, D H 2-21, J H 4, V K 1-5 and J K 1; (ii) V H 3-7, D H 1-7, J H 6, V K 4-1 and J K 3; (iii) V H 3-23, D H 2-2, J H 6, V K 1-9 and J K 2; (iv) V H 3-23, D H 6-6, J H 4, V K 1-9 and J K 4; (v) V H 1-2, D H 2-15, J H 3, V K 1-12 and J K 4; (vi) V H 4-34, D H 3-9, J H 4, V K 3-20 and J K 4; (vii) V H 4-34, D H 1-1, J H 4, V K 3-20 and J K 4; and (viii) V H 4-34, D H 3-3, J H 4, V K 2-24 and J K 4.
In a sixth aspect, the invention features an antibody or antigen-binding fragment thereof that specifically binds to hTL1A or Fhm with an equilibrium dissociation constant (K D ) of about 1 nM or less, as measured by surface plasmon resonance assay (for example, BIACORE™). In certain embodiments, the antibody of the invention exhibits a K D of about 800 pM or less; about 700 pM or less; about 600 pM or less; about 500 pM or less; about 400 pM or less; about 300 pM or less; about 200 pM or less; about 150 pM or less; about 100 pM or less; about 90 pM or less; about 80 pM or less; about 50 pM or less; or 30 pM or less.
In a seventh aspect, the present invention provides an anti-hTL1A antibody or antigen-binding fragment thereof that binds hTL1A protein of SEQ ID NO:244, but does not cross-react with a variant thereof, such as Fhm of SEQ ID NO:246, as determined by, for example, ELISA, surface plasmon resonance assay, or Luminex® xMAP® Technology, as described herein. Fhm contains a single amino acid substitution at position 167, corresponding to Gln in hTL1A, with Arg (see U.S. Pat. No. 6,521,422). In related embodiments, the invention also provides an anti-hTL1A antibody or antigen-binding fragment thereof that binds a hTL1A protein and cross-reacts with an Fhm. In another related embodiment, the invention provides an anti-hTL1A antibody or antigen binding fragment thereof that does not cross-react with mouse TL1A (mTL1A: SEQ ID NO:250, encoded by the nucleotide sequence of SEQ ID NO:249) but does cross-react with TL1A of cynomolgus monkey ( Macaca fascicularis , or MfTL1A: SEQ ID NO:248, encoded by the nucleotide sequence of SEQ ID NO:247) or rhesus monkey ( Macaca mulatta : the same amino acid sequence as MfTL1A). In further related embodiments, the invention provides an anti-hTL1A antibody or antigen-binding fragment thereof that cross-reacts with both mTL1A and MfTL1A.
The invention encompasses anti-hTL1A antibodies having a modified glycosylation pattern. In some applications, modification to remove undesirable glycosylation sites may be useful, or e.g., removal of a fucose moiety to increase antibody dependent cellular cytotoxicity (ADCC) function (see Shield et al. (2002) JBC 277:26733). In other applications, removal of N-glycosylation site may reduce undesirable immune reactions against the therapeutic antibodies, or increase affinities of the antibodies. In yet other applications, modification of galactosylation can be made in order to modify complement dependent cytotoxicity (CDC).
In an eighth aspect, the invention features a pharmaceutical composition comprising a recombinant human antibody or fragment thereof which specifically binds hTL1A and a pharmaceutically acceptable carrier. In one embodiment, the invention features a composition which is a combination of an antibody or antigen-binding fragment thereof of the invention, and a second therapeutic agent. The second therapeutic agent may be one or more of any agent such as immunosuppressants, anti-inflammatory agents, analgesic agents, anti-allergy agents, and the like, many of which may have overlapping therapeutic effects of one another. Suitable immunosuppressants to be used in combination with the anti-hTL1A antibodies of the invention include, but are not limited to, glucocorticoids, cyclosporin, methotrexate, interferon β (IFN-β), tacrolimus, sirolimus, azathioprine, mercaptopurine, opioids, mycophenolate, TNF-binding proteins, such as infliximab, eternacept, adalimumab, and the like, cytotoxic antibiotics, such as dactinomycin, anthracyclines, mitomycin C, bleomycin, mithramycin, and the like, antibodies targeting immune cells, such as anti-CD20 antibodies, anti-CD3 antibodies, and the like. Suitable anti-inflammatory agents and/or analgesics for combination therapies with anti-hTL1A antibodies include, corticosteroids, non-steroidal anti-inflammatory drugs (NSAIDs), such as aspirin, ibuprofen, naproxen, Cox-2 inhibitors, and the like, TNF-α antagonists, IL-1 antagonists, IL-6 antagonists, acetaminophen, morphinomimetics, and the like. Suitable anti-allergy agents include antihistamines, glucocorticoids, epinephrine (adrenaline), theophylline, cromolyn sodium and anti-leukotrienes, as well as anti-cholinergics, decongestants, mast cell stabilizers, and the like.
In a ninth aspect, the invention features methods for inhibiting hTL1A activity using the anti-hTL1A antibody or antigen-binding portion of the antibody of the invention, wherein the therapeutic methods comprise administering a therapeutically effective amount of a pharmaceutical composition comprising an antibody or antigen-binding fragment of an antibody of the invention and, optionally, one or more additional therapeutic agents described above. The disease or disorder treated is any disease or condition which is improved, ameliorated, inhibited or prevented, or its occurrence rate reduced compared to that without anti-hTL1A antibody treatment, by removal, inhibition or reduction of TL1A activity. Examples of diseases or disorders treatable by the methods of the invention include, but are not limited to, inflammatory diseases and/or autoimmune diseases, such as inflammatory bowel diseases (IBD) including UC and CD, RA, MS, type 1 and type 2 diabetes, psoriasis, psoriatic arthritis, ankylosing spondylitis, atopic dermatitis, and the like; allergic reactions or conditions, including asthma, allergic lung inflammation, and the like; cancers atherosclerosis, infections, neurodegenerative diseases, graft rejection, graft vs. host diseases (GVHD), cardiovascular disorders/diseases, and the like.
Other embodiments will become apparent from a review of the ensuing detailed description.
DETAILED DESCRIPTION
Before the present invention is described in detail, it is to be understood that this invention is not limited to particular methods, and experimental conditions described, as such methods and conditions may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference in their entirety.
Definitions
The term “human TNF-like ligand 1A” or “hTL1A”, as used herein, refers to hTL1A having the nucleic acid sequence shown in SEQ ID NO:243 and the amino acid sequence of SEQ ID NO:244, or a biologically active fragment thereof, as well as hTL1A variants, including Fhm having the nucleic acid sequence shown in SEQ ID NO:245 and the amino acid sequence of SEQ ID NO:246, or a biologically active fragment thereof, unless specifically indicated otherwise.
The term “antibody”, as used herein, is intended to refer to immunoglobulin molecules comprised of four polypeptide chains, two heavy (H) chains and two light (L) chains inter-connected by disulfide bonds. Each heavy chain is comprised of a heavy chain variable region (HCVR) and a heavy chain constant region (C H ; comprised of domains C H 1, C H 2 and C H 3). Each light chain is comprised of a light chain variable region (LCVR) and a light chain constant region (C L ). The HCVR and LCVR can be further subdivided into regions of hypervariability, termed complementarity determining regions (CDR), interspersed with regions that are more conserved, termed framework regions (FR). Each HCVR and LCVR is composed of three CDRs and four FRs, arranged from amino-terminus to carboxy-terminus in the following order: FR1, CDR1, FR2, CDR2, FR3, CDR3, and FR4.
Substitution of one or more CDR residues or omission of one or more CDRs is also possible. Antibodies have been described in the scientific literature in which one or two CDRs can be dispensed with for binding. Padlan et al. (1995 FASEB J. 9:133-139) analyzed the contact regions between antibodies and their antigens, based on published crystal structures, and concluded that only about one fifth to one third of CDR residues actually contact the antigen. Padlan also found many antibodies in which one or two CDRs had no amino acids in contact with an antigen (see also, Vajdos et al. 2002 J Mol Biol 320:415-428).
CDR residues not contacting antigen can be identified based on previous studies (for example, residues H60-H65 in CDRH2 are often not required), from regions of Kabat CDRs lying outside Chothia CDRs, by molecular modeling and/or empirically. If a CDR or residue(s) thereof is omitted, it is usually substituted with an amino acid occupying the corresponding position in another human antibody sequence or a consensus of such sequences. Positions for substitution within CDRs and amino acids to substitute can also be selected empirically. Empirical substitutions can be conservative or non-conservative substitutions.
The term “human antibody”, as used herein, is intended to include antibodies having variable and constant regions derived from human germline immunoglobulin sequences. The human mAbs of the invention may include amino acid residues not encoded by human germline immunoglobulin sequences (e.g., mutations introduced by random or site-specific mutagenesis in vitro or by somatic mutation in vivo), for example in the CDRs and in particular CDR3. However, the term “human antibody”, as used herein, is not intended to include mAbs in which CDR sequences derived from the germline of another mammalian species (e.g., mouse), have been grafted onto human FR sequences.
The fully-human anti-TL1A antibodies disclosed herein may comprise one or more amino acid substitutions, insertions and/or deletions in the framework and/or CDR regions of the heavy and light chain variable domains as compared to the corresponding germline sequences. Such mutations can be readily ascertained by comparing the amino acid sequences disclosed herein to germline sequences available from, for example, public antibody sequence databases. The present invention includes antibodies, and antigen-binding fragments thereof, which are derived from any of the amino acid sequences disclosed herein, wherein one or more amino acids within one or more framework and/or CDR regions are mutated to the corresponding residue(s) of the germline sequence from which the antibody was derived, or to the corresponding residue(s) of another human germline sequence, or to a conservative amino acid substitution of the corresponding germline residues(s) (such sequence changes are referred to herein collectively as “germline mutations”). A person of ordinary skill in the art, starting with the heavy and light chain variable region sequences disclosed herein, can easily produce numerous antibodies and antigen-binding fragments which comprise one or more individual germline back-mutations or combinations thereof. In certain embodiments, all of the framework and/or CDR residues within the V H and/or V L domains are mutated back to the residues found in the original germline sequence from which the antibody was derived. In other embodiments, only certain residues are mutated back to the original germline sequence, e.g., only the mutated residues found within the first 8 amino acids of FR1 or within the last 8 amino acids of FR4, or only the mutated residues found within CDR1, CDR2 or CDR3. In other embodiments, one or more of the framework and/or CDR residue(s) are mutated to the corresponding residue(s) of a different germline sequence (i.e., a germline sequence that is different from the germline sequence from which the antibody was originally derived). Furthermore, the antibodies of the present invention may contain any combination of two or more germline mutations within the framework and/or CDR regions, e.g., wherein certain individual residues are mutated to the corresponding residues of a particular germline sequence while certain other residues that differ from the original germline sequence are maintained or are mutated to the corresponding residue of a different germline sequence. Once obtained, antibodies and antigen-binding fragments that contain one or more germline mutations can be easily tested for one or more desired property such as, improved binding specificity, increased binding affinity, improved or enhanced antagonistic or agonistic biological properties (as the case may be), reduced immunogenicity, etc. Antibodies and antigen-binding fragments obtained in this general manner are encompassed within the present invention.
The present invention also includes anti-TL1A antibodies comprising variants of any of the HCVR, LCVR, and/or CDR amino acid sequences disclosed herein having one or more conservative substitutions. For example, the present invention includes anti-TL1A antibodies having HCVR, LCVR, and/or CDR amino acid sequences with, e.g., 10 or fewer, 8 or fewer, 6 or fewer, 4 or fewer, 2 or 1, conservative amino acid substitution(s) relative to any of the HCVR, LCVR, and/or CDR amino acid sequences disclosed herein.
Unless specifically indicated otherwise, the term “antibody” (Ab), as used herein, shall be understood to encompass antibody molecules comprising two immunoglobulin heavy chains and two immunoglobulin light chains (i.e., “full antibody molecules”) as well as antigen-binding fragments thereof. The terms “antigen-binding portion” of an antibody, “antigen-binding fragment” of an antibody, and the like, as used herein, include any naturally occurring, enzymatically obtainable, synthetic, or genetically engineered polypeptide or glycoprotein that specifically binds an antigen to form a complex. Antigen-binding fragments of an antibody may be derived, e.g., from full antibody molecules using any suitable standard techniques such as proteolytic digestion or recombinant genetic engineering techniques involving the manipulation and expression of DNA encoding antibody variable and (optionally) constant domains. Such DNA is known and/or is readily available from, e.g., commercial sources, DNA libraries (including, e.g., phage-display antibody libraries), or can be synthesized. The DNA may be sequenced and manipulated chemically or by using molecular biology techniques, for example, to arrange one or more variable and/or constant domains into a suitable configuration, or to introduce codons, create cysteine residues, modify, add or delete amino acids, etc.
Non-limiting examples of antigen-binding fragments include: (i) Fab fragments; (ii) F(ab′)2 fragments; (iii) Fd fragments; (iv) Fv fragments; (v) single-chain Fv (scFv) molecules; (vi) dAb fragments; and (vii) minimal recognition units consisting of the amino acid residues that mimic the hypervariable region of an antibody (e.g., an isolated complementarity determining region (CDR) such as a CDR3 peptide), or a constrained FR3-CDR3-FR4 peptide. Other engineered molecules, such as domain-specific antibodies, single domain antibodies, domain-deleted antibodies, chimeric antibodies, CDR-grafted antibodies, diabodies, triabodies, tetrabodies, minibodies, nanobodies (e.g. monovalent nanobodies, bivalent nanobodies, etc.), small modular immunopharmaceuticals (SMIPs), and shark variable IgNAR domains, are also encompassed within the expression “antigen-binding fragment,” as used herein.
An antigen-binding fragment of an antibody will typically comprise at least one variable domain. The variable domain may be of any size or amino acid composition and will generally comprise at least one CDR which is adjacent to or in frame with one or more framework sequences. In antigen-binding fragments having a V H domain associated with a V L domain, the V H and V L domains may be situated relative to one another in any suitable arrangement. For example, the variable region may be dimeric and contain V H -V H , V H -V L or V L -V L dimers. Alternatively, the antigen-binding fragment of an antibody may contain a monomeric V H or V L domain.
In certain embodiments, an antigen-binding fragment of an antibody may contain at least one variable domain covalently linked to at least one constant domain. Non-limiting, exemplary configurations of variable and constant domains that may be found within an antigen-binding fragment of an antibody of the present invention include: (i) V H -C H 1; (ii) V H -C H 2; (iii) V H -C H 3; (iv) V H -C H 1-C H 2; (v) V H -C H 1-C H 2-C H 3; (vi) V H -C H 2-C H 3; (vii) V H -C L ; (viii) V L -C H 1; (ix) V L -C H 2, (x) V L -C H 3; (xi) V L -C H 1-C H 2; (xii) V L -C H 1-C H 2-C H 3; (xiii) V L -C H 2-C H 3; and (xiv) V L -C L . In any configuration of variable and constant domains, including any of the exemplary configurations listed above, the variable and constant domains may be either directly linked to one another or may be linked by a full or partial hinge or linker region. A hinge region may consist of at least 2 (e.g., 5, 10, 15, 20, 40, 60 or more) amino acids which result in a flexible or semi-flexible linkage between adjacent variable and/or constant domains in a single polypeptide molecule. Moreover, an antigen-binding fragment of an antibody of the present invention may comprise a homo-dimer or hetero-dimer (or other multimer) of any of the variable and constant domain configurations listed above in non-covalent association with one another and/or with one or more monomeric V H or V L domain (e.g., by disulfide bond(s)).
As with full antibody molecules, antigen-binding fragments may be monospecific or multispecific (e.g., bispecific). A multispecific antigen-binding fragment of an antibody will typically comprise at least two different variable domains, wherein each variable domain is capable of specifically binding to a separate antigen or to a different epitope on the same antigen. Any multispecific antibody format, including the exemplary bispecific antibody formats disclosed herein, may be adapted for use in the context of an antigen-binding fragment of an antibody of the present invention using routine techniques available in the art.
In certain embodiments, antibody or antibody fragments of the invention may be conjugated to a therapeutic moiety (“immunoconjugate”), such as a cytotoxin, a chemotherapeutic drug, an immunosuppressant or a radioisotope.
The term “specifically binds,” or the like, means that an antibody or antigen-binding fragment thereof forms a complex with an antigen that is relatively stable under physiological conditions. Specific binding can be characterized by an equilibrium dissociation constant (K D ) of about 3000 nM or less (i.e., a smaller K D denotes a tighter binding), about 2000 nM or less, about 1000 nM or less; about 500 nM or less; about 300 nM or less; about 200 nM or less; about 100 nM or less; about 50 nM or less; about 1 nM or less; or about 0.5 nM or less. Methods for determining whether two molecules specifically bind are well known in the art and include, for example, equilibrium dialysis, surface plasmon resonance, and the like. An isolated antibody that specifically binds hTL1A may, however, exhibit cross-reactivity to other antigens, such as TL1A molecules from other species, for example, cynomolgus monkey TL1A (SEQ ID NO:248), and/or mouse TL1A (SEQ ID NO:250), and/or a TL1A variant, such as Fhm (SEQ ID NO:246). Moreover, multi-specific antibodies (e.g., bispecifics) that bind to hTL1A and one or more additional antigens are nonetheless considered antibodies that “specifically bind’ hTL1A, as used herein.
The term “high affinity” antibody refers to those antibodies having a binding affinity to hTL1A, expressed as K D , of about 1×10 −9 M or less, about 0.5×10 −9 M or less, about 0.25×10 −9 M or less, about 1×10 −10 M or less, or about 0.5×10 −10 M or less, as measured by surface plasmon resonance, e.g., BIACORE™ or solution-affinity ELISA.
The term “K D ”, as used herein, is intended to refer to the equilibrium dissociation constant of a particular antibody-antigen interaction.
By the term “slow off rate”, “Koff” or “k d ” is meant an antibody that dissociates from hTL1A with a rate constant of 1×10 −3 s −1 or less, preferably 1×10 4 s −1 or less, as determined by surface plasmon resonance, e.g., BIACORE™.
By the term “intrinsic affinity constant” or “k a ” is meant an antibody that associates with hTL1A at a rate constant of about 1×10 3 M −1 s −1 or higher, as determined by surface plasmon resonance, e.g., BIACORE™.
An “isolated antibody”, as used herein, is intended to refer to an antibody that is substantially free of other mAbs having different antigenic specificities (e.g., an isolated antibody that specifically binds hTL1A is substantially free of Abs that specifically bind antigens other than hTL1A). An isolated antibody that specifically binds hTL1A may, however, have cross-reactivity to other antigens, such as TL1A molecules from other species, such as cynomolgus monkey and mouse, and/or hTL1A variants, such as Fhm.
A “neutralizing antibody”, as used herein (or an “antibody that neutralizes TL1A activity”), is intended to refer to an antibody whose binding to TL1A results in inhibition of at least one biological activity of TL1A. This inhibition of the biological activity of TL1A can be assessed by measuring one or more indicators of TL1A biological activity by one or more of several standard in vitro or in vivo assays known in the art (also see examples below).
The term “surface plasmon resonance”, as used herein, refers to an optical phenomenon that allows for the analysis of real-time biospecific interactions by detection of alterations in protein concentrations within a biosensor matrix, for example using the BIACORE™ system (Pharmacia Biosensor AB, Uppsala, Sweden and Piscataway, N.J.).
The term “epitope” is a region of an antigen that is bound by an antibody. Epitopes may be defined as structural or functional. Functional epitopes are generally a subset of the structural epitopes and have those residues that directly contribute to the affinity of the interaction. Epitopes may also be conformational, that is, composed of non-linear amino acids. In certain embodiments, epitopes may include determinants that are chemically active surface groupings of molecules such as amino acids, sugar side chains, phosphoryl groups, or sulfonyl groups, and, in certain embodiments, may have specific three-dimensional structural characteristics, and/or specific charge characteristics.
The term “substantial identity” or “substantially identical,” when referring to a nucleic acid or fragment thereof, indicates that, when optimally aligned with appropriate nucleotide insertions or deletions with another nucleic acid (or its complementary strand), there is nucleotide sequence identity in at least about 90%, and more preferably at least about 95%, 96%, 97%, 98% or 99% of the nucleotide bases, as measured by any well-known algorithm of sequence identity, such as FASTA, BLAST or GAP, as discussed below.
As applied to polypeptides, the term “substantial similarity” or “substantially similar” means that two peptide sequences, when optimally aligned, such as by the programs GAP or BESTFIT using default gap weights, share at least 90% sequence identity, even more preferably at least 95%, 98% or 99% sequence identity. Preferably, residue positions which are not identical differ by 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 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, which is 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: cysteine and methionine. Preferred conservative amino acids substitution groups are: valine-leucine-isoleucine, phenylalanine-tyrosine, lysine-arginine, alanine-valine, glutamate-aspartate, and asparagine-glutamine. Alternatively, a conservative replacement is any change having a positive value in the PAM250 log-likelihood matrix disclosed in Gonnet et al. (1992) Science 256: 1443 45, herein incorporated by reference. A “moderately conservative” replacement is any change having a nonnegative value in the PAM250 log-likelihood matrix.
Sequence similarity for polypeptides is typically measured using sequence analysis software. Protein analysis software matches similar sequences using measures of similarity assigned to various substitutions, deletions and other modifications, including conservative amino acid substitutions. For instance, GCG software contains programs such as GAP and BESTFIT which can be used with default parameters to determine sequence homology or sequence identity between closely related polypeptides, such as homologous polypeptides from different species of organisms or between a wild type protein and a mutein thereof. See, e.g., GCG Version 6.1. Polypeptide sequences also can be compared using FASTA with default or recommended parameters; a program in GCG Version 6.1. FASTA (e.g., FASTA2 and FASTA3) provides alignments and percent sequence identity of the regions of the best overlap between the query and search sequences (Pearson, 2000, supra). Another preferred algorithm when comparing a sequence of the invention to a database containing a large number of sequences from different organisms is the computer program BLAST, especially BLASTP or TBLASTN, using default parameters. See, e.g., Altschul et al., 1990, J. Mol. Biol. 215: 403 410 and, 1997, Nucleic Acids Res. 25:3389 402, each of which is herein incorporated by reference.
By the phrase “therapeutically effective amount” is meant an amount that produces the desired effect for which it is administered. The exact amount will depend on the purpose of the treatment, the age and the size of a subject treated, the route of administration, and the like, and will be ascertainable by one skilled in the art using known techniques (see, for example, Lloyd (1999) The Art, Science and Technology of Pharmaceutical Compounding).
Preparation of Human Antibodies
Methods for generating human antibodies in transgenic mice are known in the art. Any such known methods can be used in the context of the present invention to make human antibodies that specifically bind to TL1A.
Using VELOCIMMUNE™ technology or any other known method for generating monoclonal antibodies, high affinity chimeric antibodies to TL1A are initially isolated having a human variable region and a mouse constant region. As in the experimental section below, the antibodies are characterized and selected for desirable characteristics, including affinity, selectivity, epitope, and the like.
In general, the antibodies of the instant invention possess very high affinities, typically possessing K D of from about 10 −12 M through about 10 −9 M, when measured by binding to antigen either immobilized on solid phase or in solution phase. The mouse constant regions are replaced with desired human constant regions, for example, wild-type IgG1 (SEQ ID NO:255) or IgG4 (SEQ ID NO:256), or modified IgG1 or IgG4 (for example, IgG4 with Ser-108 substituted with Pro as shown in SEQ ID NO:257), to generate the fully human antibodies of the invention. While the constant region selected may vary according to specific use, high affinity antigen-binding and target specificity characteristics of the antibodies reside in the variable region.
Epitope Mapping and Related Technologies
To screen for antibodies that bind to a particular epitope, a routine cross-blocking assay such as that described in Antibodies , Harlow and Lane (Cold Spring Harbor Press, Cold Spring Harb., NY) can be performed. Other methods include alanine scanning mutants, peptide blots (Reineke, 2004, Methods Mol Biol 248:443-63) (herein specifically incorporated by reference in its entirety), or peptide cleavage analysis. In addition, methods such as epitope excision, epitope extraction and chemical modification of antigens can be employed (Tomer, 2000, Protein Science 9: 487-496) (herein specifically incorporated by reference in its entirety).
The term “epitope” refers to a site on an antigen to which B and/or T cells respond. B-cell epitopes can be formed both from contiguous amino acids or noncontiguous amino acids juxtaposed by tertiary folding of a protein. Epitopes formed from contiguous amino acids are typically retained on exposure to denaturing solvents, whereas epitopes formed by tertiary folding are typically lost on treatment with denaturing solvents. An epitope typically includes at least 3, and more usually, at least 5 or 8-10 amino acids in a unique spatial conformation.
Modification-Assisted Profiling (MAP), also known as Antigen Structure-based Antibody Profiling (ASAP) is a method that categorizes large numbers of mAbs directed against the same antigen according to the similarities of the binding profile of each antibody to chemically or enzymatically modified antigen surfaces (US 2004/0101920, herein specifically incorporated by reference in its entirety). Each category may reflect a unique epitope either distinctly different from or partially overlapping with epitope represented by another category. This technology allows rapid filtering of genetically identical mAbs, such that characterization can be focused on genetically distinct mAbs. When applied to hybridoma screening, MAP may facilitate identification of rare hybridoma clones that produce mAbs having the desired characteristics. MAP may be used to sort the anti-TL1A mAbs of the invention into groups of mAbs binding different epitopes.
The present invention includes hTL1A antibodies that bind to the same epitope as any of the specific exemplary antibodies described herein. Likewise, the present invention also includes anti-hTL1A antibodies that compete for binding to hTL1A or a hTL1A fragment with any of the specific exemplary antibodies described herein.
One can easily determine whether an antibody binds to the same epitope as, or competes for binding with, a reference anti-hTL1A antibody by using routine methods known in the art. For example, to determine if a test antibody binds to the same epitope as a reference anti-hTL1A antibody of the invention, the reference antibody is allowed to bind to a hTL1A protein or peptide under saturating conditions. Next, the ability of a test antibody to bind to the hTL1A molecule is assessed. If the test antibody is able to bind to hTL1A following saturation binding with the reference anti-hTL1A antibody, it can be concluded that the test antibody binds to a different epitope than the reference anti-hTL1A antibody. On the other hand, if the test antibody is not able to bind to the hTL1A molecule following saturation binding with the reference anti-hTL1A antibody, then the test antibody may bind to the same epitope as the epitope bound by the reference anti-hTL1A antibody of the invention.
To determine if an antibody competes for binding with a reference anti-hTL1A antibody, the above-described binding methodology is performed in two orientations: In a first orientation, the reference antibody is allowed to bind to a hTL1A molecule under saturating conditions followed by assessment of binding of the test antibody to the hTL1A molecule. In a second orientation, the test antibody is allowed to bind to a hTL1A molecule under saturating conditions followed by assessment of binding of the reference antibody to the TL1A molecule. If, in both orientations, only the first (saturating) antibody is capable of binding to the TL1A molecule, then it is concluded that the test antibody and the reference antibody compete for binding to hTL1A. As will be appreciated by a person of ordinary skill in the art, an antibody that competes for binding with a reference antibody may not necessarily bind to the identical epitope as the reference antibody, but may sterically block binding of the reference antibody by binding an overlapping or adjacent epitope.
Two antibodies bind to the same or overlapping epitope if each competitively inhibits (blocks) binding of the other to the antigen. That is, a 1-, 5-, 10-, 20- or 100-fold excess of one antibody inhibits binding of the other by at least 50% but preferably 75%, 90% or even 99% as measured in a competitive binding assay (see, e.g., Junghans et al., Cancer Res. 1990:50:1495-1502). Alternatively, two antibodies have the same epitope if essentially all amino acid mutations in the antigen that reduce or eliminate binding of one antibody reduce or eliminate binding of the other. Two antibodies have overlapping epitopes if some amino acid mutations that reduce or eliminate binding of one antibody reduce or eliminate binding of the other.
Additional routine experimentation (e.g., peptide mutation and binding analyses) can then be carried out to confirm whether the observed lack of binding of the test antibody is in fact due to binding to the same epitope as the reference antibody or if steric blocking (or another phenomenon) is responsible for the lack of observed binding. Experiments of this sort can be performed using ELISA, RIA, surface plasmon resonance, flow cytometry or any other quantitative or qualitative antibody-binding assay available in the art.
Immunoconjugates
The invention encompasses a human anti-TL1A monoclonal antibody conjugated to a therapeutic moiety (“immunoconjugate”), such as a cytotoxin, a chemotherapeutic drug, an immunosuppressant or a radioisotope. Cytotoxin agents include any agent that is detrimental to cells. Examples of suitable cytotoxin agents and chemotherapeutic agents for forming immunoconjugates are known in the art, see for example, WO 05/103081, herein specifically incorporated by reference).
Bispecifics
The antibodies of the present invention may be monospecific, bispecific, or multispecific. Multispecific mAbs may be specific for different epitopes of one target polypeptide or may contain antigen-binding domains specific for more than one target polypeptide. See, e.g., Tutt et al., 1991 , J. Immunol. 147:60-69. The human anti-hTL1A mAbs can be linked to or co-expressed with another functional molecule, e.g., another peptide or protein. For example, an antibody or fragment thereof can be functionally linked (e.g., by chemical coupling, genetic fusion, noncovalent association or otherwise) to one or more other molecular entities, such as another antibody or antibody fragment, to produce a bispecific or a multispecific antibody with a second binding specificity.
An exemplary bi-specific antibody format that can be used in the context of the present invention involves the use of a first immunoglobulin (Ig) C H 3 domain and a second Ig C H 3 domain, wherein the first and second Ig C H 3 domains differ from one another by at least one amino acid, and wherein at least one amino acid difference reduces binding of the bispecific antibody to Protein A as compared to a bi-specific antibody lacking the amino acid difference. In one embodiment, the first Ig C H 3 domain binds Protein A and the second Ig C H 3 domain contains a mutation that reduces or abolishes Protein A binding such as an H95R modification (by IMGT exon numbering; H435R by EU numbering). The second C H 3 may further comprise a Y96F modification (by IMGT; Y436F by EU). Further modifications that may be found within the second C H 3 include: D16E, L18M, N44S, K52N, V57M, and V82I (by IMGT; D356E, L358M, N384S, K392N, V397M, and V422I by EU) in the case of IgG1 antibodies; N44S, K52N, and V82I (IMGT; N384S, K392N, and V422I by EU) in the case of IgG2 antibodies; and Q15R, N44S, K52N, V57M, R69K, E79Q, and V82I (by IMGT; Q355R, N384S, K392N, V397M, R409K, E419Q, and V422I by EU) in the case of IgG4 antibodies. Variations on the bi-specific antibody format described above are contemplated within the scope of the present invention.
Bioequivalents
The anti-hTL1A antibodies and antibody fragments of the present invention encompass proteins having amino acid sequences that vary from those of the described mAbs, but that retain the ability to bind human TL1A. Such variant mAbs and antibody fragments comprise one or more additions, deletions, or substitutions of amino acids when compared to parent sequence, but exhibit biological activity that is essentially equivalent to that of the described mAbs. Likewise, the hTL1A mAb-encoding DNA sequences of the present invention encompass sequences that comprise one or more additions, deletions, or substitutions of nucleotides when compared to the disclosed sequence, but that encode an anti-hTL1A antibody or antibody fragment that is essentially bioequivalent to an anti-hTL1A antibody or antibody fragment of the invention. Examples of such variant amino acid and DNA sequences are discussed above.
Two antigen-binding proteins, or antibodies, are considered bioequivalent if, for example, they are pharmaceutical equivalents or pharmaceutical alternatives whose rate and extent of absorption do not show a significant difference when administered at the same molar dose under similar experimental conditions, either single does or multiple dose. Some antibodies will be considered equivalents or pharmaceutical alternatives if they are equivalent in the extent of their absorption but not in their rate of absorption and yet may be considered bioequivalent because such differences in the rate of absorption are intentional and are reflected in the labeling, are not essential to the attainment of effective body drug concentrations on, e.g., chronic use, and are considered medically insignificant for the particular drug product studied. In one embodiment, two antigen-binding proteins are bioequivalent if there are no clinically meaningful differences in their safety, purity, and potency.
In one embodiment, two antigen-binding proteins are bioequivalent if a patient can be switched one or more times between the reference product and the biological product without an expected increase in the risk of adverse effects, including a clinically significant change in immunogenicity, or diminished effectiveness, as compared to continued therapy without such switching.
In one embodiment, two antigen-binding proteins are bioequivalent if they both act by a common mechanism or mechanisms of action for the condition or conditions of use, to the extent that such mechanisms are known.
Bioequivalence may be demonstrated by in vivo and in vitro methods. Bioequivalence measures include, e.g., (a) an in vivo test in humans or other mammals, in which the concentration of the antibody or its metabolites is measured in blood, plasma, serum, or other biological fluid as a function of time; (b) an in vitro test that has been correlated with and is reasonably predictive of human in vivo bioavailability data; (c) an in vivo test in humans or other mammals in which the appropriate acute pharmacological effect of the antibody (or its target) is measured as a function of time; and (d) in a well-controlled clinical trial that establishes safety, efficacy, or bioavailability or bioequivalence of an antibody.
Bioequivalent variants of anti-hTL1A antibodies of the invention may be constructed by, for example, making various substitutions of residues or sequences or deleting terminal or internal residues or sequences not needed for biological activity. For example, cysteine residues not essential for biological activity can be deleted or replaced with other amino acids to prevent formation of unnecessary or incorrect intramolecular disulfide bridges upon renaturation.
Therapeutic Administration and Formulations
The invention provides therapeutic compositions comprising the anti-hTL1A antibodies or antigen-binding fragments thereof of the present invention and the therapeutic methods using the same. The administration of therapeutic compositions in accordance with the invention will be administered with suitable carriers, excipients, and other agents that are incorporated into formulations to provide improved transfer, delivery, tolerance, and the like. A multitude of appropriate formulations can be found in the formulary known to all pharmaceutical chemists: Remington's Pharmaceutical Sciences, Mack Publishing Company, Easton, Pa. These formulations include, for example, powders, pastes, ointments, jellies, waxes, oils, lipids, lipid (cationic or anionic) containing vesicles (such as LIPOFECTIN™), DNA conjugates, anhydrous absorption pastes, oil-in-water and water-in-oil emulsions, emulsions carbowax (polyethylene glycols of various molecular weights), semi-solid gels, and semi-solid mixtures containing carbowax. See also Powell et al. “Compendium of excipients for parenteral formulations” PDA, 1998, J Pharm Sci Technol 52:238-311.
The dose may vary depending upon the age and the size of a subject to be administered, target disease, the purpose of the treatment, conditions, route of administration, and the like. When the antibody of the present invention is used for treating various conditions and diseases directly or indirectly associated with TL1A, including inflammatory diseases/disorders, autoimmune diseases/disorders, allergic reactions, and the like, in an adult patient, it is advantageous to intravenously or subcutaneously administer the antibody of the present invention at a single dose of about 0.01 to about 20 mg/kg body weight, more preferably about 0.02 to about 7, about 0.03 to about 5, or about 0.05 to about 3 mg/kg body weight. Depending on the severity of the condition, the frequency and the duration of the treatment can be adjusted. In certain embodiments, the antibody or antigen-binding fragment thereof of the invention can be administered as an initial dose of at least about 0.1 mg to about 800 mg, about 1 to about 500 mg, about 5 to about 300 mg, or about 10 to about 200 mg, to about 100 mg, or to about 50 mg. In certain embodiments, the initial dose may be followed by administration of a second or a plurality of subsequent doses of the antibody or antigen-binding fragment thereof in an amount that can be approximately the same or less than that of the initial dose, wherein the subsequent doses are separated by at least 1 day to 3 days; at least one week, at least 2 weeks; at least 3 weeks; at least 4 weeks; at least 5 weeks; at least 6 weeks; at least 7 weeks; at least 8 weeks; at least 9 weeks; at least 10 weeks; at least 12 weeks; or at least 14 weeks.
Various delivery systems are known and can be used to administer the pharmaceutical composition of the invention, e.g., encapsulation in liposomes, microparticles, microcapsules, recombinant cells capable of expressing the mutant viruses, receptor mediated endocytosis (see, e.g., Wu et al., 1987, J. Biol. Chem. 262:4429-4432). Methods of introduction include, but are not limited to, intradermal, intramuscular, intraperitoneal, intravenous, subcutaneous, intranasal, epidural, and oral routes. The composition may be administered by any convenient route, for example by infusion or bolus injection, by absorption through epithelial or mucocutaneous linings (e.g., oral mucosa, rectal and intestinal mucosa, etc.) and may be administered together with other biologically active agents. Administration can be systemic or local.
The pharmaceutical composition can be also delivered in a vesicle, in particular a liposome (see Langer, 1990, Science 249:1527-1533; Treat et al., 1989, in Liposomes in the Therapy of Infectious Disease and Cancer, Lopez Berestein and Fidler (eds.), Liss, New York, pp. 353-365; Lopez-Berestein, ibid., pp. 317-327; see generally ibid.).
In certain situations, the pharmaceutical composition can be delivered in a controlled release system. In one embodiment, a pump may be used (see Langer, supra; Sefton, 1987, CRC Crit. Ref. Biomed. Eng. 14:201). In another embodiment, polymeric materials can be used; see, Medical Applications of Controlled Release, Langer and Wise (eds.), CRC Pres., Boca Raton, Fla. (1974). In yet another embodiment, a controlled release system can be placed in proximity of the composition's target, thus requiring only a fraction of the systemic dose (see, e.g., Goodson, in Medical Applications of Controlled Release, supra, vol. 2, pp. 115-138, 1984).
The injectable preparations may include dosage forms for intravenous, subcutaneous, intracutaneous and intramuscular injections, drip infusions, etc. These injectable preparations may be prepared by methods publicly known. For example, the injectable preparations may be prepared, e.g., by dissolving, suspending or emulsifying the antibody or its salt described above in a sterile aqueous medium or an oily medium conventionally used for injections. As the aqueous medium for injections, there are, for example, physiological saline, an isotonic solution containing glucose and other auxiliary agents, etc., which may be used in combination with an appropriate solubilizing agent such as an alcohol (e.g., ethanol), a polyalcohol (e.g., propylene glycol, polyethylene glycol), a nonionic surfactant [e.g., polysorbate 80, HCO-50 (polyoxyethylene (50 mol) adduct of hydrogenated castor oil)], etc. As the oily medium, there are employed, e.g., sesame oil, soybean oil, etc., which may be used in combination with a solubilizing agent such as benzyl benzoate, benzyl alcohol, etc. The injection thus prepared is preferably filled in an appropriate ampoule. A pharmaceutical composition of the present invention can be delivered subcutaneously or intravenously with a standard needle and syringe. In addition, with respect to subcutaneous delivery, a pen delivery device readily has applications in delivering a pharmaceutical composition of the present invention. Such a pen delivery device can be reusable or disposable. A reusable pen delivery device generally utilizes a replaceable cartridge that contains a pharmaceutical composition. Once all of the pharmaceutical composition within the cartridge has been administered and the cartridge is empty, the empty cartridge can readily be discarded and replaced with a new cartridge that contains the pharmaceutical composition. The pen delivery device can then be reused. In a disposable pen delivery device, there is no replaceable cartridge. Rather, the disposable pen delivery device comes prefilled with the pharmaceutical composition held in a reservoir within the device. Once the reservoir is emptied of the pharmaceutical composition, the entire device is discarded.
Numerous reusable pen and autoinjector delivery devices have applications in the subcutaneous delivery of a pharmaceutical composition of the present invention. Examples include, but certainly are not limited to AUTOPEN™ (Owen Mumford, Inc., Woodstock, UK), DISETRONIC™ pen (Disetronic Medical Systems, Burghdorf, Switzerland), HUMALOG MIX 75/25™ pen, HUMALOG™ pen, HUMALIN 70/30™ pen (Eli Lilly and Co., Indianapolis, Ind.), NOVOPEN™ I, II and III (Novo Nordisk, Copenhagen, Denmark), NOVOPEN JUNIOR™ (Novo Nordisk, Copenhagen, Denmark), BD™ pen (Becton Dickinson, Franklin Lakes, N.J.), OPTIPENT™, OPTIPEN PRO™, OPTIPEN STARLET™, and OPTICLIKT™ (sanofi-aventis, Frankfurt, Germany), to name only a few. Examples of disposable pen delivery devices having applications in subcutaneous delivery of a pharmaceutical composition of the present invention include, but certainly are not limited to the SOLOSTAR™ pen (sanofi-aventis), the FLEXPEN™ (Novo Nordisk), and the KWIKPEN™ (Eli Lilly).
Advantageously, the pharmaceutical compositions for oral or parenteral use described above are prepared into dosage forms in a unit dose suited to fit a dose of the active ingredients. Such dosage forms in a unit dose include, for example, tablets, pills, capsules, injections (ampoules), suppositories, etc. The amount of the aforesaid antibody contained is generally about 0.1 to about 800 mg per dosage form in a unit dose; especially in the form of injection, the aforesaid antibody is contained in about 1 to about 500 mg, in about 5 to 300 mg, in about 8 to 200 mg, and in about 10 to about 100 mg for the other dosage forms.
Combination Therapies
The invention further provides therapeutic methods for treating diseases or disorders, which is directly or indirectly associated with hTL1A, by administering the hTL1A mAb or fragment thereof of the invention in combination with one or more additional therapeutic agents. The additional therapeutic agent may be one or more of any agent that is advantageously combined with the antibody or fragment thereof of the invention, including immunosuppressants, anti-inflammatory agents, analgesic agents, anti-allergy agents, and the like. Suitable immunosuppressants include, but are not limited to, glucocorticoids, cyclosporin, methotrexate, interferon β (IFN-β), tacrolimus, sirolimus, azathioprine, mercaptopurine, opioids, mycophenolate, TNF-binding proteins, such as infliximab, eternacept, adalimumab, and the like, cytotoxic antibiotics, such as dactinomycin, anthracyclines, mitomycin C, bleomycin, mithramycin, and the like, antibodies targeting immune cells, such as anti-CD20 antibodies, anti-CD3 antibodies, and the like. Suitable anti-inflammatory agents and/or analgesics for combination therapies with the anti-hTL1A antibodies include, corticosteroids, non-steroidal anti-inflammatory drugs (NSAIDs), such as aspirin, ibuprofen, naproxen, Cox-2 inhibitors, and the like, TNF-α antagonists (e.g., Infliximab or REMICADE® by Centocor Inc.; golimumab by Centocor Inc.; etanercept or ENBREL® by Amgen/Wyeth; adalimumab or HUMIRA® by Abbott Laboratories, and the like), IL-1 antagonists (e.g., IL-1-binding fusion proteins, for example, ARCALYST® by Regeneron Pharmaceuticals, Inc., see U.S. Pat. No. 6,927,044; KINERET® by Amgen, and the like), IL-6 antagonists (e.g., anti-IL-6 receptor antibodies as disclosed in U.S. Pat. No. 7,582,298, and ACTEMRA® by Roche), acetaminophen, morphinomimetics, and the like. Suitable anti-allergy agents, which can block the action of allergic mediators, or to prevent activation of cells and degranulation processes, include antihistamines, glucocorticoids, epinephrine (adrenaline), theophylline, cromolyn sodium and anti-leukotrienes, such as montelukast (SINGULAIR® by Merck) or zafirlukast (ACCOLATE® by AstraZeneca), as well as anti-cholinergics, decongestants, mast cell stabilizers, and other compounds that can impair eosinophil chemotaxis.
The hTL1A mAb or fragment thereof of the invention and the additional therapeutic agent(s) can be co-administered together or separately. Where separate dosage formulations are used, the antibody or fragment thereof of the invention and the additional agents can be administered concurrently, or separately at staggered times, i.e., sequentially, in appropriate orders.
EXAMPLES
The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the methods and compositions of the invention, and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers used but some experimental errors and deviations should be accounted for. Unless indicated otherwise, molecular weight is average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
Example 1
Generation of Human Antibodies to Human TL1A
VELOCIMMUNE™ mice were immunized with human TL1A, and the antibody immune response monitored by antigen-specific immunoassay using serum obtained from these mice. Anti-hTL1A antibody-expressing B cells were harvested from the spleens of immunized mice shown to have elevated anti-hTL1A antibody titers and were fused with mouse myeloma cells to form hybridomas. The hybridomas were screened and selected to identify cell lines expressing hTL1A-specific antibodies using assays as described below. The assays identified several cell lines that produced chimeric anti-hTL1A antibodies designated as H2M1681N, H2M1704N, H2M1804N, H2M1805N, H2M1817N and H2M1818N. These antibodies were later converted to hIgG4 isotype by replacing the respective mouse constant regions with the hIgG4 amino acid sequence of SEQ ID NO:257, which contains a S108P mutation in the hinge region, and designated as H4H1681N, H4H1704N, H4H1804N, H4H1805N, H4H1817N and H4H1818N, respectively.
Human TL1A-specific antibodies were also isolated directly from antigen-immunized B cells without fusion to myeloma cells, as described in U.S. Pat. No. 7,582,298, which is hereby incorporated by reference in its entirety. Heavy and light chain variable regions were cloned to generate fully human anti-hTL1A antibodies designated as H4H1719P, H4H1725P, H4H1738P, H4H1742P, H4H1745P, H4H1750P and H4H1752P. Stable recombinant antibody-expressing CHO cell lines were established.
Example 2
Variable Gene Utilization Analysis
To analyze the structure of antibodies produced, the nucleic acids encoding antibody variable regions were cloned and sequenced. From the nucleic acid sequence and predicted amino acid sequence of the antibodies, gene usage was identified for each Heavy Chain Variable Region (HCVR) and Light Chain Variable Region (LCVR). Table 1 shows the gene usage for selected antibodies in accordance with the invention.
TABLE 1
HCVR
LCVR
Antibody
V H
D H
J H
V K
J K
H2M1704
3-7
1-7
6
4-1
3
H2M1681
3-23
2-21
4
1-5
1
H2M1817
4-34
3-9
4
3-20
4
H2M1804
4-34
1-1
4
3-20
4
H2M1818
3-11
4-17
6
4-1
1
H2M1805
4-34
3-3
4
2-24
4
H4H1719
3-9
3-3
6
2-28
2
H4H1725
1-2
2-15
3
1-12
4
H4H1738
3-15
4-4
6
2-28
2
H4H1742
3-23
2-2
6
1-9
2
H4H1745
3-23
6-6
4
1-9
4
H4H1750
3-30
4-17
6
1-17
1
H4H1752
3-23
1-7
4
1-5
1
Table 2 shows the heavy and light chain variable region amino acid sequence pairs of selected anti-hTL1A antibodies and their corresponding antibody identifiers. The N and P designations refer to antibodies having heavy and light chains with identical CDR sequences but with sequence variations in regions that fall outside of the CDR sequences (i.e., in the framework regions). Thus, N and P variants of a particular antibody have identical CDR sequences within their heavy and light chain variable regions but contain modifications within the framework regions.
TABLE 2
mAb Name
HCVR/LCVR
(H2M- or H4H-)
SEQ ID NOS
1704N
2/10
1681N
18/26
1804N
34/42
1805N
50/58
1817N
66/74
1818N
82/90
1719N
98/106
1719P
114/116
1725N
118/126
1725P
134/136
1738N
138/146
1738P
154/156
1745N
158/166
1745P
174/176
1750N
178/186
1750P
194/196
1752N
198/206
1752P
214/216
1742N
218/226
1742P
234/236
Example 3
TL1A Binding Affinity Determination
Binding affinities and kinetic constants were determined by surface plasmon resonance at 25° C. and 37° C. as indicated in Tables 3-5 for human monoclonal anti-TL1A antibodies binding to the following TL1A species variants: human (h) (CHO-expressed, residues 72-251 of SEQ ID NO:244, with N-terminal His 6 -tag), cynomolgus monkey (Mf) ( E. coli -expressed, residues 72-251 of SEQ ID NO:248, with or without N-terminal Met), cynomolgus monkey (CHO-expressed, residues 72-251 of SEQ ID NO:248, with N-terminal His 6 -tag), mouse (m) ( E. coli -expressed, residues 76-252 of SEQ ID NO:250, with or without N-terminal Met), mouse (CHO-expressed, residues 76-252 of SEQ ID NO:250, with N-terminal His 6 -tag), and rat (CHO cell-expressed; residues 76-252 of SEQ ID NO:258, with N-terminal His 6 -tag). Binding constants were also determined for the hTL1A variant, Fhm ( E. coli -expressed, residues 72-251 of SEQ ID NO:246 containing Q167R substitution, with or without N-terminal Met). Measurements were conducted on a T100 BIACORE™ instrument. Antibodies, expressed with either mouse Fc (designated with prefix “H2M”) or human IgG4(S108P) Fc (designated with prefix “H4H”), were captured onto an anti-Fc sensor surface, and at least three different concentrations of the soluble TL1A proteins ranging from 1.25 nM to 100 nM were injected over the sensor surface. Kinetic association (k a ) and dissociation (k d ) rate constants were determined by fitting the data to a 1:1 binding model using BIAevaluation 4.1 curve fitting software (BIAcore Life Sciences). Molar concentrations of TL1A/Fhm used in the data fitting assumed a monomeric state for TL1A in solution. Binding dissociation equilibrium constants (K D ) and dissociative half-lives (t 1/2 ) were calculated from the kinetic rate constants as: K D (M)=k d /k a ; and t 1/2 (min)=[In2/(60*k d )]. NB: No binding under the conditions tested; NT: Not tested in this experiment; *: Fitted k d values below 1×10 −6 (1/s) are slower than the detection limit under these experimental conditions; therefore, k d values were set at 1×10 −6 (1/s) for the purpose of approximating K D and t 1/2 ; **: Equilibrium dissociation constants for antibodies were determined under steady state conditions.
As shown in Tables 3 and 4, antibodies bound with high affinity to CHO-expressed forms of both human and monkey TL1A proteins at 25° C. (13 and 12 antibodies with K D <1 nM, respectively) and at 37° C. (13 and 12 antibodies with K D <1 nM, respectively). H4H1750P bound significantly weaker to the monkey compared to the human TL1A protein. H4H1704N bound to CHO-expressed mTL1A with K D <2 nM at both 25° C. and 37° C. H4H1818N bound CHO-expressed mTL1A at 25° C. (K D ˜7 nM) but not at 37° C. Five antibodies, H4H1681N, H4H1738P, H4H1750P, H4H1752P and H4H1805N, did not bind to CHO-expressed rat TL1A at either 25° C. or 37° C.; the other eight antibodies bound to rat TL1A at both temperatures with K D ranging from ˜0.6 pM to ˜16 nM.
As shown in Table 5, three antibodies (H2M1681N, H4H1752P and H2M1805N) did not demonstrate binding to the E. coli -expressed Fhm variant [hTL1A(Q167R)] under the conditions tested. Three antibodies (H2M1704N, H4H1725P, and H2M1818N) demonstrated weak binding (K D ranging from ˜60 nM to ˜170 nM) to mouse TL1A expressed in E. coli as assessed under steady-state conditions, while all other tested antibodies did not bind to the mouse TL1A protein under the tested conditions.
TABLE 3
CHO-expressed TL1A at 25° C.
hTL1A
hTL1A
MfTL1A
MfTL1A
mTL1A
mTL1A
rTL1A
rTL1A
K D
t 1/2
K D
t 1/2
K D
t 1/2
K D
t 1/2
mAb
(pM)
(min)
(pM)
(min)
(pM)
(min)
(pM)
(min)
H4H1681N
263
36
404
25
NB
NB
NB
NB
H4H1704N
39.2
453
59.9
276
194
46
404
25
H4H1719P
481
44
417
45
NB
NB
364
38
H4H1725P
63.6
185
346
64
NB
NB
317
26
H4H1738P
608
64
361
93
NB
NB
NB
NB
H4H1742P
60.4
755
115
577
NB
NB
78
144
H4H1745P
164
172
115
231
NB
NB
2.7 (nM)
4
H4H1750P
15.8*
11550*
8.6 (nM)
21
NB
NB
NB
NB
H4H1752P
156
197
213
139
NB
NB
NB
NB
H4H1804N
291
51
264
49
NB
NB
321
43
H4H1805N
365
73
342
74
NB
NB
NB
NB
H4H1817N
321
103
356
92
NB
NB
2.5 (nM)
25
H4H1818N
124
120
119
122
7.1 (nM)
12
88
92
TABLE 4
CHO-expressed TL1A at 37° C.
hTL1A
hTL1A
mTL1A
rTL1A
K D
t 1/2
MfTL1A
MfTL1A
mTL1A
t 1/2
rTL1A
t 1/2
mAb
(pM)
(min)
K D (pM)
t 1/2 (min)
K D (pM)
(min)
K D (pM)
(min)
H4H1681N
254
31
226
32
NB
NB
NB
NB
H4H1704N
1.00*
11550*
0.93*
11550*
1.3
27
46
133
(nM)
H4H1719P
7.61
1912
2.01
5784
NB
NB
78
86
H4H1725P
23.9
758
17.7
888
NB
NB
411
15
H4H1738P
571
51
465
60
NB
NB
NB
NB
H4H1742P
4.37*
11550*
4.45*
11550*
NB
NB
653
27
H4H1745P
177
129
173
124
NB
NB
16.5 (nM)
11
H4H1750P
13.8*
11550*
17.1
11
NB
NB
NB
NB
(nM)
H4H1752P
225
96
223
91
NB
NB
NB
NB
H4H1804N
45.8
286
78
167
NB
NB
127
88
H4H1805N
299
80
352
68
NB
NB
NB
NB
H4H1817N
27.8
1098
25.6
1150
NB
NB
1.6 (nM)
26
H4H1818N
0.925*
11550*
0.804*
11550*
NB
NB
0.61*
11550*
TABLE 5
E. coli -expressed Fhm/TL1A
25° C.
37° C.
25° C.
37° C.
25° C.
Fhm
Fhm
Fhm
Fhm
MfTL1A
MfTL1A
MfTL1A
MfTL1A
mTL1A
mAb
K D (pM)
t 1/2 (min)
K D (pM)
t 1/2 (min)
K D (pM)
t 1/2 (min)
K D (pM)
t 1/2 (min)
K D (pM)**
H2M1681N
NB
NB
NT
NT
546
54
1.5 (nM)
14
NB
H2M1704N
282
52
NT
NT
285
57
751
16
127 (nM)
H4H1719P
109
96
174
42
242
79
289
40
NB
H4H1725P
28.9
447
43.6
194
63.7
292
62.2
174
62 (nM)
H4H1738P
1020
19
3100
4
1360
18
4.2 (nM)
4
NB
H4H1742P
437
129
696
45
593
97
945
35
NB
H4H1745P
115
226
207
71
141
221
281
74
NB
H4H1750P
204
623
244
335
52.7 (nM)
4
456 (nM)
1
NB
H4H1752P
NB
NB
NB
NB
274
122
1320
29
NB
H2M1804N
192
108
NT
NT
176
172
218
118
NB
H2M1805N
NB
NB
NT
NT
345
67
439
36
NB
H2M1817N
451
57
NT
NT
1250
37
1.0 (nM)
30
NB
H2M1818N
1080
17
NT
NT
1840
10
4.1 (nM)
3
171 (nM)
Experiment 4
Inhibition of TL1A by Anti-hTL1A Antibodies
HEK293 cell lines (CRK01573, ATCC) were generated to stably express human DR3 (full-length; SEQ ID NO:252) or mouse DR3 (full-length; SEQ ID NO:259) along with a luciferase reporter [NFκB response element (5×)-luciferase-IRES-GFP]. NFκB activation by TL1A has been shown previously (Migone et al., 2002, Immunity 16:479-492). In order to test the membrane-bound form of TL1A and TL1A variants, HEK293 cell lines were generated that stably express full length human TL1A (SEQ ID NO:244), full-length human TL1A with Gln-167 substituted by Arg [Fhm; TL1A(Q167R); SEQ ID NO:246], full-length TL1A from cynomolgus monkey, Macaca fascicularis (MfTL1A; SEQ ID NO:248), full length mouse TL1A (SEQ ID NO:250), and full length rat TL1A (SEQ ID NO:258). The stable cell lines were isolated and maintained in 10% fetal bovine serum (FBS; Irvine Scientific), Dulbecco's Modified Eagle Medium (DMEM; Irvine Scientific), non-essential amino acids (NEAA; Irvine Scientific), Penicillin/Streptomycin (Invitrogen), and G418 (Invitrogen).
For the bioassay, human or mouse DR3 reporter cells were seeded into 96-well assay plates at 1×10 4 cells/well in low serum media, i.e., 0.1% FBS and OPTIMEM® (Invitrogen), and incubated at 37° C. and 5% CO 2 overnight. The next day, soluble TL1A or FHM (sTL1A or sFHM) was serially diluted at 1:3 and added to cells at concentrations ranging from 0.002 nM to 100 nM (plus a buffer control containing no TL1A). For inhibition, antibodies were serially diluted at 1:3 and added to cells at concentrations ranging from 0.002 nM to 100 nM (plus a buffer control containing no antibody) in the presence of constant concentrations of TL1A or Fhm: 800 pM hTL1A (CHO cell-expressed; residues 72-251 of SEQ ID NO:244, with N-terminal His 6 -tag), 100 pM hTL1A ( E. coli -expressed; residues 72-251 of SEQ ID NO:244, with or without N-terminal Met), 500 pM Fhm (CHO cell-expressed; residues 72-251 of SEQ ID NO:246), 400 pM MfTL1A (CHO cell-expressed; residues 72-251 of SEQ ID NO:248, with N-terminal His 6 -tag), 400 pM MfTL1A ( E. coli -expressed; residues 72-251 of SEQ ID NO:248, with or without N-terminal Met), 50 pM mouse TL1A (CHO cell-expressed; residues 76-252 of SEQ ID NO:250, with N-terminal His 6 -tag), 20 pM mouse TL1A ( E. coli -expressed; residues 76-252 of SEQ ID NO:250, with or without N-terminal Met), and 50 pM rat TL1A (CHO cell-expressed; residues 76-252 of SEQ ID NO:258, with N-terminal His 6 -tag). Luciferase activity was detected after 5.5 hours of incubation at 37° C. and 5% CO 2 . The results are shown in Table 6. Control mAb1: Positive control (an anti-hTL1A antibody with heavy and light chain variable domains having the amino acid sequences corresponding to SEQ ID NOS:21 and 27 of US 2009/0280116); control mAb2: Negative control (irrelevant antibody); NB: No binding under the conditions tested; NT: Not tested in this assay; *: Inhibition is not to baseline at the highest antibody concentration of 100 nM.
TABLE 6
hTL1A
hTL1A
Fhm
MfTL1A
MfTL1A
mTL1A
mTL1A
rTL1A
sTL1A or sFhm
(CHO)
( E. Coli )
(CHO)
(CHO)
( E. Coli )
(CHO)
( E. Coli )
(CHO)
EC50 (nM)
0.63
0.12
0.32
0.86
2.02
0.08
0.01
0.06
Constant TL1A or
800
100
500
400
400
50
20
50
Fhm (pM)
IC50
H4H1681N
0.17
0.02
NB
0.03
0.02
NB
NB
NB
[nM]
H4H1704N
0.13
0.06
0.17
0.01
0.03
NB
NB
0.40
H4H1804N
0.07
0.03
0.10
0.03
0.02
NB
NB
3.64
H4H1805N
0.10
0.04
185.50*
0.03
0.02
NB
NB
NB
H4H1817N
0.11
0.04
0.12
0.04
0.02
NB
NB
23.87
H4H1818N
0.37
0.29
0.62
0.13
0.06
NB
NB
1.10
H4H1719P
0.06
0.02
0.08
0.01
0.02
NT
NB
NT
H4H1725P
0.05
0.02
0.07
0.01
0.02
NB
NB
63.43
H4H1738P
0.39
0.16
0.33
0.39
0.07
NT
NB
NT
H4H1742P
0.31
0.19
0.53
0.26
0.07
NB
NB
6.12
H4H1745P
0.09
0.06
0.15
0.05
0.03
NB
NB
NB
H4H1750P
0.90
2.17
3.10
154.70
32.47*
NT
NB
NT
H4H1752P
0.36
0.21
NB
0.12
0.05
NT
NB
NT
Control
NB
0.74
NB
NB
3.25
NT
NB
NT
mAb1
Control
NB
NB
NB
NB
NB
NB
NT
NB
mAb2
As shown in Table 6, thirteen anti-TL1A antibodies were shown to inhibit soluble human TL1A (CHO and E. coli -expressed) stimulation of the human DR3 receptor expressed on HEK293 cells as determined using a luciferase reporter for NFκB activation. A positive control antibody (control mAb1) inhibited E. coli -expressed, but not CHO-expressed, hTL1A. Ten antibodies also inhibited stimulation of hDR3-expressing cells by Fhm (hTL1A with Q167R). H4H1681N, H4H1805N and H4H1752P did not fully inhibit Fhm at the highest antibody concentration of 100 nM. All thirteen antibodies also blocked MfTL1A (Table 6). Mouse TL1A (produced from both CHO and E. coli ) stimulated NFκB activation in the hDR3 reporter cells; however, none of the 13 anti-human TL1A antibodies inhibited E. coli -expressed mouse TL1A in this assay (Table 6). Nine selected antibodies were further tested and did not demonstrate blocking of CHO-expressed mouse TL1A in this assay (Table 6).
To test the ability of TL1A expressed on cells to stimulate signaling in the hDR3 reporter system, bioassays were performed as described above for soluble TL1A with the following changes: Adherent HEK293/TL1A cells were dissociated using Enzyme-Free Dissociation Solution (Chemicon) and added to adherent hDR3 reporter cells after serially diluting the TL1A cells at 1:2 starting from 2×10 5 cells to 195 cells (plus a no-cell control). For inhibition by antibodies, 1×10 4 cells were added together with serially diluted antibodies from 100 nM to 0.002 nM (plus a control containing no antibody). The results are shown in Table 7. Control mAb1 and mAb2: Same as the assays above. NB: No binding under the conditions tested; NT: Not tested in this assay; *: Inhibition is not to baseline at the highest antibody concentration of 100 nM.
TABLE 7
Cell-Bound TL1A or
HEK293/
HEK293/
HEK293/
HEK293/
HEK293/
Fhm
hTL1A
Fhm
MfTL1A
mTL1A
rTL1A
EC50 (cells)
23474
47921
8465
12366
9773
Constant TL1A or
10,000
Fhm (# cells)
IC50 [nM]
H4H1681N
0.66
NB
3.07
NT
NT
H4H1704N
1.11
1.58
3.76
NB
NT
H4H1804N
0.56
1.23
2.23
NB
3.99
H4H1805N
0.82
54.10*
1.93
NB
NB
H4H1817N
1.11
0.62
5.04
NB
94.96*
H4H1818N
1.54
1.42
4.29
NT
NT
H4H1719P
0.82
0.84
3.00
NT
NT
H4H1725P
0.66
0.94
2.82
NB
190.30*
H4H1738P
7.47
7.75
20.25
NT
NT
H4H1742P
6.55
8.39
18.45
NB
NT
H4H1745P
0.76
2.12
4.28
NT
NT
H4H1750P
12.82
29.52*
107.40*
NT
NT
H4H1752P
1.99
138.10*
11.67
NT
NT
Control mAb1
NB
NB
NB
NB
NT
Control mAb2
NB
NB
NB
NB
NB
As shown in Table 7, all thirteen antibodies blocked the stimulation of hDR3-expressing cells by hTL1A expressed on cells. With cell-bound Fhm, all antibodies inhibited significantly except H4H1681N, H4H1805N, H4H1750P and H4H1752P, which did not inhibit fully at the highest tested antibody concentration of 100 nM. With cell-bound MfTL1A, all antibodies inhibited, except H4H1750 that did not inhibit completely at the highest tested antibody concentration of 100 nM. Six of the antibodies H4H1704N, H4H1804N, H4H1805N, H4H1817N, H4H1725P, and H4H1742P were tested for blocking cell-surface mTL1A stimulation of mDR3 cells; and none showed inhibition. Reporter cells expressing mouse DR3 could also be stimulated by rTL1A-expressing 293 cells, with an observed EC 50 of 9773 cells (Table 7). Four antibodies were tested in the rTL1A/mDR3 assay: three antibodies H4H1804N, H4H1817N, H4H1725P blocked while H4H1805N did not block stimulation of mDR3 cells by cell-surface rTL1A (Table 7). Control mAb1 blocked E. coli - expressed soluble hTL1A and MfTL1A stimulation of hDR3 cells, but failed to block the CHO-expressed forms of hTL1A and MfTL1A under all tested conditions (Table 6). Control mAb1 also did not inhibit stimulation of hDR3-expressing cells by any of the cell-surface expressed TL1A and Fhm under all tested conditions (Table 7).
Experiment 5
Blocking of TL1A to hDR3 and DcR3 by Anti-TL1A Antibodies
The ability of antibodies to block human TL1A binding to its cognate receptors, the DR3 and DcR3 receptors, was measured using a competition sandwich ELISA. In addition, blocking of a human TL1A variant FHM (human TL1A Q167R) and the cynomolgus monkey ( Macaca fascicularis ) TL1A (MfTL1A) protein binding to the human DR3 or DcR3 receptors was measured in the same manner. Constant amounts of biotinylated human TL1A or FHM (both expressed with a 6-His tag in CHO cells) or biotinylated MfTL1A (expressed in CHO cells) were separately titrated with varying amounts of antibodies. The antibody-protein complexes were incubated in solution (1 hr, 25° C.) and then transferred to microtiter plates coated with human DR3 (hDR3) or human DcR3 (hDcR3) expressed as human IgG1 Fc fusion proteins. After one hour at 25° C. the wells were washed, and bound human or monkey TL1A was detected with streptavidin conjugated with horseradish peroxidase (HRP). Wells were developed with a TMB solution to produce a colorimetric reaction and quenched with aqueous sulfuric acid before reading absorbance at 450 nm on a Perkin-Elmer Victor X5 plate reader. A sigmoidal dose-response curve was fit to the data using the Prism™ data analysis package. The calculated IC50 value, defined as the concentration of antibody required to block 50% of TL1A binding to hDR3 or hDcR3, was used as an indicator of blocking potency. Both fully human anti-hTL1A mAbs and comparator antibodies, i.e., control mAb1 (an anti-hTL1A antibody with heavy and light chain variable domains having the amino acid sequences corresponding to SEQ ID NOS:21 and 27, respectively, of US 2009/0280116) and control mAb3 (an anti-hTL1A antibody with heavy and light chain variable domains having the amino acid sequences corresponding to SEQ ID NOS:57 and 48, respectively, of US 2009/0280116), were included in the study. The results are shown in Table 8. NB: No binding under the conditions tested; NT: Not tested. Concentrations of biotinylated soluble ligands: (1) 150 pM; (2) 500 pM; (3) 10 pM; and (4) 50 pM.
As shown in Table 8, most of the fully human mAbs show effective blocking of the TL1A/hDR3 and TL1A/hDcR3 binding interaction, with several showing IC50 values below 50 pM. Two of the antibodies, H4H1752P and H4H1805N, strongly blocked binding of both human and monkey TL1A binding to both hDR3 and hDcR3 but failed to block binding of FHM to either hDR3 or hDcR3, suggesting that the binding epitope for these two antibodies may involve the region near the FHM mutation site (hTL1A with Q167R). The crystal structure of hTL1A shows that residue Q167 occurs within a surface-exposed loop (Zhan et al., 2009, Biochemistry 48: 7636-7645).
TABLE 8
DcR3
hDR3
hDR3
hDR3
DcR3
DcR3
MfTL1A
hTL1A (CHO) 1
FHM (CHO) 1
MfTL1A (CHO) 2
hTL1A (CHO) 3
FHM (CHO) 3
(CHO) 4
mAb ID
IC 50 (pM)
IC 50 (pM)
IC 50 (pM)
IC 50 (pM)
IC 50 (pM)
IC 50 (pM)
H4H1681N
60
>10000
141
17
90
93
H2M1681N
37
>10000
61
13
234
149
H4H1704N
30
44
42
77
170
110
H2M1704N
NT
NT
NT
NT
NT
NT
H4H1719P
22
23
46
44
45
61
H4H1725P
15
18
16
68
85
145
H4H1738P
69
152
117
122
150
68
H4H1742P
64
214
240
181
231
127
H4H1745P
18
44
50
58
85
118
H4H1750P
341
589
5209
656
626
NB
H4H1752P
104
NB
110
31
NB
56
H4H1804N
40
69
71
175
>10000
34
H2M1804N
46
102
81
120
>10000
9
H4H1805N
14
NB
26
33
436
313
H2M1805N
6
NB
13
12
2241
1138
H4H1817N
114
235
101
270
NT
322
H2M1817N
154
249
137
890
666
776
H4H1818N
119
202
123
232
NT
1102
H2M1818N
154
317
239
396
NB
55
Control
>10000
NB
5300
>1000
NT
21000
mAb1
Control
>10000
NB
17000
8600
NT
NT
mAb3
Example 6
Cell Surface Binding Competition of Anti-TL1A Antibodies with Soluble hTL1A
Human embryonic kidney 293 cells stably transfected to over-express cell-surface hTL1A were first stained in a flow cytometric experiment with eight anti-hTL1A antibodies at four concentrations (1, 0.1, 0.01, and 0.003 μg/ml). Bound human antibodies were detected using an allophycocyanin-labeled goat F(ab′) 2 specific for human Fcγ [or anti-hFcγ-APC F(ab′) 2 , Jackson ImmunoResearch, #109-136-170]. The lowest antibody concentration providing significant staining levels was then used in a competition binding experiment. A negative isotype control antibody (human IgG4) was used at 1 μg/ml to define the background signal. For the competition experiment, eight antibody samples, at the minimal concentrations identified above, were first treated with soluble hTL1A expressed from CHO cells at concentrations ranging from 0.03 μg/ml to 10 μg/ml. After pre-incubation for 30 min on ice, the antibody/hTL1A mixture was added to 293/HEK-hTL1A cells that had been isolated by centrifugation in a 96-well conical plate. After incubation for an additional 10 minutes on ice, the cells were washed. The secondary reagent, anti-h Fcγ-APC F(ab′) 2 , was added to all wells at a 200-fold dilution to detect bound antibodies. Samples were incubated for 15 minutes on ice, away from light, and then washed. Cells were processed on an BD™ LSR II Flow Cytometer (BD Biosciences) to detect anti-hTL1A antibodies bound to the cell surface, and data were analyzed using FlowJo software (version 8.8.6; Tree Star Inc.). The results are shown in Table 9. Maximum signal: Anti-hTL1A antibody binding in the absence of soluble hTL1A; Minimum signal: Signal recorded when 1 μg/ml of isotype control antibody was added in place of the anti-hTL1A antibody. NT: Not tested.
TABLE 9
Mean Fluorescence Intensity for
Soluble
anti-hTL1A antibodies (H4H) binding to cell-surface hTL1A
hTL1A
1704N
1725P
1742P
1804N
1805N
1817N
1681N
1745P
(μg/ml)
0.1 μg/ml
0.1 μg/ml
1 μg/ml
0.1 μg/ml
0.1 μg/ml
1 μg/ml
1 μg/ml
1 μg/ml
10
NT
NT
NT
NT
NT
NT
16.9
15
3
22.6
34.9
19.9
28.9
23.6
25.2
28.5
19.5
1
26
29.2
32.7
33.7
25.1
29.1
80.9
26.9
0.3
31.5
40.7
44.7
33.5
36.8
23.6
236
115
0.1
132
84.5
79.4
51.1
60.2
97.2
327
93.1
0.03
163
207
126
126
156
85.3
318
80
Maximum
116
211
126
127
158
110
320
87.2
signal
Minimum
27.5
27.5
27.5
27.5
27.5
27.5
17.9
17.9
signal
As shown in Table 9, the signals from the eight tested antibodies could be competed down to baseline levels by the addition of excess soluble hTL1A, demonstrating the specificity of binding of the antibodies to cell-surface hTL1A.
Example 7
Blocking of hTL1A-Dependent CD4 + T-Cell Stimulation by Anti-TL1A Antibodies
To determine the ability of anti-hTL1A antibodies to block hTL1A-dependent stimulation of human CD4 + T-cells, an in vitro assay was developed in which hTL1A/anti-CD3/anti-CD28-stimulated release of IFN-gamma (IFN-γ) was measured in the presence or absence of antibodies. Human CD4 + T-cells were isolated from fresh buffy coats prepared from human blood samples obtained from the New York Blood Center. Cells from a single donor were kept separate from other donor cells for each assay. The CD4 + T-cells were added to the wells of a 96-well plate at 3.5×10 5 cells per well. To each well was then added soluble hTL1A (residues 72-251 of NP_005109.2 with an N-terminal hexa-histidine tag, expressed from CHO cells) to a final concentration of 1 μg/ml (16 nM, assuming hTL1A forming trimers in solution) in RPMI+10% FBS, L-glutamine and penicillin/streptomycin. To each well was also added the anti-hTL1A antibodies or an isotype control antibody to final concentrations of 1.0 μg/ml or 3.0 μg/ml (6.7 nM or 20 nM, respectively). The samples were incubated for 15 minutes at 4° C. in the dark, followed by the additions of anti-hCD3 (BD Pharmingen, cat #555336) and anti-hCD28 (BD Pharmingen, cat #555725) to each well to final concentrations of 1.0 μg/ml. Samples were incubated for 24 hours at 37° C., the supernatants harvested, and IFN-γ levels determined by ELISA. The blocking effect (average from two separate wells for each condition) of each antibody on each human CD4 + T-cell donor sample is represented as the reduction from maximal signal divided by maximal response window; i.e., % Blocking=[(Max−Inhib)/(Max−Min)]×100, where “Max”, “Inhib”, and “Min” are concentrations of IFN-γ measured for CD4 + human T-cells treated as follows: “Max”—treated with [hTL1A+anti-hCD3+anti-hCD28+isotype control mAb]; “Min:”—treated with [anti-hCD3+anti-hCD28+isotype control mAb]; and “Inhib”—treated with [hTL1A+anti-hCD3+anti-hCD28+anti-hTL1A test mAb]. Antibodies for which IFN-γ blockade surpassed the “Min” baseline level are represented as 100% blockade. Ratio (Max/Min) is the ratio of the IFN-γ concentration produced from human CD4 + T-cells treated under Max and Min conditions as defined above.
As shown in Table 10, the antibodies H4H1725P, H4H1805N, H4H1817N, and H4H1804N significantly blocked hTL1A-stimulated IFN-γ release at both 1 μg/ml and 3 μg/ml concentrations, with nearly complete blockade (>80%) observed for most donors at the higher antibody concentration. The results for blockade of IFN-γ secretion by thirteen different anti-hTL1A antibodies against CD4 + T-cells from 10 different human donors are further summarized in Table 11. SD: Standard Deviation.
TABLE 10
% Blocking of IFN-γ production in human T-cells
from 10 donors
Donor #
Ratio
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
mAb ID
(Max/Min)
5
4
10
10
4
3
4
3
8
2
H4H1725P
mAb
90
100
70
85
45
80
60
85
50
95
H4H1805N
1 μg/ml
100
100
90
100
100
100
100
100
90
100
H4H1817N
(6.7 nM)
100
100
90
90
100
45
55
100
55
80
H4H1804N
95
100
80
90
100
50
10
100
50
0
H4H1725P
mAb
95
100
95
100
90
80
90
100
90
100
H4H1805N
3 μg/ml
100
100
95
100
80
100
100
100
70
100
H4H1817N
(20 nM)
100
100
100
100
100
100
100
100
95
85
H4H1804N
100
100
95
100
100
100
100
100
100
80
TABLE 11
Average %
Average %
Average %
Blocking (SD)
Blocking (SD)
Blocking (SD)
mAb ID
0.1 μg/ml mAb
1 μg/ml mAb
3 μg/ml mAb
H4H1681N
20% (24)
45% (30)
95%
(7)
H4H1704N
22% (29)
53% (27)
98%
(5)
H4H1719P
10% (22)
37% (23)
78%
(30)
H4H1725P
13% (14)
80% (20)
94%
(7)
H4H1738P
25% (30)
41% (35)
81%
(18)
H4H1742P
10% (22)
58% (33)
83%
(16)
H4H1745P
22% (27)
36% (36)
91%
(7)
H4H1750P
11% (14)
42% (35)
89%
(15)
H4H1752P
18% (25)
52% (35)
71%
(30)
H4H1804N
26% (30)
68% (38)
98%
(6)
H4H1805N
21% (28)
98% (4)
94%
(10)
H4H1817N
25% (33)
81% (22)
98%
(5)
H4H1818N
25% (33)
42% (33)
71%
(35)
Isotype Control
16% (21)
26% (33)
28%
(27)
IFN-γ levels were also measured at six different antibody concentrations (ranging from 0.03 μg/ml to 10 μg/ml) for each of six different antibodies added to CD4 + T-cells from twelve human donors. Curve fitting to the data allowed estimation of the antibody concentration at which half-maximal inhibition was achieved for each antibody for each donor cell sample. The average (±SD) concentrations for achieving half-maximal inhibition are provided in Table 12.
TABLE 12
mAb IC 50 (nM)
Donor #
H4H1725P
H4H1742P
H4H1805N
H4H1817N
H4H1804N
H4H1704N
D1
3.4
24
2.4
6.6
6.8
—
D2
3.2
4.6
5.5
3.1
8.6
—
D3
5.4
10
3.4
4.7
8.6
—
D4
4.7
13
2.5
2.4
7.7
—
D5
7.0
12
2.9
8.5
6.7
17
D6
5.4
10
3.4
4.7
8.6
11
D7
13
31
8.0
7.0
12
12
D8
12
27
5.1
7.0
11
19
D9
6.4
56
5.9
9.5
8.1
7.5
D10
4.1
12
2.8
7.3
12
10
D11
6.1
27
3.0
7.3
7.6
11
D12
6.4
14
3.1
9.4
7.5
8.0
Average
6.4
20
4.0
6.5
8.8
12
(±SD)
(3.1)
(14)
(1.7)
(2.3)
(1.9)
(4.1)
Four of the antibodies, H4H1725P, H4H1804N, H4H1805N, H4H1817N exhibited average half-maximal inhibition concentrations below 10 nM (ranging approximately 4-9 nM). | A fully human antibody or antigen-binding fragment of a human antibody that specifically binds and inhibits human TNF-like ligand 1A (hTL1A) is provided. The human anti-hTL1A antibodies are useful in treating diseases or disorders associated with TL1A, such as inflammatory diseases or disorders, e.g., inflammatory bowel diseases, including ulcerative colitis and Crohn's disease, rheumatoid arthritis, and the like; autoimmune diseases or disorders, such as multiple sclerosis, diabetes, and the like; and allergic reactions, such as asthma and allergic lung inflammation. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 60/816,657, filed Jun. 27, 2006 and titled “TRI-POLE I.V. STAND,” the disclosure of which is hereby incorporated by reference.
INTRODUCTION TO THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to devices used as mobile support stands for intravenous (“I.V.”) fluid containers, pumps, monitors and other equipment. The exemplary embodiments described herein accommodate a greater number of pieces of equipment, with a smaller footprint, and with the same or better stability than prior mobile support stands.
[0004] It is a first aspect of the present invention to provide a portable intravenous stand comprising: (a) a base including a plurality of wheels; (b) a plurality of vertical supports extending from the base; (c) a plurality of cross-members mounted to the plurality of vertical supports to maintain the vertical supports in relative position to one another; and (d) an intravenous retainer loop mounted to at least one of the plurality of vertical supports.
[0005] In a more detailed embodiment of the first aspect, at least one of the plurality of cross-members includes an opening therethrough. In yet another more detailed embodiment, the plurality of vertical supports are uniformly distributed about a vertical axis extending through the base. In a further detailed embodiment, the base includes at least three symmetrical legs, and at least three of the symmetrical legs each include at least one of the plurality of wheels. In still a further detailed embodiment, the invention also includes supplemental weights mounted to the base. In a more detailed embodiment, the invention also includes a handle mounted to at least one of a vertical support of the plurality of vertical supports and a cross-member of the plurality of cross-members. In a more detailed embodiment, the invention also includes a plurality of intravenous retainer loops mounted to at least one of the plurality of vertical supports and the plurality of cross-members. In another more detailed embodiment, the invention also includes a plurality of clamps vertically repositionable along at least one of the plurality of vertical supports. In yet another more detailed embodiment, at least one of the plurality of supports is circular in cross-section.
[0006] It is a second aspect of the present invention to provide a portable intravenous stand comprising: (a) a portable base; (b) a plurality of vertical supports mounted to the portable base, the plurality of vertical supports including at least three supports triangularly oriented; (c) a plurality of platforms mounted to the plurality of vertical supports, at least one of the plurality of platforms mounted to the at least three supports to maintain the at least three supports in a triangular orientation; and (d) an intravenous retainer loop mounted to at least one of the plurality of vertical supports.
[0007] In a more detailed embodiment of the second aspect, at least one of the plurality of platforms mounted to the at least three supports is vertically repositionable. In yet another more detailed embodiment, the invention also includes a supplemental weight mounted to the portable base, wherein the portable base includes a weight dowel receiving the supplemental weight. In a further detailed embodiment, the invention also includes a handle mounted to at least one of a vertical support of the plurality of vertical supports and a platform of the plurality of platforms. In still a further detailed embodiment, the invention also includes a plurality of intravenous retainer loops mounted to at least one of a vertical support of the plurality of vertical supports and a platform of the plurality of platforms. In a more detailed embodiment, the portable base includes at least three symmetrical legs, and at least three of the symmetrical legs each include a wheel.
[0008] It is a third aspect of the present invention to provide a portable intravenous stand comprising: (a) a portable base; (b) a plurality of vertical supports mounted to the portable base, the plurality of vertical supports including at least three supports triangularly oriented; (c) a plurality of platforms repositionably mounted to the plurality of vertical supports, at least two of the plurality of platforms mounted to the at least three supports to maintain the at least three supports in a triangular orientation; (d) an intravenous loop mounted to at least one of: (i) the plurality of platforms, and (ii) the plurality of vertical supports; and (e) a plurality of repositionable clamps vertically repositionable along at least one of the plurality of vertical supports, where the portable base is disproportionately weighted to lower a center of gravity of the stand.
[0009] In a more detailed embodiment of the third aspect, the portable base includes a weight dowel receiving a supplemental weight to lower the center of gravity of the stand. In yet another more detailed embodiment, at least a portion of the portable base is generally circular in cross-section, and the portion of the portable base generally circular in cross-section includes a plurality of semicircular cut-outs distributed along the periphery of the cross-section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a plan view of a first exemplary intravenous stand pursuant to the instant invention;
[0011] FIG. 2 is a plan view of the first exemplary intravenous stand rotated 1200 ;
[0012] FIG. 3 is an overhead view of an exemplary tray for use with the first exemplary intravenous stand of FIGS. 1 and 2 ;
[0013] FIG. 4 is an elevated perspective view of a second exemplary intravenous stand;
[0014] FIG. 5 is an elevated perspective view from the front of the second exemplary intravenous stand of FIG. 4 , loaded with intravenous pumps; and
[0015] FIG. 6 is a profile view of a rear portion of the second exemplary intravenous stand of FIG. 4 , loaded with intravenous pumps.
DETAILED DESCRIPTION
[0016] The exemplary embodiments of the present invention are described and illustrated below to encompass devices used as mobile support stands for intravenous (“I.V.”) fluid containers, pumps, monitors and other equipment. The exemplary embodiments described herein accommodate a greater number of pieces of equipment, with a smaller footprint, and with the same or better stability than prior mobile support stands. Of course, it will be apparent to those of ordinary skill in the art that the preferred embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention.
[0017] Referring to FIGS. 1-3 , a first exemplary mobile intravenous stand 10 includes a base 12 with castered wheels 20 , support poles 14 , an upper platform 16 , and an intermediate platform 18 .
[0018] The base 12 is generally circular in shape with six generally semi-circular cut-outs 32 . The base is supported from the floor by six castered wheels 20 , one mounted to each of the six projections from the base. Additionally, a weight 24 is affixed to the underside of the base 12 (see FIGS. 1 and 2 ). The weight 24 is provided to assure that the center of gravity is approximate the base 12 , even when the stand 10 is completely loaded with equipment.
[0019] The support poles 14 are hollow cylinders mounted orthogonally to the base 12 in a triangular arrangement. The support poles 14 are attached to the intermediate platform 18 and the upper platform 16 by way of set screws perpendicularly interfacing the poles 14 extending through holes approximate the apexes of the platforms. The intermediate platform 18 and upper platform 16 are generally triangular in shape and have openings 26 through their approximate centers to accommodate objects such as power cords or other throughputs. A standard equipment mount 22 is attached to the upper platform 16 . A standard I.V. bag hanger 25 may be attached to the top of one or more of the support poles 14 . Bars 28 are mounted horizontally between the support poles 14 at a height to allow for easy gripping as handles. Power supply units 30 are mounted on the support poles 14 between the base 12 and the intermediate platform 18 .
[0020] In this first exemplary embodiment, the base 12 is 26 inches in diameter. The shape of the base 12 is designed to provide mounting locations for the castered wheels 20 that are widely spaced for increased stability while minimizing the overall weight of the mobile support stand. The weight 24 attached to the underside of the base 12 augments the stability of the stand by lowering its center of gravity. In exemplary form, the weight 24 is welded directly to the underside of the base 12 , and is between 35 lbs and 45 lbs.
[0021] The total height of the mobile support stand 10 is approximately 68 inches. The support poles 14 are equally spaced 12 inches on center. The support poles 14 are hollow to minimize the overall weight of the stand as well as maintaining the center of gravity as low as possible. The support poles 14 have an outer diameter of 0.875 inches to accept standard medical equipment mounting hardware. The equilateral triangular arrangement of the support poles 14 in the exemplary embodiment provides an optimum number of poles 14 for mounting equipment and increases the stability of the stand by allowing an even distribution of weight. This first exemplary embodiment can support at least fifteen syringe pumps, one infusion pump, and one monitor, as well a numerous bags of I.V. fluid.
[0022] The handles 28 attached between the support poles 14 provide a convenient place to grasp the stand 10 when moving it.
[0023] The upper platform 16 and the intermediate platform 18 each have an opening 26 through which cables may be run. Cable management is important to prevent the inadvertent unplugging of equipment. Additionally, restraining the cables near the center of the stand reduces the risk of catching a cable on a protruding object when the stand is moved and reduces the trip hazard from loose cables.
[0024] The equipment mount 22 attached to the upper platform 16 provides a convenient location for various medical monitors. It is easily visible and reachable by the nursing staff. Including the monitor mount on the I.V. support stand eliminates the need for another rolling stand or other support equipment that would take up additional floor space and increase the difficulty of transporting a patient.
[0025] The support poles 14 extend from the base 12 generally to the full height of the stand 10 . This design improves the strength and sturdiness of the stand and allows a greater number of pieces of equipment to be mounted safely. In addition, the weight of the supported equipment is directly transferred to the base 12 , thereby eliminating unnecessary structural weak points that could be present in a design with branching support poles.
[0026] The power supplies 30 located on the lower portion of the support stand provide a convenient place to plug in the equipment that is mounted on the stand. By including on-board power supplies, fewer cords have to be unplugged when the stand is moved. Locating the power supplies near the bottom of the stand contributes to the low center of gravity and therefore increases the stability of the stand.
[0027] Although this first exemplary stand 10 shows only one I.V. bag hanger, each of the support poles is capable of receiving a hanger attachment. The I.V. bag hangers attached to support stands using thumbscrews.
[0028] FIG. 4-6 show a second exemplary I.V. stand 110 . This second exemplary stand includes a base 112 with castered wheels 120 , support poles 114 , an upper platform 116 , and an intermediate platform 118 . In this exemplary embodiment, the base 112 comprises eight uniformly distributed legs 128 and a central platform 130 that includes a weight dowel 132 . The weight dowel 132 is adapted to receive the central opening in circular or cylindrical weights 134 to lower the center of gravity of the stand 110 . Each of the platforms 116 , 118 includes a central opening 126 , as well as secondary openings 136 approximate the apexes that allow throughput of each of the support poles 114 . In exemplary form, each platform 116 , 118 includes a set screw opening 138 extending normal to the openings 136 . Each set screw opening 138 receives a set screw 140 to mount the platform 116 , 118 to the support poles. Likewise, loosening of the set screws 140 allows for vertical repositioning of one or all of the platforms 116 , 118 .
[0029] The second exemplary I.V. stand 110 also includes an I.V. bag hanger 125 and a standard equipment mount 122 . In exemplary form, the stand 110 is operative to support more than twelve syringe pumps 142 , an infusion pump (not shown), and a monitor (not shown), as well a numerous bags of I.V. fluid (not shown).
[0030] Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein. | A portable intravenous stand comprising: (a) a base including a plurality of wheels; (b) a plurality of vertical supports extending from the base; (c) a plurality of cross-members mounted to the plurality of vertical supports to maintain the vertical supports in relative position to one another; and (d) an intravenous retainer loop mounted to at least one of the plurality of vertical supports. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from Japanese Patent Application No. 2011-069546 filed on Mar. 28, 2011, the entire contents of which are incorporated herein by reference.
TECHNICAL FIELD
Aspects of the invention relate to an optical scanning device that is used in an image forming apparatus such as laser printer.
BACKGROUND
As a printer of an electrophotographic type, there is known a printer including a photosensitive member on which an electrostatic latent image is formed and an exposure device that forms an electrostatic latent image on a surface of the photosensitive member by scanning laser beam based on image data to the photosensitive member.
As the exposure device provided to the printer, related-art shows an optical scanning device which has a light source unit that emits a light beam, a polygon scanner that deflects and scans the light beam emitted from the light source unit and an optical box that accommodates therein the light source unit and the polygon scanner.
In the related-art optical scanning device, both the light source unit and the polygon scanner are fixed to a bottom face part of the optical box. Also, the bottom face part is provided with ribs that surround the polygon scanner.
SUMMARY
In the related-art optical scanning device, when the polygon scanner rotates at high speed, a resonance, which changes a relative position between the light source unit and the polygon scanner, may be generated by vibrations caused due to the rotation of the polygon scanner.
When the relative position between the light source unit and the polygon scanner is changed by the resonance, the precision of the light beam emitted onto a surface of the photosensitive member is lowered and an image quality of a printed image may be deteriorated.
Accordingly, an object of the invention is to provide an optical scanning device capable of suppressing an image quality of a printed image from being deteriorated.
According to an aspect of the invention, there is provided an optical scanning device including: a light source part that is provided in a resin-molded casing and emits a laser beam; a deflector that is arranged in the casing downstream of the light source part with respect to an emission direction of the laser beam and deflects and scans the laser beam, the deflector including, a rotary polygon mirror that reflects the laser beam, a driving source that rotates the rotary polygon mirror, and a substrate member that supports the rotary polygon mirror and the driving source and is fixed to the casing; and the casing including, a fixed wall that extends in a direction perpendicular to a mirror surface of the rotary polygon mirror, a first fixing part that is provided to the fixed wall and fixes the light source part, a second fixing part that is provided to the fixed wall and fixes the substrate member, and a reinforcing part that is provided to the fixed wall and extends toward the emission direction so as to continuously connect the first fixing part and the second fixing part.
According to the invention, the light source part that emits the laser beam is fixed to the first fixing part provided to the fixed wall of the casing, the substrate member of the deflector that deflects and scans the laser beam is fixed to the second fixing part provided to the fixed wall of the casing and the reinforcing part that extends in the emission direction of the laser beam is provided to the fixed wall of the casing so as to continuously connect the first fixing part and the second fixing part.
Accordingly, the fixed wall between the light source part and the deflector is continuously connected and thus reinforced by the reinforcing part extending in the emission direction of the laser beam.
As a result, it is possible to suppress the resonance that changes a relative position between the light source part and the deflector, which is caused due to the rotation of the rotary polygon mirror, and further to suppress an image quality of a printed image from being deteriorated.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a central sectional view of a laser printer;
FIG. 2 is a sectional view showing a scanner unit that is a first illustrative embodiment of an optical scanning device of the invention;
FIG. 3 is an A-A sectional view of the scanner unit shown in FIG. 2 ;
FIG. 4 illustrates a casing of a scanner unit of each illustrative embodiment, in which,
FIG. 4A shows a second illustrative embodiment,
FIG. 4B shows a third illustrative embodiment,
FIG. 4C shows a fourth illustrative embodiment,
FIG. 4D shows a fifth illustrative embodiment,
FIG. 4E shows a sixth illustrative embodiment,
FIG. 4F shows a seventh illustrative embodiment, and
FIG. 4G shows an eighth illustrative embodiment;
FIG. 5 is a bottom view of a scanner unit that is a ninth illustrative embodiment of the optical scanning device of the invention;
FIG. 6 is a side view of the scanner unit shown in FIG. 5 ; and
FIG. 7 illustrates a casing of a scanner unit of each comparative example, in which,
FIG. 7A shows a first comparative example,
FIG. 7B shows a second comparative example, and
FIG. 7C shows a third comparative example.
DETAILED DESCRIPTION
1. Overall Configuration of Laser Printer
As shown in FIG. 1 , a laser printer 1 has a feeder unit 3 and an image forming unit 4 in a body casing 2 .
A front cover 5 for attaching and detaching a developing unit 10 is provided on one sidewall of the body casing 2 . The front cover 5 is configured to be opened and closed freely.
Meanwhile, in the descriptions hereinafter, the side (right side of FIG. 1 ) at which the cover 5 is provided is referred to as the front side and the opposite side (left side of FIG. 1 ) thereto is referred to as the rear side. Also, the left and right sides are defined when seeing the printer 1 from the front side. That is, the front side in a direction perpendicular to the sheet of FIG. 1 is the left side and the back side in a direction perpendicular to the sheet of FIG. 1 is the right side.
(1) Feeder Unit
The feeder unit 3 has a sheet feeding tray 6 that stacks and accommodates sheets P. The sheet feeding tray 6 is detachably attached to a bottom part in the body casing 2 . A sheet feeding roller 7 is arranged upper to the front end of the sheet feeding tray 6 and register rollers 8 are arranged at the rear side of the sheet feeding roller 7 .
The sheets P accommodated in the sheet feeding tray 6 are delivered one by one toward the register rollers 8 by rotation of the sheet feeding roller 7 . The sheet is then delivered toward the image forming unit 4 (between a photosensitive drum and a transfer roller 16 , which will be described later) by rotations of the register rollers 8 at a predetermined timing.
(2) Image Forming Unit
The image forming unit 4 has a scanner unit 9 , which is an example of the optical scanning device, a developing unit 10 and a fixing unit 11 .
(2-1) Scanner Unit
The scanner unit 9 is arranged at an upper part in the body casing 2 . As shown with a dashed line, the scanner unit 9 emits a laser beam L based on image data toward the photosensitive drum 14 (which will be described later) of the developing unit 10 and moves the laser beam L at high speed in one side in left-right direction (main scanning direction), thereby scanning a surface of the photosensitive drum 14 .
(2-2) Developing Unit
The developing unit 10 is arranged lower to the scanner unit 9 . The developing unit 10 has a drum cartridge 12 and a developing cartridge 13 that is detachably mounted to the drum cartridge 12 .
The photosensitive drum 14 that extends in the left-right direction and has a substantially cylindrical shape is rotatably provided in the drum cartridge 12 . Also, a scorotron-type charger 15 and a transfer roller 16 are arranged around the photosensitive drum 14 in the drum cartridge 12 .
The developing cartridge 13 is arranged at the front side of the photosensitive drum 14 and has a developing roller 17 .
The developing roller 17 is rotatably supported to a rear end portion of the developing cartridge 13 so that it is exposed from the back side. The developing roller faces and contacts a front side of the photosensitive drum 14 so as to press the photosensitive drum 14 from the front side.
Also, the developing cartridge 13 accommodates therein toner corresponding to respective colors in a front space of the developing roller 17 .
(2-3) Development/Transfer Operations
The toner in the developing cartridge 13 is carried on a surface of the developing roller 17 as the developing roller 17 is rotated.
In the meantime, as the photosensitive drum 14 is rotated, the surface of the photosensitive drum 14 is uniformly charged by the scorotron-type charger 15 and then exposed by the high-speed scanning of the laser beam L (refer to the dashed line in FIG. 1 ) emitted from the scanner unit 9 . Thereby, an electrostatic latent image, which corresponds to an image to be formed on the sheet P, is formed on the surface of the photosensitive drum 14 .
When the photosensitive drum 14 is further rotated, the toner carried on the surface of the developing roller 17 is supplied to the electrostatic latent image formed on the surface of the photosensitive drum 14 . Thereby, the electrostatic latent image of the photosensitive drum 14 becomes a visible image and a toner image by reversal developing is carried on the surface of the photosensitive drum 14 .
The toner image is transferred onto the sheet P that is conveyed (to a transfer position) between the photosensitive drum 14 and the transfer roller 16 .
(2-4) Fixing Unit
The fixing unit 11 is provided at the rear of the developing unit 10 and has a heating roller 18 and a pressing roller 19 that is pressure-contacted to the heating roller 18 .
The toner image transferred onto the sheet P is heated and pressed and thus heat-fixed on the sheet P while the sheet P passes between the heating roller 18 and the pressing roller 19 .
(3) Sheet Discharge
The sheet P having the toner image fixed thereon is conveyed toward sheet discharge rollers 20 and is discharged onto a sheet discharge tray 21 , which is formed on an upper surface of the body casing 2 , by the sheet discharge rollers 20 .
2. Details of Scanner Unit
(1) Configuration of Scanner Unit
As shown in FIGS. 2 and 3 , the scanner unit 9 has, in a casing 31 made of resin, a light source 32 , which is an example of the light source part, a first cylindrical lens 33 , a deflector 34 , an fθ lens 35 , a mirror 36 and a second cylindrical lens 37 .
As specifically described later, the casing 31 has a substantially flat box shape that is thin in the upper-lower direction. Specifically, the casing 31 has a lower wall 40 that extends from front to rear and from left to right and is an example of the fixed wall, a sidewall 39 that extends upward from a periphery of the bottom wall 40 and an upper wall (not shown) that is opposed to the lower wall 40 in the upper-lower direction and is connected with the sidewall 39 at a periphery thereof. The lower wall 40 of the casing 31 is formed with a penetrated emission port 44 for emitting the laser beam L toward the photosensitive drum 14 .
The emission port 44 has a substantially rectangular shape extending in the left-right direction at a rear end portion of the casing 31 , when seen in a plan view.
The light source 32 is disposed at a substantial center of a right end portion of the casing 31 in the front-rear direction. Also, the light source 32 has a light source holder 53 , a semiconductor laser 51 and a coupling lens 52 .
The light source holder 53 has a substantially rectangular flat plate shape extending from front to rear and from left to right, when seen in a plan view, and is formed at both end portions thereof in the front-rear direction with an insertion penetration hole (not shown) into which a light source fixing screw 54 (which will be described later) is inserted, respectively.
The semiconductor laser 51 is supported at a substantial center of a rear end portion of the light source holder 53 in the front-rear direction. The semiconductor laser 51 emits the laser beam L toward the left side (specifically, toward the left-front side).
The coupling lens 52 is supported at a substantial center of a left end portion of the light source holder 53 in the front-rear direction so that it is opposed to the semiconductor laser 51 . The coupling lens 52 converts the laser beam L, which is emitted from the semiconductor laser 51 , into a parallel light flux.
The first cylindrical lens 33 has a substantially flat plate shape extending in the front-rear direction (specifically, in a direction connecting the right-front side and the left-rear side) and is arranged with an interval at the left side of the light source 32 so that it is opposed to the coupling lens 52 . The first cylindrical lens 33 has refractive power only in a sub-scanning direction (direction perpendicular to both the traveling direction of the laser beam L and the scanning direction of the laser beam L).
The deflector 34 is disposed at the left-front side of the first cylindrical lens 33 , in the left-front end portion of the casing 31 . The deflector 34 has a motor base plate 63 that is an example of the substrate member, a motor 62 that is an example of the driving source and a polygon mirror 61 that is an example of the rotary polygon mirror.
The motor base plate 63 has a substantially rectangular flat plate shape extending from front to rear and from left to right, when seen in a plan view, and supports the motor 62 . Each of four corners of the motor base plate 63 is formed with an insertion penetration hole (not shown) into which a deflector fixing screw 66 (which will be described later) is inserted, respectively.
The motor 62 has a substantially cylindrical shape extending in the upper-lower direction and is fixed on a lower surface of the motor base plate 63 . The motor 62 has a driving shaft 65 that extends in the upper-lower direction and can be rotated.
The polygon mirror 61 has a substantially regular hexagonal flat plate shape when seen in a plan view and has a thickness in the upper-lower direction. Each side of the polygon mirror 61 is formed with a mirror surface 64 extending in the upper-lower direction. The polygon mirror 61 is supported, at a substantial center thereof when seen in a plan view, to a lower end portion of the driving shaft 65 of the motor 62 so that it cannot be relatively rotated. Also, the polygon mirror 61 is arranged to face the lower wall 40 of the casing 31 with an interval therebetween in the upper-lower direction.
The fθ lens 35 is a lens having an fθ characteristic, has a substantially flat plate shape extending in the left-right direction. The fθ lens 35 is arranged at a substantial center of the casing 31 in the front-rear direction and at the rear side of the deflector 34 to face the polygon mirror 61 . A rear end surface of the fθ lens 35 has a substantially circular arc shape having a predetermined curvature so that a substantial center thereof in the left-right direction protrudes rearward. A front end surface of the fθ lens 35 has a substantially circular arc shape having a curvature smaller than that of the rear end surface so that a substantial center thereof in the left-right direction is concave rearward.
The mirror 36 has a substantially flat plate shape extending in the left-right direction and is disposed at a rear side periphery of the emission port 44 to face the fθ lens 35 , in the rear end portion of the casing 31 . Also, the mirror 36 has a front face that is a mirror surface and is inclined such that it is directed downward as it is directed toward the rear side, so that the front face is opposed to the emission port 44 .
The second cylindrical lens 37 has a substantially flat plate shape extending in the left-right direction and is arranged to face the mirror 36 in the emission port 44 . The second cylindrical lens 37 has refractive power only in the sub-scanning direction.
(2) Details of Casing
(2-1) Configuration Regarding Fixing of Light Source, First Cylindrical Lens and Deflector
In the casing 31 , two light source fixing parts 41 for fixing the light source 32 , which are an example of the first fixing part, a first cylindrical lens fixing part 42 for fixing the first cylindrical lens 33 and four deflector fixing parts 43 for fixing the deflector 34 , which are an example of the second fixing part, are provided.
The respective light source fixing parts 41 are arranged with an interval in the front-rear direction at a substantial center of the right end portion of the casing 31 in the front-rear direction so that the respective light source fixing parts correspond to the respective insertion penetration holes (not shown) of the light source holder 53 . Each of the light source fixing parts 41 has a substantially cylindrical shape (refer to FIG. 3 ) extending and protruding vertically from the lower wall 40 of the casing 31 and has a screw hole (not shown) at a substantially diametrical center thereof, which is formed downward from the upper end surface.
The light source fixing screws 54 inserted into the respective insertion penetration holes (not shown) of the light source holder 53 are screwed into the respective light source fixing parts 41 , so that the light source holder 53 of the light source 32 is fixed.
The first cylindrical lens fixing part 42 is arranged at a left side of the front light source fixing part 41 and has a substantially rectangular frame shape extending in the front-rear direction, when seen in a plan view. In the meantime, left and right sidewalls of the first cylindrical lens fixing part 42 are notched at parts through which the laser beam L passes.
The first cylindrical lens 33 is fitted and fixed in the first cylindrical lens fixing part 42 .
The respective deflector fixing parts 43 are arranged at the left-front end portion of the casing 31 in two lines of left and right, which are parallel, in the front-rear direction with an interval therebetween, so that they correspond to the respective insertion penetration holes (not shown) of the motor base plate 63 . Each of the deflector fixing parts 43 has a substantially cylindrical shape extending and protruding vertically from the lower wall 40 of the casing 31 (refer to FIG. 3 ) and has a screw hole (not shown) at a substantially diametrical center thereof, which is formed downward from the upper end surface.
The deflector fixing screws 66 inserted into the respective insertion penetration holes (not shown) of the motor base plate 63 are screwed into the respective deflector fixing parts 43 , so that the motor base plate 63 of the deflector 34 is fixed.
(2-2) Configuration about Reinforcement of Casing
In the casing 31 , a first rib 45 and a second rib 46 , which are an example of the reinforcing part, are provided.
The first rib 45 is a protrusion that protrudes upward from the lower wall 40 of the casing 31 and extends in the left-right direction while being curved. The first rib 45 is arranged between the polygon mirror 61 and the fθ lens 35 at the rear side of the light path of the laser beam L so that it follows the laser beam L heading for the polygon mirror 61 from the light source 32 .
Specifically, the first rib 45 integrally has a first part 45 A, a second part 45 B and a third part 45 C.
The first part 45 A continuously connects the rear light source fixing part 41 and a rear end portion of the first cylindrical lens fixing part 42 . Specifically, the first part 45 A extends from the rear light source fixing part 41 to the left-front side, is bent leftward at the left side of the coupling lens 52 , further extends in the left-front direction and is then connected to the rear end portion of the first cylindrical lens fixing part 42 .
The second part 45 B continuously connects the rear end portion of the first cylindrical lens fixing part 42 and one of the deflector fixing part 43 which is positioned at the left-rear side. Specifically, the second part 45 B has a substantially linear shape extending in a direction of connecting the right-rear side and the left-front side so that it is inclined at an angle smaller than 90 degrees with respect to the laser beam L passing a center of the scanning range of the laser beam L in the left-right direction. Also, the second part 45 B is notched downward from the upper end at a left half thereof facing the polygon mirror 61 in the front-rear direction so that it does not interfere with the laser beam L.
The third part 45 C has a substantially linear shape extending in the left-right direction so that it continuously connects one of the deflector fixing parts 43 , which is located at the left-rear side, and the left sidewall 39 of the casing 31 .
The second rib 46 is a protrusion that protrudes upward from the lower wall 40 of the casing 31 and extends in the left-right direction while being curved. The second rib 46 is arranged at the front side of the light path of the laser beam L with an interval between the first rib 45 so that it follows the laser beam L heading for the polygon mirror 61 from the light source 32 . That is, when projected in the upper-lower direction, the first rib 45 and the second rib 46 are arranged to sandwich the laser beam L, which is heading for the polygon mirror 61 from the first cylindrical lens 33 , in the front-rear direction.
Specifically, the second rib 46 integrally has a first part 46 A, a second part 46 B and a third part 46 C.
The first part 46 A continuously connects the front light source fixing part 41 and the front end portion of the first cylindrical lens fixing part 42 . Specifically, the first part 46 A extends from the front light source fixing part 41 to the left-rear side, is bent leftward at the left-front side of the coupling lens 52 , further extends in the left-lower direction and is then connected to the front end portion of the first cylindrical lens fixing part 42 .
The second part 46 B continuously connects the front end portion of the first cylindrical lens fixing part 42 and one of the deflector fixing part 43 which is positioned at the left-front side (i.e., the deflector fixing part 43 located at the most distant position from the first cylindrical lens fixing part 42 ). Specifically, the second part 46 B of the second rib 46 has a substantially linear shape extending in a direction of connecting the right-rear side and the left-front side so that it is inclined at an angle smaller than 90 degrees with respect to the laser beam L passing a center of the scanning range of the laser beam L in the left-right direction. Also, when projected in the upper-lower direction, a left half of the second part 46 B of the second rib 46 extends to cross the front end portion of the polygon mirror 61 in the left-right direction, and is notched downward from the upper end thereof so that it does not interfere with the polygon mirror 61 (refer to FIG. 3 ).
The third part 46 C has a substantially linear shape extending in the left-right direction so that it continuously connects one of the deflector fixing parts 43 , which is located at the left-front side, and the left sidewall 39 of the casing 31 .
Also, two light source reinforcement ribs 48 , which respectively connect the respective light source fixing parts 41 and the right sidewall 39 of the casing 31 , are provided in the casing 31 .
Specifically, a rear-light source part side plate 49 , which is arranged with an interval at the rear side of the light source 32 and extends leftward continuously from the right sidewall 39 of the casing 31 , and a front-light source part side plate 50 , which is arranged with an interval at the front side of the light source 32 and extends leftward continuously from the right sidewall 39 of the casing 31 , are formed in the casing 31 .
The front light source reinforcement rib 48 has a substantially linear shape extending in the front-rear direction so that it continuously connects the front light source fixing part 41 and the front-light source part side plate 50 . That is, the front light source reinforcement rib 48 is connected to the right sidewall 39 of the casing 31 via the front-light source part side plate 50 .
Also, the rear light source reinforcement rib 48 has a substantially linear shape extending in the front-rear direction so that it continuously connects the rear light source fixing part 41 and the rear-light source part side plate 49 . That is, the rear light source reinforcement rib 48 is connected to the right sidewall 39 of the casing 31 via the rear-light source part side plate 49 .
(3) Operations of Scanner Unit
When the scanner unit 9 is operated, the motor 62 of the deflector 34 is first driven and then the polygon mirror 61 is rotated at high speed.
Then, the laser beam L is emitted from the light source 32 toward the polygon mirror 61 that is being rotated.
When the laser beam L emitted from the light source 32 passes the first cylindrical lens 33 , the laser beam is converged in the sub-scanning direction and then enters onto the polygon mirror 61 that is being rotated.
Then, as the laser beam L is reflected from the mirror surface 64 of the polygon mirror 61 , the laser beam is deflected to perform equiangular movement and is scanned in the main scanning direction.
The laser beam L scanned by the polygon mirror 61 is converted into a constant speed scanning when passing through the fθ lens 35 . Then, the laser beam L is reflected from the mirror 36 . After that, the laser beam L passes through the second cylindrical lens 37 and is then illuminated on the surface of the photosensitive drum 14 .
3. Operational Effects
(1) According to the scanner unit 9 , as shown in FIG. 2 , the first rib 45 and second rib 46 extending toward the emission direction (the left-front side) of the laser beam L are provided on the lower wall 40 of the casing 31 so as to continuously connect the light source fixing parts 41 provided on the lower wall 40 of the casing 31 and the deflector fixing parts 43 provided on the lower wall 40 of the casing 31 .
Therefore, it is possible to continuously connect and reinforce the lower wall 40 between the light source 32 and the deflector 34 by the first rib 45 and second rib 46 extending toward the emission direction of the laser beam L.
As a result, it is possible to suppress the resonance that changes the relative position between the light source 32 and the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 . Accordingly, it is possible to suppress the image quality of a printed image from being deteriorated.
(2) According to the scanner unit 9 , as shown in FIG. 2 , the first rib 45 and second rib 46 extend so that the ribs are inclined at the angle smaller than 90 degrees with respect to the laser beam L passing to a center of the scanning range of the laser beam L in the left-right direction.
Therefore, it is possible to enable the first rib 45 and second rib 46 to follow the laser beam L, which is emitted from the light source part (light source 32 and first cylindrical lens 33 ) while being inclined in the left-front direction.
As a result, it is possible to further reinforce the lower wall 40 of the casing 31 with respect to the emission direction of the laser beam L.
(3) According to the scanner unit 9 , as shown in FIG. 2 , the second rib 46 continuously connects the deflector fixing part 43 of the left-front side, which is located at the most distant position from the light source fixing part 41 , and the light source fixing part 41 .
Therefore, it is possible to make the second rib 46 long in the left-right direction, so that it is possible to further reinforce the lower wall 40 of the casing 31 .
(4) According to the scanner unit 9 , as shown in FIG. 2 , the first rib 45 and the second rib 46 continuously connect the deflector fixing parts 43 and the left sidewall 39 of the casing 31 .
Therefore, it is possible to connect the lower wall 40 and the left sidewall 39 of the casing 31 by the first rib 45 and second rib 46 .
As a result, it is possible to suppress the resonance that changes the relative position between the light source 32 and the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 .
(5) According to the scanner unit 9 , as shown in FIG. 2 , when projected in the upper-lower direction, the second rib 46 extends to cross the polygon mirror 61 in the left-right direction.
Therefore, it is possible to reinforce the lower wall 40 of the casing 31 at a position at which the second rib overlaps with the polygon mirror 61 , when projected in the upper-lower direction.
As a result, it is possible to further suppress the resonance that changes the relative position between the polygon mirror 61 and the light source 32 .
(6) According to the scanner unit 9 , as shown in FIG. 2 , when projected in the upper-lower direction, the first rib 45 and second rib 46 continuously connect the light source fixing parts 41 and the deflector fixing parts 43 of the left-rear and left-front sides, respectively, so as to sandwich the laser beam L heading for the polygon mirror 61 from the light source 32 in the front-rear direction.
Therefore, it is possible to reinforce the lower wall 40 of the casing 31 at both the front and rear sides of the light path of the laser beam L.
As a result, it is possible to further reinforce the lower wall 40 of the casing 31 with respect to the emission direction of the laser beam L.
(7) According to the scanner unit 9 , as shown in FIG. 3 , the polygon mirror 61 is provided below the motor base plate 63 . That is, the motor base plate 63 is provided above the lower wall 40 of the casing 31 with the polygon mirror 61 being interposed therebetween.
Therefore, it is possible to arrange the deflector 34 based on the lengths of the first rib 45 and second rib 46 in the upper-lower direction.
As a result, when the first rib 45 and second rib 46 are formed, it is possible to suppress the scanner unit 9 from becoming larger.
(8) According to the scanner unit 9 , as shown in FIG. 2 , the light source 32 of the light source part (light source 32 and first cylindrical lens 33 ) has the semiconductor laser 51 that emits the laser beam L and the coupling lens 52 that converts the laser beam L from the semiconductor laser 51 into the parallel light flux.
Therefore, the first rib 45 and second rib 46 can reinforce the lower wall 40 of the casing 31 between the semiconductor laser 51 and coupling lens 52 and the deflector 34 .
As a result, it is possible to suppress the resonance that changes the relative position between the light source 32 of the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 .
(9) According to the scanner unit 9 , as shown in FIG. 3 , the first rib 45 and second rib 46 are protrusions that extend upward from the lower wall 40 of the casing 31 .
Therefore, it is possible to reinforce the lower wall 40 of the casing 31 by a simple configuration.
(10) According to the scanner unit 9 , as shown in FIG. 3 , the respective deflector fixing parts 43 extend vertically from the lower wall 40 of the casing 31 and the motor base plate 63 is screwed to the respective deflector fixing parts 43 .
Therefore, it is possible to securely fix the motor base plate 63 to the respective deflector fixing parts 43 with a simple configuration.
(11) According to the scanner unit 9 , as shown in FIG. 2 , the first part 45 A of the first rib 45 and the first part 46 A of the second rib 46 , which reinforce the lower wall 40 between the light source 32 and the first cylindrical lens 33 , are provided in the casing 31 .
Therefore, it is possible to further suppress the resonance that changes the relative position between the light source 32 and the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 .
As a result, it is possible to further suppress the image quality of the printed image from being deteriorated.
4. Respective Illustrative Embodiments
(1) Second to Eighth Illustrative Embodiments
Second to eighth illustrative embodiments are described with reference to FIG. 4 . In the meantime, FIG. 4 shows only the main parts of FIG. 2 . In the second to eighth illustrative embodiments, the same members as those of the first illustrative embodiment are indicated with the same reference numerals and the descriptions thereof are omitted.
In the above-described first illustrative embodiment, the casing 31 is provided with the first rib 45 that connects the light source fixing part 41 and the deflector fixing part 43 of the left-rear side and the second rib 46 that connects the light source fixing part 41 and the deflector fixing part 43 of the left-front side, and the first rib 45 and the second rib 46 are connected to the sidewall 39 .
In the second illustrative embodiment, as shown in FIG. 4A , the first rib 45 of the first illustrative embodiment is formed of the first part 45 A and the second part 45 B and the second rib 46 is formed of the first part 46 A and the second part 46 B. That is, in the second illustrative embodiment, the first rib 45 and the second rib 46 are not connected to the sidewall 39 , differently from the first illustrative embodiment.
Further, in the third illustrative embodiment, as shown in FIG. 4B , a third rib 81 that is an example of the reinforcing part continuously connecting the deflector fixing part 43 of the left-rear side and the deflector fixing part 43 of the left-front side is additionally provided to the configuration of the second illustrative embodiment. The third rib 81 is a protrusion having a substantially linear shape that protrudes upward from the lower wall 40 of the casing 31 , when seen in a plan view.
Further, in the fourth illustrative embodiment, as shown in FIG. 4C , only the second rib 46 is provided in comparison to the configuration of the second illustrative embodiment.
Further, in the fifth illustrative embodiment, as shown in FIG. 4D , the second rib 46 is configured to connect the light source fixing part 41 and the deflector fixing part 43 of the right-rear side and the third ribs 81 are configured to connect the deflector fixing parts 43 of the left-rear and left-front sides, the deflector fixing parts 43 of the left-front and right-front sides, the deflector fixing parts 43 of the right-front and right-rear sides and the deflector fixing parts 43 of the right-rear and left-rear sides, respectively.
Further, in the sixth illustrative embodiment, as shown in FIG. 4E , the third ribs 81 of the fifth illustrative embodiment are configured to connect the deflector fixing parts 43 of the left-rear and left-front sides and the deflector fixing parts 43 of the right-rear and left-rear sides, respectively.
Further, in the seventh illustrative embodiment, as shown in FIG. 4F , the first rib 81 of the fifth illustrative embodiment is configured to connect the deflector fixing parts 43 of the right-rear and left-rear sides.
Further, in the eighth illustrative embodiment, as shown in FIG. 4G , only the second rib 46 of the fifth illustrative embodiment is provided.
According to the third and fifth to seventh illustrative embodiments, as shown in FIGS. 4B and 4D to 4 F, the third rib 81 continuously connects at least two deflector fixing parts 43 .
Accordingly, it is possible to suppress the vibrations of the deflector fixing parts 43 connected to each other and to thus suppress the vibration of the deflector 34 itself.
As a result, it is possible to suppress the resonance that changes the relative position between the light source 32 and the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 .
According to the fifth to eighth illustrative embodiments, as shown in FIGS. 4D to 4G , the second rib 46 continuously connects the deflector fixing part 43 of the right-rear side (the deflector fixing part 43 positioned to be closest to the mirror surface 64 of the polygon mirror 61 , from which the laser beam L is reflected) and the light source fixing part 41 .
Therefore, it is possible to reinforce the lower wall 40 of the casing 31 between the mirror surface 64 of the polygon mirror 61 , from which the laser beam L is reflected, and the light source 32 .
As a result, it is possible to further suppress the resonance that changes the relative position between the light source 32 and the polygon mirror 61 of the deflector 34 , which is due to the vibrations caused due to the rotation of the polygon mirror 61 of the deflector 34 .
In addition, in the above respective illustrative embodiments, the same operational effects as those of the first illustrative embodiment can be realized.
(2) Ninth Illustrative Embodiment
A ninth illustrative embodiment is described with reference to FIGS. 5 and 6 . Meanwhile, in the ninth illustrative embodiment, the same members as those of the first illustrative embodiment are indicated with the same reference numerals and the descriptions thereof are omitted.
In the first illustrative embodiment, the first rib 45 and second rib 46 are provided to protrude upward from the lower wall 40 of the casing 31 . However, in the ninth illustrative embodiment, as shown in FIGS. 5 and 6 , a first rib 71 and a second rib 72 are provided to protrude downward from the lower wall 40 of the casing 31 .
The first rib 71 is a protrusion having a substantially linear shape that protrudes downward from the lower wall 40 of the casing 31 and extends in the left-right direction, when seen in a plan view, and integrally has a first left rib 71 A and a first right rib 71 B.
The first left rib 71 A continuously connects the lower wall 40 below the first cylindrical lens fixing part 42 and a part of the deflector fixing part 43 of the left-rear side, which protrudes downward.
The first right rib 71 B continuously connects the lower wall 40 below the first cylindrical lens fixing part 42 and a part of the rear light source fixing part 41 , which protrudes downward.
The second rib 72 is a protrusion having a substantially linear shape that protrudes downward from the lower wall 40 of the casing 31 and extends in the left-right direction, when seen in a plan view, and integrally has a second left rib 72 A and a second right rib 72 B.
The second left rib 72 A continuously connects the lower wall 40 below the first cylindrical lens fixing part 42 and a part of the deflector fixing part 43 of the left-front side, which protrudes downward.
The second right rib 72 B continuously connects the lower wall 40 below the first cylindrical lens fixing part 42 and a part of the front light source fixing part 41 , which protrudes downward.
According to the ninth illustrative embodiment, it is possible to provide the first rib 71 and second rib 72 on an opposite surface (lower surface) to an upper surface of the lower wall 40 to which the deflector 34 is fixed so that the ribs protrude downward from the lower wall 40 of the casing 31 .
Accordingly, it is possible to reinforce the lower wall 40 of the casing 31 while simplifying the configuration of the inside of the casing 31 , to which the deflector 34 is fixed, and further freely designing the layout thereof.
Additionally, in the ninth illustrative embodiment, the same operational effects as the first illustrative embodiment can be realized.
EXAMPLES
For the configurations described in the above illustrative embodiments and configurations of comparative examples which are described below, vibration analysis is performed.
1. Comparative Examples
(1) Comparative Example 1
As shown in FIG. 7A , a rib 91 that is not continuous to any of the respective light source fixing parts 41 and respective deflector fixing parts 43 is provided at a substantial center of the casing 31 , when seen in a plan view.
(2) Comparative Example 2
As shown in FIG. 7B , only the third ribs 81 of the fifth illustrative embodiment were provided.
(3) Comparative Example 3
As shown in FIG. 7C , a rib was not provided within a range of an angle smaller than 90 degrees with respect to the laser beam L passing to a center of the scanning range of the laser beam L in the left-right direction (that is, a rib that reinforces the casing 31 was not substantially provided).
2. Vibration Analysis
(1) Analysis Solver
LS-DYNA R4.2.1
(2) Method
Implicit method, eigenvalue analysis
(3) Material Properties of Casing
Young's modulus: 4380 MPa
Density: 1.0 g/cm 3
(4) With the above-described conditions, natural frequencies were analyzed in resonance modes (resonance mode (1) and resonance mode (2)) in which the relative position between the light source 32 and the deflector 34 changes. The analysis results are shown in table 1. Note that, the higher the natural frequency, the higher the rigidity of the casing.
TABLE 1
Natural frequencies (Hz) in
respective resonance modes
resonance
resonance
mode (1)
mode (2)
First illustrative embodiment
207.7
461.8
Second illustrative embodiment
179.4
439.6
Third illustrative embodiment
181.1
439.7
Fourth illustrative embodiment
175.9
435.0
Fifth illustrative embodiment
172.3
439.0
Sixth illustrative embodiment
170.0
439.7
Seventh illustrative embodiment
169.0
439.4
Eighth illustrative embodiment
167.0
425.7
Comparative example 1
170.3
430.3
Comparative example 2
168.7
404.5
Comparative example 3
166.0
407.6 | An optical scanning device including: a light source part that is provided in a resin-molded casing and emits a laser beam; a deflector that is arranged in the casing and deflects and scans the laser beam, the deflector including, a rotary polygon mirror that reflects the laser beam, a driving source that rotates the rotary polygon mirror, and a substrate member; and the casing including, a fixed wall that extends in a direction perpendicular to a mirror surface of the rotary polygon mirror, a first fixing part that is provided to the fixed wall and fixes the light source part, a second fixing part that is provided to the fixed wall and fixes the substrate member, and a reinforcing part that is provided to the fixed wall and extends toward the emission direction so as to continuously connect the first fixing part and the second fixing part. | 1 |
DESCRIPTON
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The invention relates to sewing machines with push-button controls.
2. Description of the Prior Art
It is well known to provide a sewing machine with pattern selecting push-buttons. Push-button controls may be seen, for example, in U.S. Pat. No. 4,297,956, for "Zig-zag Sewing Machine Having Base-Mounted Operating Elements for Controlling Sewing" issued Nov. 3, 1981, and in U.S. Pat. No. 3,332,380 for "Device for Free Selection of Zig-zag Pattern Discs in Sewing Machines" issued July 25, 1967.
The present invention relates to a compact push-button control arrangement of the kind which is disclosed in the copending patent application of William Weisz, for "Push-Button Control Module for a Sewing Machine", Serial No. 06/449,721, filed 12/14/82, and wherein a larger number of slidable contiguously stacked push-button extensions are present in a vertical column opposite stacked slidable cam followers that are actuable by the push-button extensions.
It is an object of the present invention, in a push-button control arrangement which includes a large number of vertically stacked slidable push-button extensions, to prevent an excessive build up of friction between the said extensions and to prevent an accumulation of manufacturing thickness variations in the stacked extensions such as would interfere with the proper operation of the control.
It is a further object of the invention, in a push-button control arrangement, to prevent an excessive build-up of friction and disadvantageous accumulation of manufacturing thickness variations in vertically stacked slidable push-button extensions and cam followers.
Other objects and advantages of the invention will become apparent during a reading of the specification taken in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
A push-button control for a sewing machine including a large number of push-buttons with slidable vertically stacked contiguous push-button extensions to act against slidable cam followers in alignment with the push-button extensions is provided with fixed spaced apart plates to engage certain of the extensions and cam followers and so support the push-buttons and cam followers in discrete sets. The plates are affixed to vertical posts and are preferably of a resilient material having openings with enlarged end portions through which the plates can be threaded on the posts, and narrow portions into which the posts can be snapped by lateral movement of the plates to cause the plates to elastically grip the posts.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sewing machine control module embodying the construction of the present invention;
FIG. 2 is an enlarged perspective view of the control module with portions broken away to show internal parts;
FIG. 3 is a perspective view showing a typical set of push-buttons on a supporting plate;
FIG. 4 is a perspective view showing several sets of push-buttons and cam followers on set dividing plates;
FIGS. 5, 6 and 7 are perspective views showing how set dividing plates are affixed to upright posts in the control module.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, reference character 20 designates a sewing machine push-button control module of the king disclosed in U.S. Patent Application Ser. No. 06/449,721, mentioned hereinbefore. As shown, the module includes mulitiple rows of push-buttons numbered 1 through 16, and additional push-buttons 17 and 18. Each of push-buttons 1 through 18 is formed with a rearward extension which is identified by a reference character that is the same as the principle reference character, but has a subscript e added thereto. Reference character 19e denotes a floating push-button extension associated with each of push-buttons 17 and 18 in the manner described in the aforementioned patent application. The extensions are all vertically stacked and slidable on one another.
The push-button extensions and push-buttons are supported in accordance with the invention in sets 22, 24, 26, 28 and 30. Set 22 is the lower most set and it is supported in the module on a member 32 engaged by extension 13e. The other sets are supported on set dividing plates 34, 36, 38 and 40 in engagement with extensions 9e, 5e, le and 19e, respectively. Plates 34, 36, 38 and 40 are affixed in the module on cylindrical posts 42, 44 and 46 extending between and secured in the bottom plate 33 and top plate 48 of the module. Each of the push-button extensions includes elongate slots 50 and 52, and the posts 42 and 44 extend through these slots to guide sliding movement of the push-button extensions. Post 46 extends through slots 54 in slidable cam followers and serves to guide sliding movement thereof in the module. The followers are aligned with and are actuable by the push-button extensions. Such followers are designated by the same numbers as the actuating push-button extensions, but have a subscript f added thereto in place of the e used in association with the numbers identifying the extensions. The cam followers are operable by rotatable cams 56 (of which there is one for each follower); a pivoted wobble plate 58 is operable by the cam followers; and a needle bight controllong member 59 is operable by the wobble plate acting through link 60 and bell crank 61 all in the manner described in the aforementioned patent application.
Plates 34, 36, 38 and 40 are preferably of a resilient plastic material. Each of the plates is formed with through openings which include an enlarged end portion 62 and a narrower portion 64 extending to the edge 66 of the plate. When the module 20 is assembled, the posts 42, 44 and 46 are threaded through the enlarged portions 62 of the plate openings, posts 42 and 44 are passed through the slots 52 and 50 respectively in the push-button extensions, and post 46 is passed through the slots 54 in the cam followers. The plates are then affixed to the posts in spaced apart locations by being moved laterally so as to cause the plates at the narrower portions 64 of the through openings where formed with circular cut-outs 68 to be elastically snapped into undercuts 78 (reduced cross-sectional portions) in the posts. The plates are formed with V-shaped slots 72 alongside of the plate openings in which posts 42 and 44 are received. Such V-shaped slots facilitate temporary enlargement of the narrower portions 64 of the openings 60 as the plates are moved laterally to elastically embrace the undercuts in the posts.
In the described construction, each of plates 32, 34, 36, 38 and 40 supports a fraction of the total number of push-button extensions and a fraction of the total number of cam followers. The accumulation of weight in the various sets of push-button extensions and cam followers separated by the snap-on plates is therefor limited, and a build-up of large frictional forces between the slidable plates and slidable cam followers is prevented. The separation of the push-button extensions and cam followers into sets by the snap-on plates also prevents a deleterious build-up of manufacturing tolerance variations in the push-button extensions and/or the cam followers such as could otherwise prevent proper cooperation between the extensions and cam followers.
It is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only, and is not to be construed as a limitation of the invention. Numerous alterations and modifications by the structure herein disclosed will suggest themselves to those skilled in the art, and all such modifications which do not depart from the spirit and scope of the invention are intended to be included within the scope of the appended claims. | A control module for a sewing machine is provided with spaced apart plates, each to support a set of push-buttons arranged in multiple rows. The push-buttons include extensions which are contiguously stacked vertically for slidable movement and operate against aligned posts in actuated position of the push-buttons. | 3 |
FIELD OF THE INVENTION
The present invention relates to 6-methylpyridine derivative useful as an antiviral agent, and more particularly novel 6-methylpyridine derivative having an excellent inhibitory effect on replication of Hepatitis C virus (HCV), represented by the following formula I:
or pharmaceutically acceptable salts thereof, to a method for preparing thereof, and to an antiviral pharmaceutical composition comprising the compound as an active ingredient.
DESCRIPTION OF THE RELATED ART
Hepatitis C virus (HCV) is the major etiological agent of non-A and non-B viral hepatitis, mainly being post-transfusion and community-acquired. Once infected with HCV, approximately 80% of infected people, given its symptom is manifested, progress to chronic hepatitis, and the rest 20% of infected people progress to acute hepatitis causing hepatic cirrhosis, which is eventually transferred to liver cancer. According to a recently published report, more than 200 million worldwide are infected with HCV. For instance, more than 4.5 million Americans are infected with the same virus (The number is likely to be 15 million in maximum.) and more than 5 million Europeans are HCV patients.
HCV is a member of the Flaviviridae family. More specifically, HCV has about 9.5 kb sized (+)-RNA (single stranded positive-sense RNA) genome inside its envelope. RNA genome consists of an untranslational region at 5′ and 3′ ends (UTR) and a long open reading frame (ORF). This ORF is expressed as a polyprotein including 3,010 to 3,040 amino acids by host cell enzymes and divided into 3 structural proteins and 6 nonstructural proteins by host cell enzymes and its own protease. Also, there is a uniformly conserved region in the 5′ end and the 3′ end of the genome, respectively. This region is believed to play an important role for protein expression and RNA replication of the virus.
The long ORF is expressed as a polyprotein, and through co-translational or post-translational processing, it is processed into structural proteins, i.e. core antigen protein (core) and surface antigen protein (E1, E2), and nonstructural proteins, NS2 (protease), NS3 (serine protease, helicase), NS4A (serine protease cofactor), NS4B (protease cofactor, involved in resistance), NS5A, and NS5B (RNA dependent RNA polymerase, RdRp), each contributing to replication of virus. The structural proteins are divided into core, E1, and E2 by signal peptidase of the host cell. Meanwhile, the nonstructural proteins are processed by serine protease (NS3) and cofactor (NS2, NS4A, and NS4B) of the virus. The core antigen protein together with surface antigen protein of the structural protein compose a capsid of the virus, and the nonstructural proteins like NS3 and NS5B play an important role of the RNA replication of the virus (Reference: Bartenschager, R., 1997, Molecular targets in inhibition of hepatitis C virus replication, Antivir. Chem. Chemother. 8: 281-301).
Similar to other Flaviviruses, the 5′ and 3′ ends of the virus RNA has a uniformly conserved untranslational region (UTR). Generally, this region is known to play a very important role in replication of the virus. The 5′ end has 5′-UTR composed of 341 nucleotides, and this part has the structure of 4 stem and loop (I, II, III, and IV). Actually, this functions as an internal ribosome entry site (IRES) necessary for translation processing to express protein. Particularly, the stem III, which has the biggest and the most stable structure with conserved sequence, has been reported to play the most essential part for ribosome binding. In addition, a recent study tells that the virus proteins are expressed by initiation of translational processing from AUG that exists in the single RNA of the stem IV (Reference: Stanley, M. Lemon and Masao Honda, 1997, Internal ribosome entry sites within the RNA genomes of hepatitis C virus and other Flaviviruses, seminars in Virology 8:274–288).
Moreover, the 3′ end has 3′-UTR composed of 318 nucleotides. This part is known to play a very important role in the initiation step of binding of NS5B, an essential enzyme of RNA replication. The 3′-UTR, according to the sequence and tertiary structure, is composed of three different parts: -X-tail-5′ starting from the 5′end to 98th nucleotide (98nt), -poly(U)- having UTP consecutively, and the rest of 3′-UTR-. More specifically, X-tail-5′ part consists of 98 nucleotides having a very conserved sequence, and has three stem and loop structures, thereby forming a very stable tertiary structure. Probably, this is why X-tail-5′ part is considered very essential of NS5B binding. Also, it is reported that -poly(U)- part induces a pyrimidine track, facilitating RNA polymerase effect. Lastly, the rest part of 3′-UTR part has the tertiary structure of loop and plays an important role in NS5B binding. However, its structure is known somewhat unstable. Overall, the 3′end region of HCV RNA is known to have an essential structure in NS5B binding when the RNA replication starts (Reference: Yamada et al., 1996, Genetic organization and diversity of the hepatitis C virus genome, Virology 223:255–281).
Among other enzymes of HCV, NS5B is the one that is directly involved in RNA replication and thus it is very important. NS5B is an enzyme consisting of 591 amino acids having the molecular weight of about 68 kDa. There are two RNA-binding domains (RBD), i.e. RBD1 and RBD2, in the NS5B enzyme. RBD1 exists between the amino acid numbers 83 and 194, and RBD2 exists between the amino acid numbers 196 and 298. Meanwhile, essential motif amino acids for RNA binding and activity are ‘Asp’ (amino acid number 220), ‘Gly’ (amino acid number 283), ‘Gly’ (amino acid number 317), ‘Asp’ (amino acid number 318), ‘Asp’ (amino acid number 319), and ‘Lys’ (amino acid number 346). Further, provided that there exists a RNA template of the virus itself, this enzyme can lead a polymerization reaction without another primer (Reference: Lohmann, V. et al., 1997, Biochemical properties of hepatitis C virus NS5B RNA dependent RNA polymerase and identification of amino acid sequence motifs essential for enzymatic activity, J. viral. 71:8416–8428).
RNA genome of HCV was isolated in 1989 by molecular cloning (Reference: Choo, Q-L, et al., 1989, Isolation of a cDNA clone derived from a blood-borne non-A, non-B viral hepatitis genome. Science 244:359–362). Although there have been a number of molecular biological researches on HCV from that point, there were always limitations due to lack of more effective cell culture systems and animal models. Fortunately, the above problem has been somewhat resolved by the introduction of a hepatoma cell line which made it possible to replicate HCV more stably (Reference: Lohmann, V., F. Korner, J-O Koch, U. Herian, L. Theilmann, R. Bartenschlarger, 1999, Replication of subgenomic hepatitis c virus RNAs in a hepatoma cell line. Science 285:110–113).
So far, no one has actually found vaccine or therapeutics that is very effective for HCV. Hence, many pharmaceutical companies and institutes around the world are now trying to develop therapeutics and prevention of hepatitis C. HCV patients are prevalent in the world, and its frequency to be progressed to hepatic cirrhosis and/or liver cancer is much higher than HBV. Also, despite its high frequency to be progressed to chronic hepatitis, the research on infection mechanism of the virus is still under progress. People are infected with HCV through blood transfusion or medication via phleboclysis or tattooing, but most of cases HCV infection takes place through a direct blood contact. However, 40–50% of the HCV patients still do not exactly know how they became infected. In view of this situation, it is a very urgent matter to develop a new vaccine and therapeutics to treat the diseases. In general, HCV exist as diverse genotypes between strains and mutation. Once a person is progressed to chronic hepatitis from HCV, it is not hard to see reinfection or coinfection owing to genetic variants. Because of this, few succeeded to develop an effective vaccine for HCV. Another example of HCV treatments is using alpha interferon (α-interferon). However, this approach proved to be not that good because the effects of alpha interferon on different HCV genotypes were very diverse and when its administration was discontinued, patients relapsed into hepatitis C in most of cases. Hence it will be important to develop an inhibitor that binds only to a particular HCV protein in order to control HCV replication. The best targets of such research are NS3 protease/helicase and NS5B RNA polymerase of HCV. These enzymes are very useful for developing anti-HCV agent since these types of enzyme is not necessary for the host cell but essential for its own replication. In other words, NS5B of HCV (RNA dependent RNA polymerase) is an essential enzyme for HCV, and this makes the enzyme a good target for suppressing the replication of HCV.
Now that HCV is not easily treated by vaccine, a new therapy using α-interferon and Ribavirin was introduced. But this, too, caused side effects and was not effective for treating hepatitis C. For example, about 25% of HCV patients showed no reaction to the interferon therapy, and about 25% reacted to it only for temporarily and relapsed into hepatitis C. The rest 50% of the patients maintained ALT at a normal level after the treatment was completed and their HCV RNA became negative. However, 50% of them relapsed into hepatitis C within 3–6 months. In short, only 25% of the HCV patients showed sustained response for more than 6 months. Meanwhile, the most HCV subtype found in patient world wide is 1 (1a, 1b) that is not easily treated by interferon, compared to 2 and 3 subtypes. In case of combination therapy with interferon and ribavirin, the treatment effect was doubled. What is known about ribavirin is that when it was used alone, it showed little effect on HCV and rather, caused side effects like erythroclastic anemia. Thus ribavirin was prescribed only when the interferon therapy was no good or relapsed into hepatitis C again. So far, no one actually developed an antiviral agent for treating hepatitis C by suppressing the replication of HCV.
The present invention, therefore, is directed to develop a non-nucleoside small molecule having low toxicity and side effect but manifesting excellent antiviral activity against HCV, by studying any possible compound that inhibits the activity of the recombinant HCV RNA polymerase (NS5B, RNA polymerase).
After making so much efforts for developing a compound with excellent anti-viral activity against HCV as an attempt to develop a new HCV therapeutics having low toxicity and side effect, the inventors finally succeeded to synthesize a new 6-methylpyridine derivative represented by the above chemical formula I and proved that this compound is indeed very effective for inhibiting the replication of HCV.
DISCLOSURE OF INVENTION
It is, therefore, an object of the present invention to provide 6-methylpyridine derivative, which is effective for inhibiting the replication of HCV, and pharmaceutically acceptable salts thereof and a method for preparing the compound.
Another object of the present invention is to provide a pharmaceutical composition comprising the above compound as an effective component, which has low side effect and is economical, for prevention and treatment of hepatitis C.
To achieve the above objects, the present invention provides novel 6-methylpyridine derivative, represented by the formula I shown below and its pharmaceutically acceptable salts.
As aforementioned, the above compound can be used in form of pharmaceutically acceptable salts. As for that salts, an acid addition salts that are prepared by pharmaceutically acceptable free acids are available. The compound with the chemical formula I can make pharmaceutically acceptable acid addition salts following the conventional method in the related art. As for free acids, both organic acids and inorganic acids can be used. For instance, inorganic acids include hydrochloric acid, hydrobromic acid, sulfuric acid, and phosphoric acid. Organic acids include citric acid, acetic acid, lactic acid, tartaric acid, maleic acid, fumaric acid, formic acid, propionic acid, oxalic acid, trifluoroacetic acid, benzoic acid, gluconic acid, methanesulfonic acid, glycolic acid, succinic acid, 4-toluenesulfonic acid, glutamic acid or aspartic acid.
Another aspect of the present invention provides a method for preparing 6-methylpyridine derivative, represented by the following scheme:
As shown in the above scheme, 6-Methylpyridine derivative of the present invention, represented by chemical formula I, are prepared by reacting 2-chloro-6-methylnicotinic acid of the chemical formula II with 4-(4-morpholino) aniline of the chemical formula III. The starting material, i.e. 2-chloro-6-methylnicotinic acid of the chemical formula II, and the reactant, i.e. 4-(4-morpholino)aniline of the chemical formula III are commercially available chemicals for anyone to get.
To give more details on the preparation method described above, the reactions are performed in organic solvents such as methanol, ethanol, isopropanol, dichloromethane, chloroform, acetonitrile, N,N-dimethylformamide, acetone and the like, and in the presence of the weak tertiary organic bases such as pyridine, 2,6-lutidine, 4-dimethylaminopyridine, N,N-dimethylaniline and the like, for a relatively long period of time, namely one day to 6 days at a temperature in the range of 40–80° C.
The present invention also provides the pharmaceutical compositions for treatment and prevention of hepatitis C, which contains the 6-methylpyridine derivative represented by the chemical formula I and/or its pharmaceutically acceptable salts as an active ingredient.
The compounds of the chemical formula I as the therapeutics for hepatitis C may be administered orally as well as through other routes in clinical uses, and can be used in form of general drugs. If it needs to be prepared, a generally used diluent including filler, builder, binder, humectant, dis-integration agent or surfactant or excipient can be employed. In the meantime, the solid preparation for oral administration includes tablets, pills, powder, granules or capsules. This solid preparation involves the compound of the chemical formula I and more than one excipient, for example, starch, calcium carbonate, sucrose or lactose, or gelatin. As for the liquid preparation for oral administration, suspension, solution, oily medicine or syrup can be used, but it can also employ a simple diluent, namely water, liquid paraffin, or other kinds of excipient, e.g. humectant, sweetening agent, odorant, or preservative. As for liquid preparation for non-oral administration, sterilized water solution, non-aqueous solvent, suspension or oily medicine. Preferably used non-aqueous solvent and suspension is propylene glycol, polyethylene glycol, vegetable oil like olive oil, and injectable esters like ethyl oleate.
The effective dose of the compound of the chemical formula I is controlled depending on the patient's sex, age and condition. In general, it can be dosed to adults 10–1000 mg/day, more preferably 20–500 mg/day, or one to three times dividedly per day.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, the present invention is explained in detail by the following examples. However, the examples are provided for illustration of the present invention not for limitation thereof.
EXAMPLE 1
Preparation of 6-methyl-2-[4-(4-morpholino)anilino] nicotinic acid
5 g of 2-chloro-6-methylnicotinic acid, 5.45 g of 4-(4-morpholino) aniline, and 7.2 ml of pyridine were added to 100 ml of chloroform. The mixture was heated to 60° C. and stirred for five days at 60° C. When the reaction was completed, the reaction mixture was cooled to room temperature and a little amount of precipitated solid was filtered and washed with 10 ml of chloroform to remove impurities. The solvent chloroform was concentrated under reduced pressure and the residue was crystallized with 60 ml of methanol, and stirred for 1 hour. The product was filtered, washed twice with 10 ml of methanol and dried in vacuo at 35–45° C. to give 7.31 g of the desired compound (80% yield).
m.p.: 220–221° C.
1 H-NMR (DMSO-d 6 ), ppm: δ 2.39 (s, 3H), 3.04 (t, 4H), 3.73 (t, 4H), 6.61 (dd, 1H), 6.89 (d, 2H), 7.57 (dd, 2H), 8.05 (dd, 1H), 10.21 (s, 1H)
EXPERIMENTAL EXAMPLE 1
Test of Inhibitory Effect on Activity of HCV RNA Polymerase (RNA Dependent RNA Polymerase, NS5B) In Vitro
The following in vitro experiments were conducted to find out the effect of inhibition activity of compounds of the present invention against HCV RNA Polymerase (RNA dependent RNA polymerase, NS5B).
Construct of Recombinant HCV RNA Polymerase
HCV RNA polymerase was prepared as follows.
HCV cDNA was obtained from the blood of HCV-1b type HCV patient and NS5B region (1773 bps) was amplified by PCR and cloned into pVLHIS, a baculovirus transfer vector, to prepare recombinant transfer vector. The prepared transfer vector and the wild-type AcNPV vector were cotransfected into Sf 9 cell line to yield recombinant baculovirus with the histidine-tagged recombinant vector pVLHIS-NS5B. Sufficiently cultured insect cells were infected with the resulting recombinant baculovirus and cultured in Grace' medium containing 10% FBS for 3–4 days. The culture broth was centrifuged to obtain only the infected cells. The cells were washed three times with PBS and resuspended in binding buffer [50 mM Na-phosphate (pH 8.0), 30 mM NaCl, 10 mM imidazole, 1 mM DTT, 10% glycerol, 1% NP-40], sonicated and the clearized lysate was obtained. Recombinant NS5B was purified by affinity column chromatography using a Ni-NTA His bind resin (Novagen) to produce pure NS5B protein. The (His) 6 -tagged NS5B was bound to Ni-NTA resin and washed with the binding buffer containing 50 mM imidazole. The bound NS5B was eluted with the binding buffer containing imidazole in a step-gradient manner (100–300 mM). The NS5B protein fractions were dialyzed against buffer [50 mM Tris-HCl, 50 mM NaCl, 1 mM DTT, 5 mg MgCl 2 , 10% glycerol], followed by at −70° C. in a small aliquot.
Construct of RNA Template Containing HCV 3′ end (3′-UTR)
The RNA Template containing HCV 3′ end (3′-UTR) was prepared as follows.
The 3′UTR cDNA (220 bp) of HCV was obtained from 1b HCV RNA of the blood of a hepatitis C patient by PCR and cloned into pcDNA3 vector. Linearized DNA fragment containing 3′-UTR was prepared using the restriction enzyme, EcoRI and used as a temperate for in vitro transcription using T7 RNA ploymerase to prepare RNA fragment containing 3′-UTR.
Measurement of Inhibitory Activity of Compounds of the Present Invention
Measurement of Inhibitory Activity of Compounds of the Present Invention on Recombinant HCV RNA Polymerase In Vitro
In Vitro inhibitory activity of the compounds of the present invention against recombinant HCV RNA polymerase was measured as follows.
A streptavidin-coated well plate was prepared suitable for the sample to be examined. 25 μl of 2× assay buffer [50 mM Tris-Cl (pH 7.5), 100 mM NaCl, 10 mM MgCl 2 , 20 mM KCl, 1 mM EDTA, 1 mM DTT] and 10 μl of purified HCV RNA polymerase 200 ng and 3′-UTR template RNA were added to each well. Then, 5 μl of the sample to be examined was added to have final concentrations of 10, 1, 0.1 and 0.01 μg/mL. Finally, 10 μl of a reactant solution containing DIG-(digoxigenin)-UTP, biotin-UTP, ATP, CTP, GTP, and UTP as a nucleotide for the ploymerase reaction with the RNA template of HCV 3′-UTR RNA was added to each well. The reaction mixture was incubated at 22° C. for 60 minutes. By the action of HCV polymerase, newly generated RNAs including UTP conjugated with biotin and DIG were copied and these new RNAs could bind to streptavidin coated on the well by biotin-conjugated UTP. After completion of the reaction, the plate was washed three times with 200 μl of a washing buffer (pH 7.0, Roche Co.) to remove unreacted substances and impurities. Then, 100 μl of the secondary antibody anti-DIG-POD (peroxidase, Roche Co.) was added to each well and incubated at 37° C. for 1 hour. Again, the well plate was washed with the washing buffer. Finally, 100 μl of ABTS R (Roche Co.) as a POD substrate was added to each well and reacted for 15 to 30 minutes. The optical density (OD) was measured using an ELISA reader (Bio-Tek instrument Co.) at 405 nm. The inhibitory effect on the activity of HCV polymerase was calculated by subtracting the OD of the positive control without the sample. The results are shown in Table 1 below.
TABLE 1
Test
Inhibition of activity of HCV RNA polymerase (%)
compound
10 μg/ml
1 μg/ml
0.1 μg/ml
0.01 μg/ml
Example 1
99
82
65
46
As can be seen from the above table, it is proved that the compound according to the present invention show excellent inhibitory effects on activity of HCV RNA polymerase which plays an important role in reproduction of HCV, thereby inhibiting replication of HCV by this property. Also, the compounds according to the present invention can be advantageously used as a therapeutic or prophylactic agent of hepatitis C.
EXPERIMENTAL EXAMPLE 2
Cytotoxicity Assay
To find out cytotoxicity of 6-methylpyridine derivative of the chemical formula 1, an in vitro experiment was conducted on the basis of the generally known MTT assay using HepG 2 cell line. In result, it was proved that CC 50 value of the compound employed for the experiment was greater than 100 μg/ml, indicating that it is safe compound with extremely low cytotoxicity.
INDUSTRIAL APPLICABILITY
As described above, the novel 6-methylpyridine derivative according to the present invention represented by the chemical formula I have excellent inhibitory effect on replication of hepatitis C virus and low cytotoxicity. Therefore, they can be advantageously used as a therapeutic or prophylactic agent of hepatitis C. | The present invention relates to 6-methylpyridine derivatives useful as an antiviral agent. More particularly, the present invention relates to novel 6-methylpyridine derivatives having an excellent inhibitory effect on replication of Hepatitis C virus (HCV), or pharmaceutically acceptable salts thereof, to a method for preparing thereof, and to an antiviral pharmaceutical composition comprising the compound as an active ingredient. The 6-methylpyridine derivatives of the present invention have an excellent inhibitory effect on replication of hepatitis C virus and thus can be advantageously used as a therapeutic or prophylactic agent of hepatitis C | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
N/A
BACKGROUND OF THE INVENTION
The present invention relates to the field of industrial trucks and, in particular, to a dynamic stability control system for a material handling vehicle having a lifting fork.
One method for improving material handling vehicle stability includes performing a static center-of-gravity (CG) analysis while the vehicle is at rest and limiting vehicle operating parameters (for example, maximum speed and steering angle) accordingly. However, this static calibration does not dynamically account for vehicle motion, changing lift heights, or environmental factors such as the grade of a driving surface.
Other methods for improving vehicle stability common in consumer automobiles include calculating vehicle CG during vehicle movement and employing an anti-lock braking system (ABS) to modify the cornering ability of the vehicle. These prior art methods only consider two-dimensional vehicle movement (forward-reverse and turning) and do not, for example, account for three-dimensional CG changes due to load weights being lifted and lowered while a vehicle is in motion.
It would therefore be desirable to have a method for dynamically maintaining the stability of a material handling vehicle that accounts for vehicle motion and complex CG changes imposed by a load weight.
SUMMARY OF THE INVENTION
The present invention overcomes the drawbacks of previous methods by providing a system and method for improving the dynamic stability of a material handling vehicle that is able to dynamically assess vehicle stability and adjust vehicle operation in response. The method includes analyzing dynamic vehicle properties such as velocity, travel direction, acceleration, floor grade, load weight, lift position and predicting wheel loads and three-dimensional center-of-gravity positions.
The present invention provides a method of maintaining the dynamic stability of a material handling vehicle having a vertical lift. The method includes continuously calculating dynamic center-of-gravity parameters for the vehicle over a time interval during which the vehicle is moving, wherein a vertical position of the dynamic center-of-gravity is strongly dependent on a position of the vertical lift. The method further includes continuously calculating wheel loads based on the calculated dynamic center-of-gravity parameters and adjusting vehicle operating parameters based on calculated and predicted wheel loads and center-of-gravity parameters to maintain vehicle dynamic stability.
The present invention also provides a material handling vehicle including a motorized vertical lift, traction motor, steerable wheel, steering control mechanism, and brake. The material handling vehicle further includes a stability control system having a plurality of sensors configured to measure dynamic vehicle properties, a sensor input processing circuit, a vehicle memory configured to store static vehicle properties. The control system further includes a stability computer, vehicle control computer, and a plurality of vehicle function controllers configured to maintain vehicle dynamic stability in accordance with the above-mentioned method.
Various other features of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a lift truck employing a stability control system in accordance with the present invention;
FIG. 2 is a schematic view of a control system for maintaining the dynamic stability of a material handling vehicle in accordance with the present invention;
FIG. 3 is a flowchart setting forth the steps for assessing and maintaining the dynamic stability of a material handling vehicle in accordance with the present invention;
FIGS. 4A-4C are alternate views of a free-body diagram for a three-wheeled material handling vehicle that may be employed to calculate vehicle center-of-gravity and wheel loads in accordance with the present invention; and
FIG. 5 is a schematic showing vehicle stability in relation to center-of-gravity position in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a system and method for maintaining the dynamic stability of a material handling vehicle having a vertical lift. Generally, the vehicle's wheel loads and dynamic CG parameters are calculated over a time period during which the vehicle is moving and the vehicles operating parameters are adjusted based on the calculated wheel loads and CG parameters, as well as predicted wheel load and CG parameters.
Referring now to the Figures, and more particularly to FIG. 1 , one embodiment of a material handling vehicle or lift truck 10 which incorporates the present invention is shown. The material handling vehicle 10 includes an operator compartment 12 comprising a body 14 with an opening 16 for entry and exit of the operator. The compartment 12 includes a control handle 18 mounted to the body 14 at the front of the operator compartment 12 proximate the vertical lift 19 and forks 20 carrying a load 21 . The lift truck 10 further includes a floor switch 22 positioned on the floor 24 of the compartment 12 . A steering wheel 26 is also provided in the compartment 12 disposed above the turning wheel 28 it controls. The lift truck 10 includes two load wheels 30 proximate to the fork 20 and vertical lift 21 . Although the material handling vehicle 10 as shown by way of example as a standing, fore-aft stance operator configuration lift truck, it will be apparent to those of skill in the art that the present invention is not limited to vehicles of this type, and can also be provided in various other types of material handling and lift vehicle configurations. For brevity and simplicity, material handling vehicles are hereinafter referred to simply as “vehicles” and “loaded vehicles” when carrying a load weight.
Referring now to FIG. 2 , one embodiment of a control system 34 configured to maintain vehicle dynamic stability in accordance with the present invention is shown. The control system 34 includes an array of sensors 36 linked to a sensor input processing circuit 38 , which are together configured to acquire and process signals describing dynamic vehicle properties such as speed, direction, steering angle, floor grade, tilt, load weight, lift position, and sideshift. For example, the sensor array 36 may employ a motor controller, tachometer, or encoder to measure vehicle speed; a potentiometer or feedback from a steering control circuit to measure steering angle; a load cell, hydraulic pressure transducer, or strain gauge to measure load weight; an encoder to measure lift height; or three-axis accelerometers to measure tilt, sideshift, reach, and floor grade. The sensor input processing circuit 38 is linked to a vehicle computer system 40 that includes a stability CPU 42 , vehicle memory 44 , and vehicle control computer 46 , which together analyze static vehicle properties and dynamic vehicle properties to assess vehicle stability. Changes to vehicle operating parameters based on the assessed vehicle stability are communicated from the vehicle control computer 46 to function controllers 48 , which adjust the operation of vehicle actuators, motors, and display systems 50 to maintain vehicle stability. For example, adjusted vehicle operating parameters may be received by a lift function controller 52 that activates a motor 54 to change lift position; a travel function controller 56 to relay maximum speed limitations to a vehicle motor 58 ; a display controller 60 and display 62 to communicate present or pending changes in vehicle operating parameters to a driver; and a steering function controller 68 that directs a steering motor 70 to limit steering angle. The vehicle control computer may also include a braking function controller 64 and brake 66 to adjust vehicle speed.
Referring to FIG. 3 , the above lift truck 10 and control system 34 may be employed to maintain vehicle dynamic stability. A method for maintaining dynamic vehicle stability starts at process block 100 with the input of vehicle data to the vehicle computer system 40 . Vehicle data, which is retrieved from the vehicle memory 44 , may include static vehicle properties such as unloaded vehicle weight and CG, wheelbase length, and wheel width and configuration. At process blocks 102 and 104 respectively load weight and carriage height are input from the sensor array 36 and sensor input processing circuit 38 to the computer system 40 . A residual capacity is then calculated at process block 106 to determine if vehicle capacity, for example, vehicle position and load weight, is within acceptable bounds. If, at decision block 108 , it is decided that vehicle capacity is exceeded, then the driver is notified at process block 110 and vehicle operation may be limited at process block 111 . If vehicle capacity is within the acceptable bounds, then carriage position and vehicle incline angle are input at process blocks 112 and 114 respectively.
Referring now to FIGS. 3 and 4 , loaded vehicle CG is calculated at process block 116 by the stability CPU 42 based on static vehicle properties input at process block 100 and the dynamic vehicle properties such as those input at process blocks 102 , 104 , 112 , and 114 . For example, the free-body diagram (FBD) shown in FIG. 4 shows the position of the CG, indicated by X CG , Y CG , and Z CG , in relation to the turning wheel and load wheels of a three-wheel material handling vehicle and the loaded weight W at the CG. It should be noted that Y CG is strongly dependent on load weight and lift position and that heavy load weights at increasing lift heights elevate the CG and reduce vehicle stability. If, at decision block 118 , the vehicle is deemed stable, then vehicle speed is input at process block 120 and vehicle movement is assessed at decision block 122 . If the vehicle is moving, then the steering angle is input at process block 124 and operator commands are input at process block 126 .
At process block 128 , the effects of vehicle movement on wheel loading are calculated. For example, wheel loads for a three-wheeled vehicle can be calculated by again considering the FBD of FIG. 4 , which describes the distance A from the vehicle centerline C L to the turning wheel 28 , the distance B from the C L to the load wheels 30 , and the distance L between the turning wheel 28 and the axis-of-rotation of the load wheels 30 . From these distances and the steering angle θ input at process block 124 , a heading angle α and turning radius r are calculated using the following equations:
α
=
A
tan
(
L
-
X
CG
L
tan
θ
-
B
+
A
)
;
and
Eqn
.
1
r
=
L
-
X
CG
sin
α
.
Eqn
.
2
Normal and tangential accelerations, a t and a n respectively, are then calculated using the following equations:
a
i
=
v
-
v
o
t
;
and
Eqn
.
3
a
n
=
v
2
r
;
Eqn
.
4
where v is current vehicle velocity, v o is the last measured vehicle velocity, t is the time between velocity measurements. It is then possible, using these values and by analyzing the FBD of FIG. 3 , to produce the following equations describing wheel load:
N
D
=
W
(
L
-
X
CG
)
cos
(
γ
F
)
-
WY
CG
sin
(
γ
F
)
+
WY
CG
386.4
(
a
t
cos
(
α
)
-
a
n
sin
(
α
)
)
L
;
Eqn
.
5
N
L
1
=
W
(
B
-
Z
CG
)
cos
(
γ
L
)
-
WY
CG
sin
(
γ
L
)
+
WY
CG
386.4
(
a
n
cos
(
α
)
-
a
t
sin
(
α
)
)
2
B
;
and
Eqn
.
6
N
L
2
=
W
cos
(
α
L
)
cos
(
α
F
)
-
N
D
-
N
L
1
;
Eqn
.
7
where γ L is the lateral ground angle and γ F is the fore/aft ground angle as determined at process block 114 . In this case, N D is the load at the turning wheel, N L1 is the load at the left load wheel, and N L2 is the load at the right load wheel.
Referring to FIG. 3 , at decision block 130 it is decided if the wheel loads are acceptable. If unacceptable, for example, a wheel load approaching zero or another predetermined threshold, then the system notifies the operator at process block 110 and adjusts vehicle operation at process block 111 to maintain vehicle stability. For example, the computer system 40 may adjust vehicle operation by limiting or reducing the vehicle speed and communicate these changes to the operator via the display controller 60 and display 62 . Advantageously, the present invention further improves vehicle dynamic stability by allowing future CG parameters and wheel loads to be predicted based on trends in the measured dynamic vehicle properties and for vehicle operating parameters to be adjusted accordingly.
Referring to FIGS. 3 and 5 , at process block 102 the CG position determined at process block 84 is compared to a range of stable CG positions. It is contemplated that this may be performed by locating the CG position 200 within a stability map 202 relating a range of potential CG positions to vehicle stability. It should be noted that the stability map 202 is for a four-wheeled material handling vehicles having two turning wheels 28 and two load wheels 30 . The stability map 202 may include a preferred region 204 , limited region 206 , and undesirable region 208 whose sizes are dependent on system operating parameters. For example, applications requiring a high top speed may employ more stringent vehicle stability requirements and thus reduce the size of the preferred region 204 . At process block 134 , trends in measured dynamic vehicle properties, CG parameters, and wheel loads are analyzed to predict future vehicle stability. This may be achieved, for example, by analyzing trends in CG position 200 to determine its likelihood of entering the limited region 206 or by analyzing wheel loading trends to ensure that they remain within stable bounds. To adequately model future vehicle stability it is contemplated that the CG parameters and wheel loads are calculated approximately ten times per second.
At process block 136 , vehicle operation rules are input to the computer system and, at process block 138 , parameters relating to future vehicle stability, for example, predicted wheel loads or CG position, are compared to the vehicle operation rules to determine if vehicle operating parameters should be adjusted in response. If, at decision block 140 , it is decided that vehicle operating parameters should be adjusted, then the driver is notified at process block 110 and the control system specifies an appropriate change in vehicle operating parameters to maintain vehicle stability at process block 111 . For example, if a wheel load falls below a minimum threshold specified by the vehicle operation rules, then vehicle speed may be limited to prevent further reduction in wheel load and the accompanying reduction in vehicle stability. It is contemplated that vehicle dynamic stability may also be improved in such an event by limiting steering angle, lift height, or vehicle speed.
In addition to the calculated CG parameters and wheel loads, potential force vectors projected by the vehicle may also be analyzed to maintain vehicle dynamic stability. An accelerating vehicle projects a force approximately equaling the mass of the vehicle (including a load) times vehicle acceleration. This force vector, which is centered at the CG and projected in the direction of travel, is typically counteracted by the weight of the vehicle. However, if the projected force vector exceeds the vehicle weight, then the vehicle parameters may require modification. Therefore, the present invention may analyze trends in the projected force vector and adjust vehicle operation if the force vector exceeds a threshold specified by the vehicle operation rules.
The present invention provides another method for maintaining vehicle dynamic stability. Possible low-stability scenarios such as a sudden change in vehicle speed or direction can be modeled and vehicle CG, wheel loads, and force vectors can be predicted in the event of such a scenario. If the modeled CG parameters, wheel loads, and force vectors fall outside a preferred range, then vehicle operation parameters may be adjusted to improve vehicle stability during the potential low-stability scenario.
The present invention has been described in accordance with the embodiments shown, and one of ordinary skill in the art will readily recognize that there could be variations to the embodiments, and any variations would be within the spirit and scope of the present invention. It is contemplated that addition sensors and vehicle properties could be employed to further improve vehicle stability. Conversely, vehicle properties and the associate hardware used to measure and process them may be excluded from the present invention to reduce system costs and complexity. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | A system and method that maintains the dynamic stability of a material handling vehicle having a vertical lift. The method allows static vehicle properties, such as vehicle weight, wheelbase length, and wheel configuration, and dynamic operating parameters, such as vehicle velocity, floor grade, lift position, and load weight, to be accounted for when maintaining the dynamic stability of a moving material handling vehicle. The method may include calculating and predicting center-of-gravity parameters, wheel loads, and projected force vectors multiple times a second and adjusting vehicle operating parameters in response thereto to maintain vehicle stability. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Ser. No. 07/922,828, filed Jul. 31, 1992, now U.S. Pat. No. 5,385,512, which claims the priority of Dutch Application No. 9101335 filed Aug. 2, 1991 under 35 U.S.C. § 119.
BACKGROUND OF THE INVENTION
The invention relates to a transmission between an electric motor and a tool shaft, for instance for hand tools such as an electric screwdriver and the like, which transmission is provided with an adjustable breaking coupling for discontinuing the drive torque on the tool shaft when a predetermined resistance moment on this tool shaft is exceeded.
In electric tools, particularly electric hand tools, it is known to place a slip or claw coupling between the electric motor and the tool shaft, whereby in the case of overload the tool shaft is no longer subjected to the full torque of the electric motor. The drawback to such a system is that when the motor is driven, a torque is still exerted continuously or intermittently on the tool shaft. This can be disadvantageous in particular applications. In addition, such couplings are noisy and greatly subject to wear.
There also exist protection circuits which cause the motor feed to be switched off and/or braked as soon as overload of the motor occurs. Such a switch-off system is difficult to embody particularly in conjunction with battery-powered DC-motors because the high amperages could present adverse consequences during switch-off upon overload. Moreover, the mass inertia of the rotating parts continues to act on the tool shaft during switch-off.
The object of the invention is to provide a transmission wherein a disengagement takes place between motor and tool shaft immediately after the desired resistance moment is exceeded, wherein the inertia of the rotating parts no longer has any effect on the tool shaft so that it stops immediately.
SUMMARY OF THE INVENTION
The transmission according to the invention is distinguished in that the breaking coupling in the form of two mutually slidable parts is provided with a signal generator for operating a member influencing the motor feed, which signal generator comes into operation as soon as the two parts slide relative to one another when the adjusted torque is exceeded.
Sliding of the two parts can be detected by a sensor, such as signal generator for example. It is likewise possible to convert the sliding movement into an operating movement for a switch.
The member that influences the motor feed can also be a system for reversing the polarity or short-circuiting of the motor feed so that the motor can be stopped rapidly.
In a transmission provided with a single or multistage gear wheel drive, the invention is an attempt to accommodate the breaking coupling in a stage of the drive.
In the preferred embodiment, the breaking coupling is embodied as a claw coupling with axially slidable parts under an axial spring bias. Due to the claw coupling, which is preferably provided with one or more pairs of protrusions distributed regularly along the periphery, a determined angular rotation is possible between the parts without the claw coupling again being in active engagement. Thus, the inertia of the rotating parts on the sides of the electric motor no longer has any influence on the stopping of the motor shaft which can therefore be stopped immediately.
The spring bias on the parts of the claw coupling preferably acts on the claw coupling via a lever system whereby the a range of breaking torques may be set by the adjustment means.
It is recommended herein to cause the pressure point of the spring on each lever to be displaceable relative to the lever so that a relatively large adjustment range of the spring bias on the claw coupling is possible while retaining a fixed spring setting.
In the present case, use is made in the transmission of a planetary gear wheel drive which is provided with an outer sleeve along the internal teeth of which the planet wheels roll. The invention then proposes to embody the outer sleeve as the one part of the breaking coupling. This offers the advantage that, because the outer sleeve is stationary during normal operation, the claw coupling also does not rotate. As soon as the claw coupling disengages, the sleeve will rotate and cause the drive to stop via the planet wheels. This results in direct stoppage of the tool shaft wherein virtually no lagging torque occurs due to inertia of the rotating parts.
The invention will be further described in the detailed description of an embodiment which is shown in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 shows a longitudinal section of a part of a hand tool provided with electric motor, transmission and tool shaft;
FIG. 2 shows a section along the line II--II in FIG. 1;
FIG. 3 shows a section along the line III--III in FIG. 1;
FIG. 4 shows a second embodiment of the invention corresponding with FIG. 1;
FIG. 5 shows a block diagram of a third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an electric hand tool with the transmission 1 of the present invention in its entirety. The transmission 1 is received between an electric motor 2 and a tool shaft 3. These components may be directly mounted in a housing 4 which can be of any suitable construction. The housing 4 is provided with a hand-grip 5 (partially shown), to facilitate hand use. A motor shaft 6 is connected to a gear wheel shaft 7 which co-acts with a planetary gear wheel 8 which rolls on internal teeth of a sleeve 9 which is rotatably mounted in a cylindrical sub-housing 10.
The planetary gear wheel 8 is rotatably mounted on a first rotation shaft 11 which is fixed to a freely rotating first disc 12. The disc 12 is centrally mounted on a shank of the tool shaft 3. A toothed portion 13 of a reduced-in-diameter shank of the tool shaft 3 interconnects disc 12 to a second disc 12' which is also centrally mounted on the shank of tool shaft 3. The toothed shaft 13 co-acts with a second planetary gear wheel 14 which likewise rolls on the same internal teeth of the sleeve 9. The planetary gear wheel 14 is rotatably mounted on a second rotation shaft 15 which is fixed to the second freely rotating disc 12'. As planetary gear wheels 8 and 14 roll around the internal teeth of sleeve 9, rotation shafts 11 and 15 impart rotational movement to discs 12 and 12'. Discs 12 and 12' transfer this movement to tool shaft 3. The shank of tool shaft 3 is rotatably supported by a first set of roller bearings 16 in a bearing collar 17 of sleeve 9, and a second roller bearings 18 received between the tool shaft 3 and a bearing casing 19 of the cylindrical sub-housing 10.
The transmission 1 is supported in the axial direction by roller bearings 20 which have a supporting surface with an annular end flange 21 which is fixed on an open end of the cylindrical sub-housing 10. A part 22 of the motor 2 which protrudes into the sub-housing 10 is supported by the annular flange 21.
An end wall 23 of sub-housing 10 is oriented perpendicularly to the shaft and the bearing sleeve 19. The wall 32 has a number of openings each receiving a freely movable pin 24. The pins 24, of which there are three in the preferred embodiment as shown in FIGS. 2a or b, are fixedly attached to a stationary ring 25 extending around the bearing 16.
Protrusions 26a (FIG. 3) are fixed to the forward end surface 91 of the outer sleeve 9. Protrusions 26b are fixed to the surface of the ring 25 opposite of surface 91. Together protrusions 26a and 26b comprise a claw coupling 26. The preferred position of protrusions 26a and 26b are shown in FIG. 3. During operation protrusions 26b, which are fixed to the stationary ring 25, engage protrusions 26a to prevent the rotatably mounted sleeve 9 from rotating in response to the rotation of the planetary gear wheels 8 and 14. A head end of each pin 24 remote from the ring 25 is provided with a pressure nose 27 which is in contact with an arcuate plate 28, (see FIGS. 2a and b,) the action of which will be explained hereinbelow.
Each arcuate plate 28 is pressed at one end 41 thereof against the nose 27 of the pin 24 by means of a ball 29. Three of the balls 29 are likewise arranged in suitable openings in the inner wall 30 of a adjustment collar 31. The other end of the arcuate plate engages the end wall 23 (FIGS. 2a and b, respectively) and thereby forms a pivot point. The adjustment collar 31 is held in place by a nut 32 which can be screwed onto a thread of the bearing sleeve 19. A pressure spring 33 abuts an annular roller bearing 34 assembly and the inner surface of the closing nut 32. The spring 33 serves to urge the balls 29 into engagement with respective arcuate plates 28.
A pressure pin 35 is supported in an opening in flange 21 of the sub-housing 10. The forward end of the pin 35 is received in a recess (not shown) in the rear end surface of inner sleeve 9. The rear end of the pin 35 is connected to a switch 36 which is part of the power supply circuit of motor 2. The supply circuit is, for example, a voltage source 37, such as a battery, which is connected to the motor terminals 39 via a control circuit 38. The control circuit 38 can include any known suitable control for the rotational speed and rotational direction of the motor 2, as well as a power switch. The switch 36 serves respectively to break and close the current supply circuit for the motor 2, the function of which will be explained hereinafter.
The operation of the transmission as described above is as follows.
In normal use, when the motor 2 is energized, the motor shaft 6 will drive the planetary gear wheel transmission. The planet wheels 8 and 14 roll along the internal teeth of the sleeve 9, to transfer rotational movement via shafts 11 and 15 to discs 12 and 12', which in turn transfers the rotational movement to shank 3' of shaft 3. The revolution speed of the shaft 3 will be considerably less than the revolution speed of the motor shaft 6 due to momentum loss through the two-stage planetary drive.
As the tool shaft 3 encounters increased resistance to rotation, the motor 2 will continue to provide the same torque to shaft 6 and to gear wheels 8 and 14. This situation causes a torque disparity between the shaft 6 and shaft 3. Much of the torque lost between the shaft 6 and the shaft 3 is applied to the internal teeth of sleeve 9. This torque applied to the sleeve 9 urges sleeve 9 to rotate. However, rotation of sleeve 9 is prevented by the interengagement of protrusions 26a and 26b. When the torque resistance on the shaft 3 exceeds the predetermined torque resistance created by protrusions 26a and 26b, the force on each pair of the protrusions 26a and 26b becomes so great that the protrusions 26a slide over protrusions 26b. Hence, the sleeve 9 begins to rotate relative to the ring 25.
The rotation of the sleeve 9 causes the pressure pin 35 to be moved out of the recess axially toward the switch 36 which is normally in the closed position. The pin 35 opens the switch 36. The current to the motor 2 is thereby cut off and motor 2 comes to a stop.
As the motor 2 comes to a stop, inertia compels the shaft 6 and the planet wheels 8 and 14 to continue rotating. This rotation of movement is not transferred to the tool shaft 3 because the torque resistance on the shaft 3 exceeds the torque resistance created by protrusions 26a and 26b. Instead, as soon as the protrusions 26 have passed each, the tool shaft 3 comes to an immediate stop despite the phenomenon that the motor 2 is continuing to turn the planetary drive which rotates sleeve 9.
The pressure force exerted by the ring 25 against the wall 91 of the sleeve 9 is determined by the biasing spring 33. The spring 33 rests against the closing nut 32 and biases against the pivot bearing 34. In turn, the biasing force from spring 33 is distributed from bearing 34 to the balls 29 which press against the arcuate plates 28. One end 40 of the plate 28 rests directly against the head wall 23 of the sub-housing 10 thereby forming a pivot support, while the other end 41 rests against the nose 27 of pin 24. Through nose 27, the biasing force of the spring 33 is transferred to the pin 24. The biasing force that the spring 33 transfers to pin 24 is dependent on the radial position of the ball 29 in relation to the ends of the plate 28. The radial position of the ball 29 is adjusted by rotating the adjustment collar 31. If the collar 31 is rotated so that each ball 29 is in a position directly opposite the corresponding pin 24, the biasing force from spring 33 is transferred directly onto the pins 24 without lever action. If the collar 33 is rotated counterclockwise, as shown in FIGS. 2a and b, so the balls are adjusted to a radial position remote from the pins 24, the biasing force of spring 33 acts on pins 24 by a lever action whereby the end 40 of the arcuate plates 28 serves as a fulcrum against wall 23. By adjusting the radial position of the balls 29 relative to the pins 24, the biasing force transferred from spring 33 to pins 24 is proportionally reduced or increased, depending on the direction of rotation of the adjustment collar 31. The biasing force on the pins 24 is simply adjusted by turning the collar 31 without appreciably expanding or compressing the spring 33. The biasing force acting on the pins 24 and therefore on the protrusions 26a and 26b is adjustable over a wide range without changing the spring bias.
When all three pairs of protrusions 26a and 26b are placed at the same pitch diameter, upon disengagement protrusion 26a can rotate a maximum of 120° before the protrusions 26b will engage another protrusion 26a. The free degree of rotation of sleeve 9 is therefore limited to 120°, which may be inadequate in some applications. It may be desirable to enlarge the degree of rotation of sleeve 9 and to enable stopping a greater mass having increased inertia after switching off motor 2. Thus, it is recommended to place the co-acting protrusions 26a and 26b at different pitch diameters, see R1, R2 and R3 in FIG. 3. As shown in FIG. 3 the protrusions 26a can disengage by sliding past the protrusions 26b, and rotating 360° until the protrusions 26a and 26b engage again at the same pitch diameter.
It will also be apparent that within the scope of the invention a different drive is possible between motor and tool shaft, wherein use can be made of only one pair of protrusions 26a and 26b which operates a switch 36 at a position other than shown in FIG. 1 to switch off the power supply 37 to the motor 2. In addition the switch can also serve to reverse the polarity in the motor 2, whereby a rapid braking of the rotor of the motor can likewise be obtained.
A second embodiment of the present invention with an alternative power deactivator is shown in FIG. 4. The second embodiment is likewise provided with a breaking coupling as in the preferred embodiment. The disengagement of the coupling triggers the power deactivation in a mechanical manner by the displacement of a ball.
In this second embodiment, the electric tool comprises a motor 44 connected to a transmission 45. The transmission 45 is embodied as a planetary gear system in mesh with an internal gear of a rotatable sleeve 52 within a sub-housing 46. The sleeve 52 is prevented from rotating within the sub-housing 46 by the break coupling until the coupling disengages. The sleeve 52 has a recess 52a atop the transmission 45. The sub-housing 46 has a head wall 47 with two grooves 47a and 47b. The groove 47a accommodates balls 54a and 54b and is aligned with recess 52a. Groove 47b accommodates balls 54c and 54d.
A ring 53 is arranged adjacent to the head wall 47 of the sub-housing 46 such that balls 54a and 54b are enclosed in the groove 47a of the sub-housing 46 between the ring 53 and the recess 52a. The recess 52a is just large enough to receive less than half of a ball 54a. During normal operation, the ball 54a is disposed partially within the recess 52a and partially within the groove 47a to prevent the sleeve from rotating within the sub-housing 46.
A helical spring 55 exerts a force against the ring 53 such that the ring 53 is biased toward the housing 52. The helical spring 55 is constrained on another side by an attachment to a second ring 56. The axial compression of the spring 55 can be adjusted by rotating an adjusting cup 51 which is connected to the second ring 56. By rotating the cup 51, the position of the second ring 56 is changed, thereby varying the force which the spring 55 exerts against the ring 53 and which is transferred to balls 54b and 54a. Therefore, the preset torque level is adjusted by rotating the adjusting cup 51.
A microswitch 57 is arranged on the periphery of the top row of balls 54a and 54b to detect disengagement of the coupling. A ball 58 is disposed in the tunnel 59 between the microswitch 57 and the row of balls 54a and 54b. The tunnel 59 permits the ball 58 to move only radially with respect to the tool shaft 3. A spring 57a biases switch 57 against the ball 58 to maintain contact between the ball 58 and the ball 54a. The microswitch 57 is connected between a battery and the motor 44, wherein a reverse polarity switch 59 and a revolution speed control means 60 are arranged in the form of an adjustable resistor. An electronic control can also be used instead of an adjustable resistor, to reduce the energy loss.
When the torque on the tool shaft 3 exceeds the preset torque, the sleeve 52 commences rotation, thereby pushing the ball 54a out of the recess 52a, into the groove 47a toward the other ball 54b and counter to the spring 55. Consequently, there will be less room for the extra ball 58 in the groove 47a. Hence, as the ball 54a is urged out of the recess 52a, the ball 54a will push the extra ball 58 radially in the tunnel 59 thereby urging the sensor 57 counter to the bias of the spring 57a to activate the microswitch 57.
In a third embodiment shown schematically in FIG. 5, the motor 2 drives the tool shaft 3 via a transmission 1 and a slip coupling 66. A revolution speed measuring means 68 is arranged between transmission 1 and slip coupling 66, and also between slip coupling 66 and shaft 3. Each revolution speed measuring means 68 measures the revolution speed in front of and behind the slip coupling 66 so that it can be determined whether the slip coupling 66 is slipping. The output terminals of both revolution speed measuring means 68 are therefore fed to a processing circuit 69. The processing circuit 69 determines whether the revolution speeds in front of and behind the slip coupling 66 differ, and therefore whether the motor 2 is exceeding a predetermined maximum torque. If the motor 2 does exceed the predetermined maximum torque, processing circuit 69 can discontinue power from power source 36 to the motor 2. The slip coupling is constructed such that it will disengage before the motor 2 and the other components of the machine overload.
Other configurations of protrusions are of course also possible within the scope of the invention. | Transmission between electric motor and tool shaft, for instance for hand tools such as an electric screwdriver and the like, which transmission is provided with an adjustable breaking coupling for discontinuing the drive torque on the tool shaft when a predetermined resistance moment on this tool shaft is exceeded, wherein the breaking coupling in the form of two mutually slidable parts is provided with a signal generator for controlling a member influencing the motor feed, which signal generator comes into operation as soon as the two parts slide relative to one another when the set torque is exceeded, so that a disengagement takes place between motor and tool shaft immediately after the desired resistance moment is exceeded, wherein the inertia of the rotating parts no longer has any effect on the tool shaft so that it stops immediately. | 8 |
FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a recording liquid container for storing the recording liquid to be supplied to a recording head. It also relates to an ink jet recording apparatus in which a recording liquid container in the form of a cartridge is removably mountable.
[0002] There are various apparatuses, a single or plurality of parts of which are in the form of a cartridge which can be removably mountable in the main assembly of the apparatus. For example, an ink jet printer is structured so that a single or plurality of ink cartridges are removably mountable in its main assembly.
[0003] Referring to FIG. 9, an example of a conventional ink jet printer structured as described above will be described. Hereafter, the upward, downward, forward, and rearward directions mean the directions indicated by the arrow marks in FIG. 9. This ink jet printer 1 comprises the main assembly (unshown) and an ink cartridge 2 . The ink cartridge 2 is removably mountable in the main assembly of the printer 2 .
[0004] The ink cartridge 2 has a box-shaped main structure 4 . This main structure 4 contains ink (unshown). The main structure 4 also has an ink outlet 5 , which is attached to the front portion of the bottom wall, that is, the wall which will be at the bottom after the proper mounting of the ink cartridge 2 in the main assembly of the printer 2 . The main structure 4 of the cartridge 2 also has a projection 7 and a lever 8 for locking the ink cartridge 2 in the predetermined position in the main assembly of the printer 2 . The projection 7 protrudes from the bottom front edge of the cartridge main structure 4 , and the locking lever 8 protrudes diagonally upward from the bottom rear edge of the cartridge main structure 4 . The locking lever 8 can be elastically bent toward, or away from, the cartridge main structure 4 , and has a locking claw 9 , which protrudes from a predetermined location on the rear surface of the locking lever 8 .
[0005] The printer main assembly is provided with a carriage 11 , as a cartridge holder, which has a recess 12 in which the ink cartridge 2 is removably mountable. The recess 12 has a projection 13 and a projection 14 . The projection 13 protrudes from the bottom portion of the front surface of the recess 12 , and the projection 14 projects from a predetermined location on the rear surface of the recess 12 . With the front projection 13 of the carriage 11 , the projection 7 of the ink cartridge 2 engages, whereas with the rear projection 14 , the locking claw 9 of the ink cartridge 2 engages.
[0006] The carriage 11 has an ink inlet 15 , which is attached to the front portion of the bottom wall of the recess 12 of the carriage 11 . The ink inlet 15 and the ink outlet 5 of the ink cartridge 2 can be connected or disconnected.
[0007] With the provision of the above described structural arrangement, as the ink cartridge 2 is mounted onto the carriage 11 of the printer main assembly, ink is supplied from the ink cartridge 2 to the main assembly of the ink jet printer 1 . The ink cartridge 2 is mounted onto the carriage 11 in the following manner: first, the ink cartridge 2 is to be held tilted so that its rear side becomes higher than the front side, as shown in FIG. 9( a ). Then, the ink cartridge 2 is to be lowered into the recess 12 of the carriage 11 so that the projection 7 of the ink cartridge 2 engages with the projection 13 of the carriage 11 diagonally, from behind, as shown in FIG. 9( b ).
[0008] Next, the rear side of the ink cartridge 2 is to be pushed down, while elastically bending the locking lever 8 , which is in contact with the projection 14 of the carriage, as shown in FIG. 9( c ), until the locking claw 9 of the locking lever 8 locks with the projection 14 of the carriage 11 , as shown in FIG. 9( d ).
[0009] The moment the locking claw 9 of the ink cartridge 2 locks with the projection 14 of the carriage 11 , the person who is mounting the ink cartridge 2 can feel and hear a “click”, which assures that the ink cartridge 2 has just been properly mounted on the carriage 11 .
[0010] The ink cartridge 2 properly mounted on the carriage 11 can be removed from the carriage 11 by pushing the top end portion of the locking lever 8 frontward with a finger (unshown) so that the locking claw 9 becomes disengaged from the projection 14 .
[0011] The above described structural arrangement for the ink jet printer I is very simple, and yet, makes it easy to removably mount the ink cartridge 2 onto the carriage 11 . Further, when the locking claw 9 properly engages with the projection 14 , it generates the “clicking” sound while providing a user with the feel of “click”, informing the user that the ink cartridge 2 has just been properly mounted.
[0012] However, these feel of the “click” and sound of the “click” are very subtle. Therefore, when, for example, a user who is not familiar with these “clicking” phenomena mounts the ink container 2 , the user sometimes fails to push down the ink container all the way into the recess of the carriage 11 , causing the ink cartridge 2 to end up in the state shown in FIG. 9( c ).
[0013] When the ink cartridge 2 is in the above described state shown in FIG. 9( c ), the ink outlet 5 of the ink cartridge 2 and the ink inlet 15 of the carriage 2 are improperly connected, which sometimes may prevent ink from being supplied to the printer main assembly. At a glance, however, the ink cartridge 2 appears to be property mounted on the carriage 11 . Therefore, it is difficult for the user unfamiliar with the above described structural arrangement to recognize that the ink cartridge 2 has not been properly mounted on the carriage 11 .
[0014] If the ink jet printer 1 , in which the ink container is in the above described condition, is made to carry out a printing operation, printing paper is wastefully consumed. In addition, air is sucked, along with ink, into the ink jet head, making it necessary to carry out an operation for removing the air from the ink jet head. In some cases, it is too difficult to remove such air from the ink jet, making it necessary to replace the ink jet head itself.
[0015] In order to solve the above described problem, it is possible to attach a single or plurality of electrical terminals on the rear portion of the bottom surface of the bottom wall of the ink cartridge 2 and the rear portion of the top surface of the bottom wall of the recess 12 of the carriage 11 , so that it becomes possible for the printer main assembly to electrically confirm whether or not the electrical terminal on the ink cartridge side is in contact with the electrical terminal on the carriage side (unshown).
[0016] Japanese Laid-open Patent Application 2000-037880, for example, discloses a printing apparatus (unshown), which employs an ink cartridge having an information storage medium, making it possible for information to be supplied from the ink cartridge to the printer main assembly. The ink cartridge 2 and carriage 11 , however, are sometimes contaminated by ink. Therefore, the electrical terminals such as the above described ones are highly likely to be poorly connected, making it difficult to always accurately determine whether or not the ink cartridge 2 has been properly mounted on the carriage 11 .
[0017] Further, if the electrical terminals such as those described above become shorted, it is possible that the information storage medium is subjected to a large amount of electrical load, resulting in the erasure of the information stored therein, or the destruction thereof.
[0018] The same patent application also discloses the wireless transmission of information from an ink cartridge to the printer main assembly, with the use of radio waves. This arrangement, however, has not taken into consideration the relationship between the mounting of an ink container onto the printer main assembly and the wireless communication. Therefore, it is possible that even if an ink cartridge has been improperly mounted in the printer main assembly, the wireless communication between the printer main assembly and ink cartridge may be satisfactory, making it difficult to accurately judge whether or not the ink cartridge has been properly mounted in the printer main assembly.
SUMMARY OF THE INVENTION
[0019] The present invention was made in consideration of the above described problem. Thus, its primary object is to provide a combination of an apparatus which employs a cartridge, and a cartridge therefor, which makes it possible to accurately determine whether or not the cartridge has been properly mounted into the main assembly of the apparatus.
[0020] According to an aspect of the present invention, there is provided a recording liquid container for containing liquid for recording to be supplied to recording means, said recording liquid container being detachably mountable to a mounting portion of a recording device, said recording liquid container comprising an information memory medium storing predetermined information; and wireless sending means which is capable of sending the predetermined information stored in said information memory medium within a predetermined limited range.
[0021] According to another aspect of the present invention, there is provided a container wherein said mounting portion is capable of mounting a plurality of such recording liquid containers mounted adjacent to each other, and wherein the predetermined limited range is such that wireless sending means is incapable of sending the predetermined information to the adjacent one.
[0022] According to a further aspect of the present invention, there is provided a container wherein said mounting portion is provided with receiving means for wirelessly receiving the predetermined information from said wireless sending means when said recording liquid container is substantially completely mounted to the mounting portion.
[0023] According to a further aspect of the present invention, there is provided a container wherein said recording device includes electric power supplying means for supplying electric power through electromagnetic induction, and said recording liquid container has electric power generating means for generating electric power by said electromagnetic induction and supplying the electric power to said wireless sending means.
[0024] According to a further aspect of the present invention, there is provided a container wherein said information memory medium renewably stores the predetermined information and has information accommodating means, and wherein said wireless communicating means wirelessly receives radio wave and converts the radio wave to information, which is accommodated in said information accommodating means.
[0025] According to a further aspect of the present invention, there is provided an ink jet recording apparatus having an ink cartridge mounting portion for mounting an ink cartridge for containing ink to be supplied to an ink jet head, said ink cartridge is detachably mountable to said ink jet head, wherein said ink cartridge includes an information memory medium storing predetermined information, and wireless sending means which is capable of sending the predetermined information stored in said information memory medium within a predetermined limited range; wherein said mounting portion of said recording device is provided with wireless communicating means for wirelessly receiving the information sent from said wireless sending means of said ink cartridge; and wherein said wireless communicating means is disposed in said predetermined limited range when said ink cartridge is mounted properly to said mounting portion.
[0026] According to a further aspect of the present invention, there is provided an apparatus further comprising electric power supplying means for supplying electric power to said ink cartridge through electromagnetic induction, and said ink cartridge includes electric power generating means for generating electric power through the electromagnetic induction and supplying the electric power to said wireless sending means.
[0027] According to a further aspect of the present invention, there is provided an apparatus further comprising electric power control means for permitting supply of the electric power to said electric power supplying means at predetermined timing, and error discriminating means for discriminating mounting error upon failure of wireless reception of t information by said wireless communicating means when the electric power is supplied thereto.
[0028] According to a further aspect of the present invention, there is provided an apparatus wherein said wireless communicating means is positioned outside the predetermined limited range before said ink cartridge is mounted to said mounting portion, and is positioned inside the predetermined limited range after said ink cartridge is mounted to said mounting portion.
[0029] According to a further aspect of the present invention, there is provided an apparatus wherein said mounting portion is capable of mounting a plurality of such ink cartridges, and there are provided a plurality of such wireless communicating means which are capable of communication with respective ink cartridges.
[0030] According to a further aspect of the present invention, there is provided a cartridge mounting device for detachably moounting a cartridge, wherein an apparatus in accordance with the present invention, which comprises the main assembly and a single or plurality of cartridges, is such an apparatus that comprises: the main assembly in which a single or plurality of cartridges are removably mountable; and a single or plurality of cartridges which are removably mountable in the main assembly. Each cartridge comprises: an information storage means which stores information of a predetermined type; and a wireless transmitting means capable of at least wirelessly transmitting information a specified distance. The apparatus main assembly comprises: a cartridge holding means in which a single or plurality of the cartridges are removably mountable; a wireless communicating means capable of wirelessly receiving information from the cartridge; and a wireless communicating means holding means capable of assuring that the wireless communicating means will be within the wireless communication range of the wireless transmitting means of the cartridge only after the proper mounting of the cartridge in the cartridge holding means.
[0031] The printing apparatus in accordance with the present invention, which comprises the main assembly and a single or plurality of ink cartridges, is such a printing apparatus that comprises: the main assembly in which a single or plurality of ink cartridges are removably mountable; and a single or plurality of ink cartridges which are removably mountable in the main assembly. Each ink cartridge comprises: the main structure which stores ink; an ink supplying means for supplying the ink stored in the main structure to the printer main assembly; an information storage means which stores information of a predetermined type; and a wireless transmitting means capable of at least wirelessly transmitting information a specified distance. The printer main assembly comprises: an ink cartridge holding means in which a single or plurality of the ink cartridges are removably mountable; an ink receiving means to be connected to the ink supplying means of an ink cartridge on the cartridge holding means in order to receive ink; a wireless communicating means capable of wirelessly receiving information from the ink cartridge; and a wireless communicating means holding means capable of assuring that the wireless communicating means will be within the wireless communication range of the wireless transmitting means of the ink cartridge only after the proper mounting of the ink cartridge in the ink cartridge holding means.
[0032] In the case of a printing apparatus in accordance with the present invention, as an ink cartridge is mounted in the cartridge holding means of the printer main assembly, the ink supplying means of the ink cartridge becomes connected to the ink receiving means of the printer main assembly, allowing ink to be supplied from the ink cartridge to the printer main assembly.
[0033] In addition, the information stored in the information storage means of each ink cartridge is wirelessly transmitted to the wireless communicating means of the printer main assembly by the wireless transmitting means of the ink cartridge. The wireless transmitting means of the ink cartridge, however, wirelessly transmits the information only a specified distance. Further, the communicating means holding means of the printer main assembly holds the wireless communicating means of the apparatus main assembly in such a manner that the wireless communicating means will be within the range of the wireless transmitting means of the ink cartridge only after the proper mounting of the ink cartridge in the cartridge holding means. Therefore, the information from the ink cartridge is wirelessly received by the wireless communicating means of the printer main assembly only after the proper mounting of the ink cartridge in the cartridge holding means.
[0034] Further, it is possible to provide each ink cartridge with a power generating means in which the electric power to be supplied to the wireless transmitting means of the ink cartridge is electromagnetically induced, and to provide the printer main assembly with a power supplying means for electromagnetically inducing electric power in the electric power generating means of the ink container. In such a case, the printer main assembly supplies its power supplying means with electric power, with a predetermined timing, through the power controlling means, and if the wireless communication is not established between the wireless communicating means of the printer main assembly and wireless transmitting means of the ink cartridge while the power is supplied, it is determined by an error detecting means that the ink cartridge has not been properly mounted.
[0035] The information in the form of radio waves, which are received by the wireless communicating means of an ink cartridge may be converted into electrical signals and stored in the information storage means of the ink cartridge. Further, it is possible to design the wireless communicating means holding means of the printer main assembly so that before the connection of the ink supplying means and ink receiving means, the wireless communicating means will remain outside the range of the wireless transmitting means, and only after the completion of the proper connection of the ink supplying means and ink receiving means, the wireless communicating means will be within the range of the wireless transmitting means.
[0036] Further, it is possible to design the printer main assembly so that a plurality of ink cartridges can be mounted in the cartridge holding means, and also so that the printer main assembly is provided with a plurality of wireless communicating means for wirelessly communicating one for one with the plurality of ink cartridges in the cartridge holding means.
[0037] Regarding the various means mentioned in the above description of the present invention, all that is required of them is to be able to function as described above. Thus, they may be in the form of, for example, a dedicated hardware capable of performing predetermined functions, a computer programmed to perform predetermined functions, predetermined functions realized in a computer with the use of programs, or the combinations thereof, etc.
[0038] Further, it is not mandatory that they are independent from each other. For example, two or more of the above described various means may be integrated into a single component. One means may be formed as a part of another means. A part of one means may constitutes a part of another means. In other words, they may be configured in an optimum fashion.
[0039] These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] [0040]FIG. 1 is a schematic vertical sectional view of the first embodiment of a cartridge mounting apparatus in accordance with the present invention, showing the steps followed when an ink container in the form of a cartridge is mounted into the main assembly of a printer.
[0041] [0041]FIG. 2 is an external perspective view of an ink cartridge.
[0042] [0042]FIG. 3 is a vertical sectional view of the ink cartridge, showing the internal structure thereof.
[0043] [0043]FIG. 4 is a block diagram showing the structure of the circuitry chip.
[0044] [0044]FIG. 5 is a schematic sectional view of a printing apparatus, showing the internal structure thereof.
[0045] [0045]FIG. 6 is a front plan view of the carriage, as a cartridge holding means, holding a plurality of ink cartridges.
[0046] [0046]FIG. 7 is a flowchart showing the initialization process of the printing apparatus.
[0047] [0047]FIG. 8 is a schematic vertical sectional view of the ink container and its adjacencies, at a plane parallel to the front surface of the printing apparatus, during the mounting of the ink container into the main assembly of the printing apparatus, showing the steps followed during the mounting of the ink container into the main assembly of the printing apparatus.
[0048] [0048]FIG. 9 is a schematic vertical sectional of the combination of an ink container in accordance with the prior art, and a printing apparatus in accordance with the prior art, showing the steps followed during the mounting of the former into the latter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] [Embodiment 1]
[0050] First, referring to FIGS. 1 - 7 , the first embodiment of the present invention will be described. Hereafter, the preferred embodiments of the present invention will be described with reference to the directions with respect to the ink cartridge 2 , that is, the front, rear, right, and left directions of the ink cartridge 2 . The usage of the ink container 2 as the directional reference is for the simplification of the description, and has nothing to do with the positioning of the ink cartridge 2 during the production, usage, etc., of the apparatuses in accordance with the present invention.
[0051] Referring to FIGS. 1 and 2, this embodiment of a cartridge 100 in accordance with the present invention is an ink cartridge, and is removably mountable in the main assembly 201 of a printing apparatus 200 as an example of an apparatus which employs a cartridge system.
[0052] Referring to FIGS. 1 and 2, the main assembly 101 of this ink cartridge 100 is in the form of a flat box, and is molded of a resinous substance. Referring to FIG. 3, the internal space of the main assembly 101 comprises an ink storage chamber 102 , and a negative pressure generation chamber 103 , which are separated by a partition. The ink storage chamber 102 is in connection with the negative pressure generation chamber 103 , at their bottom ends, and contains ink 104 in the liquid form.
[0053] The negative pressure generation chamber 103 has an ink outlet 106 and an air vent 107 . The ink outlet 103 is attached to the bottom portion of the negative pressure generation chamber 103 , whereas the air vent 107 is in the top wall of the negative pressure generation chamber 103 . Further, the negative pressure generation chamber 103 is filled with a porous member 108 , and the ink outlet is filled with a porous member 109 . In the case of this cartridge main assembly 101 , the ink in the ink storage chamber 102 is supplied to the printer main assembly 201 through the ink outlet 106 after going through the negative pressure generation chamber 103 .
[0054] Referring to FIGS. 1 - 3 , the cartridge main assembly 101 has a projection 111 , which is an integral part of the cartridge main assembly 101 and protrudes from the bottom front edge of the cartridge main assembly 101 . The cartridge main assembly 101 also has a cartridge locking lever 112 , which also is an integral part of the cartridge main assembly 101 and protrudes diagonally (up and backward) from the rear bottom edge of the cartridge main assembly 101 . The cartridge locking lever 112 is elastically movable in the frontward or backward of the cartridge main assembly 101 , and has a cartridge locking claw 113 , which is on a predetermined portion of the rear surface of the cartridge locking lever 112 .
[0055] This embodiment of an ink cartridge 100 in accordance with the present invention has a circuitry chip 130 , in the form of a piece of sheet, which is embedded in the rear portion of the bottom wall of the cartridge main assembly 101 . Referring to FIG. 4, this circuitry chip 130 has a flash memory 135 as an information storage means, a wireless communication circuit 136 as both a wireless transmitting means and an information storing means, and a power source circuit 137 as a part of the power generating means.
[0056] The flash memory 135 stores in an updatable fashion, the cartridge identification information (unshown) regarding the cartridge type, types of the compatible printers, production date, expiration date, remaining amount of ink, etc.
[0057] Referring to FIG. 4, to the power source circuit 137 , an induction coil 138 as a part of the power generating means is connected. This induction coil 138 constitutes, for example, the bottom layer of the circuitry chip 130 . The combination of the induction coil 138 and power source circuit 137 generates electric power, based on electromagnetic induction. The generated electric power is supplied from the power source circuit 137 to the wireless communication circuit 136 , which uses the electric power to transmits the predetermined type of information in the flash memory 135 , in the form of radio waves, and also to receive radio waves, extract predetermined type of information carried by the received radio waves, and store the information in the slash memory 135 .
[0058] This ink cartridge 100 , however, is not provided with an antenna (unshown) for extending the communication range R of the wireless communication circuit 136 . Therefore, the communication range R (radius of the sphere in which radio waves from wireless transmitting means are receivable) of the wireless communication circuit 136 is limited to “0.3 (mm)”, as shown in FIGS. 1 and 6. It should be noted here that the communication range R can be adjusted to an optimal value with the use of an antenna.
[0059] Referring to FIG. 6, the printing apparatus 200 is a full-color ink jet printer, and employs one carriage 202 , and four ink cartridges 100 . The carriage 202 functions as both a cartridge holding means and a communicating means holding means. The four ink cartridges 100 are different in the color of the ink therein (yellow, magenta, cyan, and black), and are arranged in the left-right direction, on the carriage 100 .
[0060] Referring to FIG. 1, the carriage 202 is provided with a recess 203 , which has a projection 204 and a locking claw 205 . The projection 204 protrudes rearward from the bottom portion of the front surface of the recess 203 . The locking claw 205 is for locking an ink container in the proper position, and projects frontward from a predetermined point on the rear surface of the recess 203 . With the projection 204 , which is on the front side of the carriage 202 , the projection 111 of the ink cartridge 100 engages, whereas with the locking claw 205 , the locking claw 113 of the ink cartridge 100 engages.
[0061] The carriage 202 is also provided with an ink inlet 206 as an ink receiving means, which is attached to the rear portion of the bottom wall of the recess 203 , and to which the ink inlet 106 of the ink cartridge 100 is removably connectible. More specifically, in the case of this printing apparatus 200 , a porous member, that is, a piece of porous substance (unshown), is also disposed in the ink inlet 206 . Thus, as the ink cartridge 100 is properly mounted into the recess 203 of the carriage 202 , the porous member 109 in the ink outlet 106 of the ink cartridge 100 comes into contact with, and is compressed by, the porous member in the ink inlet 206 of the carriage 202 , creating a state in which the ink 104 can be supplied to the printer main assembly 201 from the ink cartridge 100 .
[0062] Referring to FIG. 5, to the bottom surface of the carriage 202 , an ink jet head 211 is attached. This combination of the carriage 202 and ink jet head 211 is supported by a primary scan mechanism (unshown) as a cartridge moving means so that the combination can be freely moved in the left-right direction. The primary scan mechanism comprises a single or plurality of guide rails, a driver motor, etc.
[0063] In the bottom portion of the internal space of the printer main assembly 201 , there is disposed a secondary scan mechanism (unshown) comprising a feed roller 212 , a driving motor 213 , etc. A sheet of printing paper P is conveyed frontward so that it opposes the ink jet head 211 from underneath.
[0064] Next, referring to FIG. 6, four communication units 214 , as both a power supplying means and a wireless communicating means, are attached to the rear portion of the bottom surface of the carriage 202 , in alignment, one for one, with the four locations of the carriage 202 , to which the four ink cartridges 100 different in the color of the ink therein are mounted.
[0065] Although not shown, not only does each of the four communication units 214 electromagnetically induce electric current in the corresponding induction coil 138 of the ink cartridge 100 , but also it wirelessly exchanges predetermined types of information with the corresponding wireless communication circuit 136 of the ink cartridge 100 .
[0066] However, the radius of the communication range R of the circuitry chip 130 of the ink cartridge 100 employed by this printing apparatus 200 in accordance with the present invention is “0.3 mm”. Thus, each communication unit 214 is disposed so that when the ink cartridge 100 is in the proper position in the printing apparatus 200 , the distance between the communication chip 214 and the corresponding circuitry chip 130 is “0.2 mm”, for example.
[0067] Referring to FIG. 5, in the rear portion of the internal space of the printer main assembly 201 , there is disposed a circuitry substrate 215 , which is connected to the primary scan mechanism, secondary scan mechanism, ink jet head 211 , communication units 214 , etc. The circuitry substrate 215 has a microcomputer (unshown), which integrally controls each of the above listed sections.
[0068] Next, the usage of this ink cartridge 100 in accordance with the present invention, which is structured as described above, will be concretely described. In the final stage of ink cartridge production, various types of information, for example, data for identifying ink cartridge type, is stored in the circuitry chip 130 of each ink cartridge 100 . The ink cartridge 100 is mounted into the printer main assembly 201 by an end user, in the following manner, as shown in FIGS. 1 and 8.
[0069] First, referring to FIG. 1( a ), the ink cartridge 100 is to be held tilted so that the rear portion is higher than the front portion, as in the case of the printing apparatus 1 in accordance with the prior arts. Then, the ink cartridge 100 is to be mounted into the carriage 202 diagonally downward from the rear side so that the projection 111 of the ink cartridge 100 is engaged with the projection 204 of the carriage 202 , as shown in FIG. 1( b ).
[0070] Next, referring to FIG. 1( c ), the rear portion of the ink cartridge 100 is to be pushed down, while elastically bending the locking lever 112 of the ink cartridge 100 , in contact with the locking claw 205 of the carriage 202 , until the locking claw 113 of the locking lever 112 engages with the locking claw 205 of the carriage 202 , as shown in FIG. 1( d ).
[0071] Referring to FIGS. 1 ( a )- 1 ( c ), in the case of this embodiment of the present invention, that is, the printing apparatus 200 , however, the communication unit 214 of each ink cartridge 100 does not enter the communication range R of the corresponding circuitry chip 130 until the final stage of the proper mounting of the ink cartridge 100 into the carriage 202 ; the communication unit 214 of each ink cartridge 100 is in the communication range of the corresponding circuitry chip 130 only during and after the final stage of the proper and complete mounting of the ink cartridge 100 into the carriage 202 .
[0072] In other words, only as the ink cartridge 100 is properly mounted into the carriage 202 , it becomes possible for the printer main assembly 201 to wirelessly communicate with the ink cartridge 100 ; unless the ink cartridge 100 is properly mounted into the carriage 202 , the printer main assembly 201 cannot communicate with the ink cartridge 100 .
[0073] Referring to FIG. 7, as an end user, for example, mounts the four ink cartridges 100 into the printing apparatus 200 connected to a host computer (unshown), and turns on the printing apparatus 200 , the four communication units 214 of the printing apparatus 200 begin sequentially and wirelessly communicating with the four ink cartridges 100 , one for one (Steps S 1 -S 4 ).
[0074] If a given communication unit 214 does not receive radio waves (Step S 5 ), the printing apparatus 200 determines that there is no ink cartridge in the location corresponding to the given communication unit 214 , and sends signals to the host computer, informing it of the ink cartridge mount error (Step S 8 ).
[0075] As the given communication unit 214 receives radio waves from an ink cartridge 100 (Step S 5 ), it is confirmed, based on the data carried by the received radio waves, whether or not the ink cartridge 100 on the specific location of the carriage 202 , corresponding to the given communication unit 214 , is proper in various aspects and properties, for example, the color of the ink therein, amount of the ink remaining therein, expiration date, etc. (Step S 6 ). If a single or plurality of improprieties are detected in this step, error messages corresponding to the improprieties are sent to the host computer (Step S 8 ).
[0076] On the other hand, if the printing apparatus 200 determines that the four ink cartridges 100 all have been properly mounted, it sends a ready signal indicating the completion of the preparatory process to the host computer (Step S 10 ). Recognizing this signal, the host computer sends printing data to the printing apparatus 200 , and the printing apparatus 200 begins to carry out a printing operation. Incidentally, each time a printing operation is completed, the printing apparatus 200 calculates the amount of the ink 104 consumed for the operation, and updates the information regarding the remaining amount the ink 104 in the ink cartridge 100 .
[0077] In the case of this embodiment of the present invention, that is, the printing apparatus 200 , the communication unit 214 of each ink cartridge 100 does not enter the communication range R of the corresponding circuitry chip 130 until the final stage of the proper mounting of the ink cartridge 100 into the carriage 202 , as described above. In other words, the communication unit 214 of the printer main assembly is in the communication range of the corresponding circuitry chip 130 only during and after the final stage of the proper and complete mounting of the ink cartridge 100 into the carriage 202 . Therefore, whether or not the ink cartridge 100 has been properly mounted can be confirmed through the wireless communication between the circuitry chip 130 and communication unit 214 .
[0078] In addition, since the circuitry chip 130 and communication unit 214 wirelessly communicate with each other, with the use of radio waves, it is assured that even if the surface of the ink cartridge 100 and/or carriage 202 is contaminated with, or damaged by, the ink 104 , it is always satisfactorily confirmed whether or not the ink cartridge 100 is in the proper position in the carriage 202 .
[0079] Further, the carriage 202 of the printing apparatus 200 is enabled to hold four ink cartridges 100 , and is provided with four communication units 214 disposed so that they will be within the communication ranges R of the four ink cartridges 100 , one for one, only when the four ink cartridges 100 are in the proper locations in the carriage 202 . Therefore, whether or not each of the four ink cartridges 100 is in the proper location in the carriage 202 can be confirmed, independently from the other ink cartridges 100 .
[0080] Further, the radius of the communication range R of the wireless communication circuit 136 of this ink cartridge 100 in accordance with the present invention is limited to “0.3 mm” by not connecting it to a radio antenna. In other words, the communication range R is limited to a desired value with the use of the simple structural arrangement.
[0081] As described above, each ink cartridge 100 is limited in the communication range R. Therefore, even if four ink cartridges 100 are disposed on a single carriage 202 , there is no interference among the communications between the four ink cartridges 100 and the corresponding communication units 214 .
[0082] Moreover, not only can the above described wireless communication be used to confirm whether or not a given ink cartridge 100 is in the proper location of the carriage 202 , but also it can be used for the various data communication between the printer main assembly 201 and the given ink cartridge 100 . In other words, the above described structural arrangement for the combination of the ink cartridge 100 and apparatus main assembly 201 offers a plurality of functions in spite of its simplicity.
[0083] Even though the present invention was described above with reference to the embodiments of the present invention in the form of the combination of an ink cartridge and an ink jet printer, the application of the present invention is not limited to the above described embodiments. In other words, the present invention can be variously modified within the scope of its essence. That is, the present invention can be applied to various apparatuses, which employ a single or plurality of cartridges, and in the main assembly of which each cartridge must be properly mounted. For example, the present invention is applicable to: an electrophotographic printer, in the main assembly of which a single or plurality of toner cartridges are mounted; a video deck, in which a single or plurality of video cassettes are mounted; a camera in which a single or plurality of photographic film cartridges are mounted, a flexible disc drive in which a single or plurality of flexible disc-cartridges are mounted; and the like.
[0084] According to another aspect of this embodiment, the ink cartridge 100 is provided with the flash memory 135 , in which the predetermined information is stored in the updatable fashion, making it possible for the printer main assembly 201 or the like to read the predetermined information from the flash memory 135 of the ink cartridge 100 , and also to write information into the flash memory 135 . However, it is possible to provide the ink cartridge 100 with a ROM (Read Only Memory), as an information storage medium, holding the predetermined information, so that the printer main assembly 201 and a wireless communicating apparatus 209 can read the predetermined information from the ROM of the ink cartridge 100 .
[0085] Further, this embodiment demonstrates such a structural arrangement that the ink cartridge 100 is provided with a flash memory as an information storage medium. However, an EEPROM (Electrically Erasable Programmable ROM), a RAM (Random Access Memory) connected to a battery, a FeRAM (Ferro-electric RAM), a ROM, or the like, may be employed, instead of the flash memory, as the information storage medium of the ink cartridge etc.
[0086] Further, this embodiment demonstrates such a structural arrangement that the ink cartridge 100 is provided with the power generating means comprising the induction coil 138 and power source circuit 137 , and electric power is generated by electromagnetic induction. However, it is possible to provide the ink cartridge 100 with a battery.
[0087] Further, this embodiment shows such a structural arrangement that as the porous member in the ink inlet 206 of the main assembly 201 of the printing apparatus 200 comes into contact with, and is pressed against, the porous member 109 in the ink outlet 106 of the ink cartridge 100 , it becomes possible for the ink 104 to be supplied from the ink cartridge 100 to the printer main assembly 201 . However, a structural arrangement other than this one may be employed.
[0088] Further, this embodiment provides various concrete numerical values. However, the numerical values given in this embodiment may be variously modified. For example, although the communication range R of the circuitry chip 130 in this embodiment is “0.3 mm”, this value may be changed to the optimum value for determining whether or not the ink cartridge 100 is in the proper location in the printer main assembly 200 .
[0089] [Embodiment 2]
[0090] Next, referring to FIG. 8, the second embodiment of the present invention will be described. The components, members, parts thereof, etc., of this embodiment, which are the same as those of the first embodiment, are given the same names and signs as those for the first embodiment, and their details will be not be described.
[0091] The main assembly (unshown) of this embodiment of a printing apparatus in accordance with the present invention, that is, a printing apparatus 300 , is provided with a sharply pointed hollow needle-like member 301 , as an ink receiving means. The needle-like member 302 has an opening 302 , which is located a predetermine distance from the tip of the member 302 , and which leads to the hollow (unshown) of the needle-like member 302 .
[0092] There is not a porous member in the internal space main structure 303 of an ink cartridge 302 ; it is simply filled with ink 104 . To the left portion of the bottom wall of the cartridge main structure 303 , an ink outlet 304 as an ink supplying means is attached, and is hermetically sealed with a soft sealing member 305 .
[0093] In the right portion of the bottom wall of the main structure 303 of the ink cartridge 302 , there is embedded a circuitry chip 130 , whereas in the printer main assembly, there is disposed a communication unit 214 on the right side of the needle-like member 301 . Referring to FIG. 8( e ), the communication unit 214 of this printing apparatus 300 is disposed so that only when the opening 302 of the needle-like member 301 of the printer main assembly is in the internal space of the cartridge main assembly 303 of the ink cartridge 302 , the communication unit 214 will be within the communication range R of the circuitry chip 130 .
[0094] Referring to FIGS. 8 ( a )- 8 ( d ), as the ink cartridge 302 structured as described above is mounted into the main assembly of the printing apparatus 300 structured as described above, the needle-like member 301 is pushed into the sealing member 305 of the ink cartridge 302 . By the time the ink cartridge 302 is disposed in the proper position in the cartridge main assembly 303 , the opening of the 302 of the needle-like member 301 reaches the predetermined position in the cartridge main assembly 303 , making it ready for the ink 104 to be supplied from the ink cartridge 302 to the printer main assembly.
[0095] As described above, the communication unit 214 of this printing apparatus 300 will be within the communication range R of the circuitry chip 130 of the ink cartridge 302 only when the ink cartridge 302 is in the proper position in the printer main assembly. Therefore, whether or not the ink cartridge 302 has been properly mounted in the printer main assembly can be confirmed based on the initiation (or presence) of the radio communication between the circuitry chip 130 and communication unit 214 .
[0096] More specifically, only after the opening 302 of the needle-like member 301 of the printer main assembly has moved a sufficient distance into the internal space of the main structure 303 of the ink cartridge 302 , the communication unit 214 of this printing apparatus 300 will be within the communication range R of the circuitry chip 130 of the ink cartridge 302 . Therefore, an end user is prompted to keep on pushing down the ink cartridge 302 until the ink cartridge 302 reaches the point at which the ink 104 is reliably supplied to the printer main assembly. Thus, even if there are small errors in the shapes of the printer main assembly and/or ink cartridge 302 , or a small amount of play between the printer main assembly and ink cartridge 302 , it is assured that the ink 104 is always satisfactorily supplied to the printer main assembly.
[0097] According to the present invention, unless an ink cartridge is properly mounted in the main assembly of a printer, radio communication is not established between the radio transmitting means of the ink cartridge and the radio communicating means of the printer main assembly. Therefore, it is possible to satisfactorily confirm whether or not the ink cartridge is in the proper position in the printer main assembly.
[0098] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims. | A recording liquid container for containing liquid for recording to be supplied to recording means, said recording liquid container being detachably mountable to a mounting portion of a recording device, said recording liquid container includes an information memory medium storing predetermined information; and wireless sending means which is capable of sending the predetermined information stored in said information memory medium within a predetermined limited range. | 1 |
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Nonprovisional application Ser. No. 12/958,288 filed Dec. 1, 2010, which claims priority to U.S. Provisional Application No. 61/265,615, filed Dec. 1, 2009, both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Surfactants have been used to prepare stabilized formulations comprising food, beverage, pharmaceutical or nutraceutical products containing nutritional products. Surfactants such as TPGS (polyoxyethanyl-alpha-tocopheryl succinate) and TPGS-1000 (D-alpha-tocopheryl polyethylene glycol 1000 succinate) have been used as solubilizing agents for such stabilized formulations, such as water-soluble formulations including natural omega-fatty acids or non-natural omega-fatty acids. In addition, surfactants, such as PTS (1; FIG. 1 ), have also been used effectively for organometallic catalyzed reactions, such as Pd- and Ru-catalyzed reactions, that may be performed in water and at room temperature. Name reactions such as Heck, Suzuki-Miyaura and Sonogashira couplings may be carried out in ≦5 wt % PTS/water at room temperature. Other Pd-catalyzed reactions that successfully employ surfactants in water include aminations of aryl halides, allylic aminations of alcohols, and silylations of allylic ethers. Several types of Ru-catalyzed metathesis reactions, including cross- and ring-closing, were shown to be quite amenable to this medium. Such reactions using these surfactants provide products with improved impurity profiles, mild reaction conditions, and thus, result in minimal environmental impact.
[0003] We have shown that amphiphile “TPGS-750-M” (2) possesses several important advantages over other known surfactants, such as PTS and TPGS (TPGS-1000), as TPGS-750-M provides better rates of couplings and higher levels of conversion and resulting yields. The 750-M is the monomethylated polyethylene glycol, or “MPEG”, rather than the corresponding PEG diol, as found in PTS and TPGS.
[0004] The foregoing examples of the related art and limitations are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings or figures as provided herein.
SUMMARY OF THE INVENTION
[0005] The present inventor has identified a need for novel and effective surfactants and novel methods for the preparation of the surfactants. In particular, the present application discloses a new combination within the TPGS series of surfactants, namely those using racemic α-tocopherol (written alternatively as DL-α-tocopherol), together with MPEG (rather than PEG), both linked as esters to succinic acid, as new compounds that afford opportunities for multiple uses. In one aspect, a particular advantage of the present TPGS series of surfactants, including TPGS-550-M, TPGS-750-M and TPGS-1000-M, is that each employs a succinic acid linker that is based on relatively inexpensive raw material such as succinic anhydride or succinic acid. In addition, the present application discloses a novel and expedient synthesis of the surfactants that employs racemic α-tocopherol that provides significant economic advantages over the components required for the preparation of nonracemic TPGS-1000 that relies on natural vitamin E, as currently used since the introduction of TPGS by Kodak in the 1950s.
[0006] These large number of applications for using the new surfactants as described herein, include, most notably, the solubilization of nutraceuticals. Also of value are applications to pharmaceuticals, cosmetics and cosmeceuticals in water (or saline solution). These uses are in addition to their applications to green chemistry, where they enable solubilization of substrates, reagents, and catalysts, thereby leading to micellar catalysis in water as the only medium, mainly at ambient temperatures.
[0007] Accordingly, the present application discloses a novel and efficient synthesis for the preparation of TPGS-MPEG, including TPGS-550-M, TPGS-750-M and TPGS-1000-M. TPGS-750-M, for example, possesses racemic α-tocopherol as its main lipophilic component, and has a relatively inexpensive diester succinic acid linker that is appended to an MPEG chain. The novel synthesis typically employs, although is not limited to, either an MPEG chain that is a 550-M, 750-M, or a 1000-M. For synthetic purposes, use of a monomethylated polyethylene glycol, or “MPEG”, is a key modification en route to these new surfactants, as it obviates the commonly observed, undesired double-ended, diesterification that is problematic when a PEG diol is used, as in the preparation of PTS.
[0008] Representative synthetic approaches to TPGS-MPEG, as disclosed herein, are illustrated in Scheme 1.
[0000]
[0009] In one embodiment, DL-α-tocopherol may be condensed with succinic anhydride or succinic acid (“S.A.”) under condition A to provide the tocopherol-succinate intermediate II (DL-α-tocopherol succinate). The tocopherol-succinate intermediate may be isolated or may be further condensed with an MPEG under condition B to provide the TPGS-MPEG. Alternatively, MPEG may be condensed with succinic anhydride or succinic acid (“S.A.”) under condition C to form an MPEG-succinate intermediate. The MPEG-succinate intermediate may be condensed with DL-α-tocopherol under condition D to form the TPGS-MPEG.
[0010] The condensation or esterification reaction between DL-α-tocopherol and succinic anhydride or succinic acid (S.A.) may be performed under a variety of conditions noted as A. For example, the succinic anhydride may be contacted with DL-α-tocopherol in an aprotic solvent such as toluene, xylenes, ethers such as THF, diethyl ether and dioxane, ethyl acetate, acetone, DMF, N,N-dimethylacetamide, acetonitrile, MEK, MIBK, DMSO, ethyleneglycol dimethylether, hexanes, cyclohexane, pentane, cyclopentane, etc. . . . or mixtures thereof. In one aspect, the solvent is toluene. In one aspect, an inorganic base or an organic base may be added to the reaction mixture containing DL-α-tocopherol and S.A. The inorganic base may be selected from the group consisting of NaHCO 3 , Ba(OH) 2 , Ca(OH) 2 , LiOH, NaOH, KOH, Cs 2 CO 3 K 2 CO 3 , LiCO 3 , Na 2 CO 3 and mixtures thereof. The organic base may be selected from Et 3 N, DBU, DBN, and/or in the presence of DMAP. In one variation, the molar ratio of DL-α-tocopherol to S.A. may be about 1:1, 1:1.1, 1:1.2, 1:1.3, 1:1.4 or 1:1.5.
[0011] When succinic acid is employed, esterification can be performed using a catalytic amount of an acid as known in the art. In one embodiment, the activation of succinic acid to the corresponding acid halide, such as the acid chloride, may be performed by using a halogenating agent such as SOCl 2 , PCl 3 , POCl 3 , phosgene or phosgene equivalents, optionally with an amine base such as Et 3 N, DBU, DBN, pyridine, and/or in the presence of DMAP. Activation may be performed before or during the addition of DL-α-tocopherol. Also, where succinic acid is used instead of succinic anhydride, a higher molar ratio of succinic acid may be employed effectively because of the succinic acid is significantly less expensive. Accordingly, the molar ratio of DL-α-tocopherol to succinic acid may be about 1:1, 1:1.2, 1:1.3, 1:1.5, 1:1.7, 1:1.9 or 1:2. The ratio (wt/wt) of DL-α-tocopherol to the solvent may be about 0.2:1, 0.3:1, 0.4:1, 0.5:1 or about 1:1.
[0012] At higher concentration of DL-α-tocopherol, the solution may be rendered homogeneous upon heating and stirring of the reaction mixture. Optionally, a base such as an amine base, including, for example, Et 3 N, pyridine, DBN or DBU may be added. In one aspect, the amine is Et 3 N. The base may be used in a catalytic amount relative to DL-α-tocopherol, such as about 25 mole %, 15 mole %, 10 mole %, 5 mole %, 3 mole % or less. In one aspect, the base is used in about 25 mole % or less. The reaction may be performed at an elevated temperature, such as about 30 to 90° C., 40 to 80° C., 45 to 75° C., 50 to 70° C., 55 to 65° C., about 60° C., 30 to 50° C., 40 to 60° C., 50 to 70° C., 60 to 80° C. or about 70 to 90° C. In one embodiment, the reaction is performed at an elevated temperature for a sufficient period of time to provide the desired product II (DL-α-tocopherol succinate) such as for less than about 8 hours, 6 hours, 3 hours, 2 hours or about 1 hour.
[0013] In one variation, upon the completion of the reaction, water may be added to the reaction mixture, and the product II is then extracted with a solvent such as toluene, diethyl ether or THF. Optionally, the extracts containing the product II may be filtered, such as by filtration on a plug of silica gel or celite. Optionally, the plug of silica gel or celite may be washed with a solvent or solvent mixture such as about 10% to 40% EtOAc/hexane. Where higher product purity is desired, the solvent extracts may be further washed with water or 1N HCl, and then again with water. Extraction procedures may be used where the purity or quality of the starting reagents have lower purity specifications or lower purity profiles. The resulting solvent extracts may be concentrated by distillation under vacuum to provide the product II. Optionally, the product II from the condensation reaction is obtained in sufficient high purity that no filtration and/or no extraction is required; and the solvent is removed by distillation under vacuum to afford a white or semi-white solid. Accordingly, the reaction provides the product II in more than about 95% yield, 97% yield, 98% yield or about 99% yield.
[0014] In one embodiment, the product II obtained from the condensation reaction is not further purified or isolated, and the “crude” product II is further condensed with MPEG under condition B, in a one-pot procedure. Using this procedure, removal of the solvent, such as toluene, is not required where the subsequent reaction step also utilizes the same solvent. Such one-pot reaction procedures eliminate the isolation steps, including filtration, washing and solvent removal steps, and provide significantly shorter overall reaction cycle times and increase product throughput. Accordingly, the product II is then contacted with MPEG (polyethylene glycol monomethylether) under conditions as described herein to form the product V, VI or VII without any intermediate purification or isolation steps.
[0015] Depending on the desired product, the MPEG employed as the reagent in the condensation reaction may have different molecular weights, where the MPEG may be selected from any MPEG between MPEG-300 and MPEG-2000. More specifically, the choice would be MPEG-550, MPEG-750, or MPEG-1000.
[0016] In one variation, the solvent used in the condensation reaction may be an aprotic solvent such as toluene, xylenes, ethers such as THF, diethyl ether and dioxane, ethyl acetate, acetone, DMF, N,N-dimethylacetamide, acetonitrile, MEK, MIBK, DMSO, ethyleneglycol dimethylether, hexanes, cyclohexane, pentane, cyclopentane, etc. . . . or mixtures thereof. In one aspect, the solvent is toluene.
[0017] The mole ratio of II to the MPEG may be about 1:1, 1:1.01, 1:1.02, 1:1.04, 1:1.05, 1:1.1, or about 1:1.2. In one variation, the mole ratio of II to MPEG may be about 1:1.05. Optionally, a catalytic amount of an acid, such as Fe 3+ (or Zr or Al)/Montmorillonite clay catalyst, sulfuric acid, dry HCl, Amberlyst, Nafion-H, SiO 2 —Al 2 O 3 , p-TsOH, etc. . . . The mole % of the acid relative to II may be used in an amount of about 15 mole %, 10 mole %, 5 mole %, 3 mole %, or 1 mole % or less. In one variation, the acid is p-TsOH monohydrate in about 10 mole %, 5 mole % or less.
[0018] The reaction mixture comprising II, MPEG and acid in a solvent, such as toluene, may be heated at an elevated temperature, such as to reflux, to azeotropically remove water from the reaction mixture. Such azeotropic removal of water may be performed using a Dean-Stark trap or an equivalent distillation set-up to remove water. The reaction may be heated for at least 2 hours, 3 hours, 5 hours or more, until II is completely consumed. Where II is not consumed over the reaction times, optionally, the reaction mixture may be cooled below refluxing temperatures, such as about 100° C., 90° C. or 75° C. or less, and an additional amount of MPEG, such as about 5 mole % relative to the original amount of II, may be added. The resulting mixture may be re-heated to reflux until the starting material II is found to be completely or substantially consumed.
[0019] Upon completion of the reaction, the resulting mixture is cooled to room temperature and the solvent was removed by distillation under vacuum. Optionally, the resulting cooled mixture is filtered over a plug or a pad of silica gel or celite to remove dark tars or insoluble components before removal of solvent by vacuum distillation. Also optionally, an aqueous NaHCO 3 solution is added to the resulting cooled mixture and the organic product is extracted with a solvent, such as toluene, THF or CH 2 Cl 2 . The combined extracts may be dried by distillation in vacuum of dried over anhydrous Na 2 SO 4 . The product V, VI or VII may be isolated from the organic extracts by distillation in vacuum to provide the desired product as a waxy solid. The product obtained provides HPLC, 1 H NMR, 13 C NMR and M.S. spectrum consistent with the desired product.
[0020] In one particular embodiment, TPGS variants with MPEG molecular weights of approximately 550 (n=ca. 12), 750 (n=ca. 17) and 1000 (n=ca. 23) were synthesized via the 2-step route outlined in Scheme 2. Under optimized conditions on a laboratory scale of <10 g, as illustrated for TPGS-750-M, each of the two steps affords a nearly quantitative yield of the desired product. Ring opening of succinic anhydride (1.5 equiv) by α-tocopherol in warm toluene (0.5 M) takes place smoothly in five hours. The resulting acid is then put through a standard workup and filtration through silica gel to give known white solid H. See Nakamura, T.; Kijima, S. α-Tocopheryl acid succinate. G.B. Patent 1,114,150, May 15, 1968. Treatment of ester H with MPEG-750 in the usual way (cat. TsOH, toluene, heat, Dean Stark trap) gave the desired, previously unknown amphiphile VI as a waxy solid. This sequence could be smoothly scaled to >150 g, with comparable yields for each step (97% and 98%, respectively). In a similar fashion, both TPGS-600 and TPGS-550-M were prepared as viscous liquid materials. All could be stored indefinitely in vials at ambient temperatures.
[0021] In one variation, the acid H may be converted into the corresponding activated carboxylic acid derivative IIa, such as the acid chloride, acid bromide, acid iodide, ester or mixed anhydride, for condensation with an MPEG.
[0000]
[0000] wherein Z is selected from the group consisting of —Cl, —Br, —I and —OR o , wherein R o is selected from the group consisting of C 1-3 alkyl, —OC(O)C 1-6 alkyl, —OC(O)CH 2 Ph and —OSO 2 G where G is C 1-6 alkyl, aryl or substituted aryl.
[0000]
[0022] The following embodiments, aspects and variations thereof are exemplary and illustrative are not intended to be limiting in scope.
[0023] In one embodiment, using racemic vitamin E, there is provided a racemic compound of the formulae V, VI and VII:
[0000]
[0024] In another embodiment, using racemic vitamin E, there is provided a racemic compound of the formula II:
[0000]
[0025] In another embodiment, using racemic vitamin E, there is provided a method for the preparation of a surfactant having the formula V, VI or VII, the method comprising the steps of:
[0000]
[0000] contacting DL-α-tocopherol with succinic anhydride or succinic acid under conditions sufficient to form a compound of the formula II;
[0000]
[0000] contacting the compound of the formula II with MPEG-550, MPEG-750 or MPEG-1000, at an elevated temperature and under conditions sufficient to form the compound of the formula V, VI or VII, respectively, and isolating the compound of the formula V, VI or VII.
[0026] In addition to the exemplary embodiments, aspects and variations described above, further embodiments, aspects and variations will become apparent by reference to the drawings and figures and by examination of the following descriptions.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0027] Unless specifically noted otherwise herein, the definitions of the terms used are standard definitions used in the art of organic synthesis and pharmaceutical sciences. Exemplary embodiments, aspects and variations are illustratived in the figures and drawings, and it is intended that the embodiments, aspects and variations, and the figures and drawings disclosed herein are to be considered illustrative and not limiting.
[0028] “DL-α-tocopherol” as used herein refers to the racemic α-tocopherol that may be obtained by synthesis. The racemic α-tocopherol includes all possible enantiomeric and diastereomeric centers, including: 2R, 4′R, 8′R; 2R, 4′R, 8′S; 2R, 4′S, 8′S; 2S, 4′S, 8′S; 2R, 4′S, 8′R; 2S, 4′R, 8′S; 2S, 4′R, 8′R; and 2S, 4′S, 8′R; as shown below.
[0000]
[0000] The racemic α-tocopherol that may be employed in the present application also include various different ratios of each of the isomers noted above.
[0029] “MPEG” as used herein refers to polyethylene glycol monomethyl ether (PEG monomethyl ether). Suitable polyethylene glycol methyl ethers (MPEG), such as PEG-550-M, PEG-750-M or PEG-1000-M, that are derived from polyethylene glycols (PEG) are commercially available, usually as mixtures of oligomers characterized by an average molecular weight. In one embodiment, polyethylene glycol fragments of the MPEG have an average molecular weight from about 500 to about 1500, and those having an average molecular weight from about 600 to about 900, and those having an average molecular weight of about 750 being particularly preferred. Both linear and branched PEG molecules can be used in the solubilizing agents in the present application. In another embodiment, the PEG fragment of the MPEG has between 5 and 50 subunits. In another embodiment, the PEG fragment of the MPEG has between 16 and 20 subunits. In another embodiment, the PEG of the MPEG has 17 subunits.
[0030] Although most sources of MPEG (and PEG) are characterized as a range of compounds based on the number of polyethyleneoxide subunits, narrower ranges are also available (commercially and otherwise) based on a controlled polymerization of ethylene oxide. These more narrowly dispersed MPEGs (and PEGs) are also included in this application, as the routes to the corresponding surfactants fully apply to their use as well.
[0031] Each MPEG (and PEG), being a broad range of compounds varying in molecular weight as a function of the number of PEG units, is also subject to peak shaving, where either lower or higher molecular weight components are removed on either or both sides of the central, predominant component (e.g., by chromatographic separation). Such MPEG (or PEG) compositions are also fully amenable to the syntheses of their corresponding new surfactants based on the synthetic routes disclosed herein. Representative ranges, for example, below and above the center for MPEG-550 would be MPEG-450 to MPEG-650; for MPEG-750, a range of MPEG-650 to MPEG-850; and for MPEG-1000, a range of MPEG-850 to MPEG-1200. Various combinations and permutations of two or more MPEGs (and PEGs) could be pre-formed, in any ratio, and subsequently used in the routes to the corresponding mixture of TPGS-MPEG surfactants, thereby resulting in non-Gausian ratios of MPEG-containing surfactants. The chemistry routes as described within this application apply equally well to any and all such mixtures of MPEGs (or PEGs).
[0032] A “substituent,” as used herein, means a group that may be used in place of a hydrogen atom in a particular group, such as an alkyl group or an aryl group. Such substituent may include, for example: —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R″′, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R″′, —NR″C(O) 2 R′, —NR—C(NR′R″)═NR″′, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN and —NO 2 , —R′, —N 3 , —CH(Ph) 2 , fluoro(C 1-4 )alkoxy and fluoro(C 1-4 )alkyl, in a number ranging from zero to the total number of open valences on the aromatic ring system; and where R′, R″, R″′ and R″″ are preferably independently selected from hydrogen, (C 1-8 )alkyl and heteroalkyl, unsubstituted aryl and heteroaryl, (unsubstituted aryl)-(C 1-4 )alkyl, and (unsubstituted aryl)oxy-(C 1-4 )alkyl. When a compound includes more than one R group, for example, each of the R groups is independently selected as is each R′, R″, R′″ and R″″ group when more than one of these groups are present.
DESCRIPTION OF THE FIGURE
[0033] FIG. 1 illustrates a structural comparison between the various surfactants, including PTS, TPGS-750-M and TPGS (TPGS-1000).
EXPERIMENTAL
[0034] The following procedures may be employed for the preparation of the compounds of the present invention. The starting materials and reagents used in preparing these compounds are either available from commercial suppliers such as the Aldrich Chemical Company (Milwaukee, Wis.), Bachem (Torrance, Calif.), Sigma (St. Louis, Mo.), or are prepared by methods well known to a person of ordinary skill in the art, following procedures described in such references as Fieser and Fieser's Reagents for Organic Synthesis , vols. 1-17, John Wiley and Sons, New York, N.Y., 1991; Rodd's Chemistry of Carbon Compounds , vols. 1-5 and supps., Elsevier Science Publishers, 1989; Organic Reactions , vols. 1-40, John Wiley and Sons, New York, N.Y., 1991; March J.: Advanced Organic Chemistry, 4th ed., John Wiley and Sons, New York, N.Y.; and Larock: Comprehensive Organic Transformations , VCH Publishers, New York, 1989.
[0035] DL-α-Tocopherol succinate (II); <10 g scale. To a solution of DL-α-tocopherol (4.30 g, 10.00 mmol) and succinic anhydride (1.50 g, 15.00 mmol) in toluene (20 mL), Et 3 N (0.35 mL, 2.50 mmol) was added at 22° C. with stirring, and the stirring was continued at 60° C. for 5 h. Water was added to the reaction mixture, which was then extracted with CH 2 Cl 2 . The combined organic layers were washed with 1N HCl (3×50 mL), water (2×30 mL), dried over anhydrous Na 2 SO 4 , and concentrated in vacuo affording a yellow liquid, which was purified by flash column chromatography on silica gel eluting with a 10% EtOAC/hexane to 35% EtOAC/hexanes gradient to afford DL-α-tocopherol succinate (5.25 g, 99%) as a white solid, mp 68-71° C., lit mp 64-67° C.; IR (neat): 2926, 1757, 1714, 1576, 1463, 1455, 1415, 1377, 1251, 1224, 1151, 1110, 1078, 926 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ): δ 2.94 (t, J=6.8 Hz, 2H), 2.84 (t, J=6.8 Hz, 2H), 2.59 (t, J=6.8 Hz, 2H), 2.09 (s, 3H), 2.02 (s, 3H), 1.98 (s, 3H), 1.85-1.71 (m, 2H), 1.56-1.50 (m, 3H), 1.43-1.05 (m, 21H), 0.88-0.84 (m, 12H); 13 C NMR (100 MHz, CDCl 3 ): δ 178.6, 171.0, 149.7, 140.7, 126.9, 125.1, 123.2, 117.6, 75.2, 39.6, 37.8, 37.7, 37.6, 37.5, 33.0, 32.9, 31.3, 29.2, 28.8, 28.2, 25.0, 24.6, 24.0, 22.9, 22.8, 21.2, 20.8, 19.95, 19.88, 13.0, 12.2, 12.0; MS (ESI): m/z 554 (M+Na); HRMS (ESI) calcd for C 33 H 54 O 5 Na [M+Na] + =553.3869. found 553.3876.
[0036] TPGS-750-M (VI). A mixture containing DL-α-tocopherol succinate (2.97 g, 5.60 mmol), polyethylene glycol monomethylether-750 (4.00 g, 5.33 mmol) and p-TsOH (0.15 g, 0.79 mmol) in toluene (20 mL) was refluxed for 5 h using a Dean-Stark trap. After cooling to rt, the mixture was poured into saturated aqueous NaHCO 3 solution and extracted with CH 2 Cl 2 . The combined organic layers were washed with saturated NaHCO 3 (3×50 mL), brine (2×30 mL), dried over anhydrous Na 2 SO 4 and concentrated in vacuo to afford the title compound (6.60 g, 98%) as a waxy solid. IR (neat): 2888, 1755, 1739, 1465, 1414, 1346, 1281, 1245, 1202, 1109, 947, 845 cm −1 ; 1 H NMR (400 MHz, CDCl 3 ): δ 4.28-4.26 (m, 2H), 3.71-3.54 (m, PEG), 3.38 (s, 3H), 2.93 (t, J=7.2 Hz, 2H), 2.79 (t, J=7.2 Hz, 2H), 2.58 (t, J=6.8 Hz, 2H), 2.08 (s, 3H), 2.01 (s, 3H), 1.97 (s, 3H), 1.84-1.70 (m, 2H), 1.55-1.04 (m, 24H), 0.87-0.83 (m, 12H); 13 C NMR (100 MHz, CDCl 3 ): δ 172.2, 170.9, 149.5, 140.6, 126.7, 125.0, 123.0, 117.4, 94.5, 75.1, 72.0, 70.64, 70.56, 69.1, 64.0, 59.0, 39.4, 37.6, 37.5, 37.4, 37.3, 32.8, 32.7, 31.1, 29.2, 28.9, 28.0, 24.8, 24.5, 22.8, 22.7, 21.1, 20.6, 19.8, 19.7, 13.0, 12.1, 11.8; MS (ESI): m/z 1272 (M+Na).
[0037] DL-α-Tocopherol succinate (II); >150 g scale. 2,5,7,8-Tetramethyl-2-(4,8,12-trimethyltridecyl)chroman-6-ol (DL-α-Tocopherol, 66.4 g, 154.1 mmol) and methylene chloride (300 mL) were charged under nitrogen into a 1 L single necked round bottom flask which had been oven-dried and cooled under vacuum. Succinic anhydride (23.1 g, 231 mmol) was added to the clear yellow solution followed by the addition of 4-dimethylaminopyridine (9.4 g, 77.1 mmol) and finally triethylamine (21.5 mL, 154 mmol). The reaction mixture was stirred at 23° C. overnight during which time the reaction mixture became a dark purplish solution. HPLC and TLC (3:7 EtOAc:hexanes, R f =0.3) indicated the reaction was complete. The reaction mixture was poured into a 1 L separatory funnel and the flask rinsed with methylene chloride (300 mL). The organic layer was washed with 1M HCl (160 mL) (×3), water (100 mL) (×2), and saturated aqueous sodium chloride solution (250 mL). The organic layer was dried over sodium sulfate, filtered and the solvent removed in vacuo affording a dark, viscous oil. The oil was poured onto a pad of silica gel (600 g in a 1.2 L filter funnel) and then eluted first with methylene chloride (1.5 L) (to remove impurity) followed by elution with 1:1 EtOAc:hexane (3 L). Concentration of the solvent in vacuo followed by storage under high vacuum overnight affords 82.6 g of a faintly yellow semi-solid containing 4 wt. % EtOAc (79.3 g actual, 96.9%). NMR (CDCl 3 ) was consistent with the desired product. Used as is for the next reaction.
[0038] TPGS-750-M (VI). 4-oxo-4-{[2,5,7,8-tetramethyl-2-(4,8,12-trimethyltridecyl)-3,4-dihydro-2H-chromen-6-yl]oxy}butanoic acid (79.3 g, 149 mmol) was dissolved in toluene (560 mL, 5.3 mol) in a 1 L 3-necked round bottom flask under a stream of nitrogen. MPEG-750 (105 g, 142 mmol) was added to the reaction mixture followed by the addition of p-toluenesulfonic acid monohydrate (3.01 g, 15.8 mmol) which caused a slight lightening of the solution. The flask was fitted with a Dean-Stark trap (receiver filled with toluene) and a condenser. The reaction mixture was heated to reflux for 5 hours. HPLC indicates that SM still remains. The reaction mixture was cooled to room temperature, additional MPEG 750 (5.00 g, 6.78 mmol) was added, and the reaction was heated to reflux for an additional 5 hours. HPLC indicated that almost all of the SM was gone. The reaction mixture was cooled to room temperature and concentrated on a rotary evaporator to afford a viscous dark brown oil. The oil was passed through a pad of basic aluminum oxide (600 g in a 1.2 L filter funnel) eluting with methylene chloride (3 L). The solvent was removed in vacuo to afford a faintly yellow waxy solid. The material is placed under high vacuum keeping the material at 50° C. (the waxy solid liquefies at this temperature) until removal of the residual toluene and methylene chloride was complete. After cooling and re-solidification, 174 g (98.2%) of material was obtained that is identical in all aspects (HPLC, 1 H NMR, 13 C NMR) with the sample prepared on a smaller scale.
[0039] TPGS surfactants, including TPGS-550-M, TPGS-750-M and TPGS-1000-M may be prepared according to representative procedures and reaction conditions disclosed in the present application, as noted in the Tables 1-2:
[0000]
TABLE 1
Results
Reaction Conditions
(% Conversion,
Entry
Condition A:
HPLC)
1
Succinic anhydride (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
2
Succinic anhydride (1.3 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
3
Succinic anhydride (1.2 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
4
Succinic anhydride (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
5
Succinic anhydride (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (20 mole %); 60° C., 5 hrs
6
Succinic anhydride (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (15 mole %); 60° C., 5 hrs
7
Succinic anhydride (1.5 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
8
Succinic anhydride (1.3 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
9
Succinic anhydride (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
10
Succinic anhydride (1.5 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
11
Succinic anhydride (1.3 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
12
Succinic anhydride (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
13
Succinic anhydride (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
14
Succinic anhydride (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (20 mole %); 70° C., 3 hrs
15
Succinic anhydride (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (15 mole %); 70° C., 3 hrs
16
Succinic acid (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
17
Succinic acid (1.3 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
18
Succinic acid (1.2 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
19
Succinic acid (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
20
Succinic acid (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (20 mole %); 60° C., 5 hrs
21
Succinic acid (1.5 mole equiv.)
>95-99%
Toluene; Et 3 N (15 mole %); 60° C., 5 hrs
22
Succinic acid (1.5 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
23
Succinic acid (1.3 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
24
Succinic acid (1.5 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
25
Succinic acid (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 60° C., 5 hrs
26
Succinic acid (1.3 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
27
Succinic acid (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
28
Succinic acid (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (25 mole %); 70° C., 3 hrs
29
Succinic acid (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (20 mole %); 70° C., 3 hrs
30
Succinic acid (1.2 mole equiv.)
>95-99%
Xylenes; Et 3 N (15 mole %); 70° C., 3 hrs
31
Succinic acid (1.5 mole equiv.); SOCl 2
>95-99%
(1 mole equiv.)
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
32
Succinic acid (1.3 mole equiv.); SOCl 2
>95-99%
(1 mole equiv.)
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
33
Succinic acid (1.2 mole equiv.); SOCl 2
>95-99%
(1 mole equiv.)
Toluene; Et 3 N (25 mole %); 60° C., 5 hrs
[0000]
TABLE 2
Results
Reaction Conditions
(% Conversion,
Entry
Condition B:
HPLC)
1
MPEG-600 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
2
MPEG-600 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
3
MPEG-600 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
4
MPEG-600 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
5
MPEG-600 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.2 mole equiv.)
6
MPEG-600 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.17 mole equiv.)
7
MPEG-600 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.13 mole equiv.)
8
MPEG-600 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.12 mole equiv.)
9
MPEG-600 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.1 mole equiv.)
10
MPEG-600 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
11
MPEG-600 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
12
MPEG-600 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
13
MPEG-600 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
14
MPEG-600 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.2 mole equiv.)
15
MPEG-600 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.17 mole equiv.)
16
MPEG-600 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.13 mole equiv.)
17
MPEG-600 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.12 mole equiv.)
18
MPEG-600 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.1 mole equiv.)
19
MPEG-600 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
20
MPEG-750 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
21
MPEG-750 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
23
MPEG-750 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
24
MPEG-750 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
25
MPEG-750 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.2 mole equiv.)
26
MPEG-750 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.17 mole equiv.)
27
MPEG-750 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.13 mole equiv.)
28
MPEG-750 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.12 mole equiv.)
29
MPEG-750 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.1 mole equiv.)
30
MPEG-750 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
31
MPEG-750 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
32
MPEG-750 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
33
MPEG-750 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
34
MPEG-750 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.2 mole equiv.)
35
MPEG-750 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.17 mole equiv.)
36
MPEG-750 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.13 mole equiv.)
37
MPEG-750 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.12 mole equiv.)
38
MPEG-750 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.1 mole equiv.)
39
MPEG-750 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
40
MPEG-1000 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
41
MPEG-1000 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
42
MPEG-1000 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.15 mole equiv.)
43
MPEG-1000 (1.7 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.2 mole equiv.)
44
MPEG-1000 (1.5 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.17 mole equiv.)
45
MPEG-1000 (1.3 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.13 mole equiv.)
46
MPEG-1000 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.12 mole equiv.)
47
MPEG-1000 (1.2 mole equiv.)
>95-98%
Toluene (reflux), TsOH (0.1 mole equiv.)
48
MPEG-1000 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
49
MPEG-1000 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
50
MPEG-1000 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
51
MPEG-1000 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.15 mole equiv.)
52
MPEG-1000 (1.7 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.2 mole equiv.)
53
MPEG-1000 (1.5 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.17 mole equiv.)
54
MPEG-1000 (1.3 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.13 mole equiv.)
55
MPEG-1000 (1.2 mole equiv.)
>95-98%
Xylenes (105° C.), TsOH (0.12 mole equiv.)
[0040] While a number of exemplary embodiments, aspects and variations have been provided herein, those of skill in the art will recognize certain modifications, permutations, additions and combinations and certain sub-combinations of the embodiments, aspects and variations. It is intended that the following claims are interpreted to include all such modifications, permutations, additions and combinations and certain sub-combinations of the embodiments, aspects and variations are within their scope.
[0041] The entire disclosures of all documents cited throughout this application are incorporated herein by reference. | Disclosed herein are environmentally benign surfactants including TPGS-550-M, TPGS-750-M and TPGS-1000-M that comprises of diesters composed of racemic α-tocopherol, MPEG-550, MPEG-750 and MPEG-1000, respectively, and a succinic acid fragment. Also disclosed are novel and efficient methods for their synthesis. The surfactants are designed as an effective nanomicelle-forming species for dissolution of hydrophobic compounds and composition and for general use in metal-catalyzed cross-coupling reactions in water. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 07/303,326, filed Jan. 26, 1989 now U.S. Pat. No. 4,676,245, issued June 5, 1990.
TECHNICAL FIELD
The present invention relates to the surgical joining of tubular structures by use of improved anastomotic devices and to adaptations thereof for surgical closure of elongate openings.
BACKGROUND OF THE INVENTION
The use of anastomotic devices is well known in the art. See, for instance, U.S. Pat. Nos. 2,453,056 (Zack); 2,638,901 (Sugarbaker); 3,155,095 (Brown); 3,254,650 (Collito); 4,233,981 (Schonmacher); 4,294,255 (Jeroe); 4,523,592 (Daniel); 4,624,255 (Shenck et al.); 4,657,091 (Walsh et al.); 4,693,249 (Shenck et al.); 4,705,039 (Sakaguchi et al.); 4,728,328 (Hughes); and 4,747,407 (Heng et al.).
These patents are discussed in part in the above-identified parent application, the disclosure of which parent is, by reference, incorporated herein.
The known prior art devices of the type are not fully satisfactory. Some of the problems confronted are:
the device requires a pronounced eversion of the tubular structure being anastomosed;
a severe clamping pressure may be exerted which may be causative of necrosis or at least result in diminished blood flow and prolonged healing;
the device is awkward to use in contradistinction to efficient surgical procedure;
the device is relatively sophisticated with respect to manufacture and use; and
the device does not allow for the inflammation and growth of tissue of the lumen.
SUMMARY OF THE INVENTION
The present invention is directed to an improved surgical device that: is mechanically simple and inexpensive to manufacture; it is easy to use to thus facilitate efficient surgical procedure; and does not require eversion and sandwiching of the structure anastomosed or excessive clamping pressure thereon or on structures of elongate openings being closed.
In a preferred embodiment of the improved device, a pair of separate ring members have operatively associated, releasable locking elements at their distal peripheries. Each said member has a series of retaining pins adapted to impale a respective first lumen, extend generally in the direction of the luminal axis, and impale a second lumen to thus effect anastomosis of the structures with their intima apposed.
Other species of improved joinder and closure devices are disclosed.
For a more fully developed presentation of the invention, and preferred embodiments thereof, reference is made to the following descriptive matter, attached drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are plan views of a preferred embodiment of an improved anastomotic device and show the inner faces to be operatively associated.
FIGS. 2A and 2B are partial perspective views corresponding to FIGS. 1A and 1B, respectively.
FIG. 3 is a radial cross-section of the preferred embodiment in operative association.
FIG. 4 shows a diametric cross-section of the preferred embodiment in association with anastomosed structures shown in broken line.
FIGS. 5A and 5B illustrate a second embodiment of the invention.
FIG. 6 illustrates a third embodiment of the invention.
FIGS. 7 and 8 illustrate a fourth embodiment of the invention.
FIGS. 9A and 9B illustrate a fifth embodiment of the invention.
FIGS. 10A, 10B, 10C, and 10D illustrate a sixth embodiment of the invention.
FIGS. 11A and 11B illustrate a seventh embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings which illustrate preferred embodiments of the invention and wherein like numerals indicate like elements of structure, there is shown in FIGS. 1A-4 an anastomotic device wherein the designations A and B relate to respective male and female members or to structural elements thereof.
Male member 10A is configured as an annulus that is elongated in the radial direction which has an inwardly facing, generally planar surface portion 11A on the outer radial extent that operatively associates and abuts with surface 11B of female member 10B; see FIG. 3. An inwardly bead element 12A is disposed at the distal end of surface 11A and, in assembly, is adapted to lock into channel 12B of annulus 10B. The channel is formed with a flexible retaining flange 13.
At the proximal periphery of each annulus is a respective inwardly facing channel-forming means 14A, 14B. The free ends of said channel-forming means are shown in the assembly of FIG. 3 as spaced apart end faces 15A, 15B, each face lying outwardly of the plane extended of its respective associated planar surface 11A, 11B. A plurality of retaining pins 16A, 16B are spacedly disposed around the periphery of, and extend inwardly from, each said end face and spacedly alternate with the pins of the opposed series.
As shown in FIG. 4, and easily deducible from the radial section of FIG. 3, the pin lines extended form relatively small acute angles with the luminal axis x--x in order to maximize the length of organ impalement and to optimally effect pin extension into the opposed organ wall.
Note from FIG. 4 that the assembled device forms a composite channel 17 that bounds the area of organ joinder, that the outer edges of the end faces 15A, 15B abut the organ walls, and that the abutting faces 11A, 11B lend stability to the assembled device and to the spaced relationships thereof.
Thus, with respect to the lumen-forming members, which are illustrated by broken lines, the outflow of blood is inhibited, and the void 17 accommodates any swelling occurring at said area.
Obviously, the annular device will dimensionally vary in accordance with that of the tubular structure treated, and said end faces and pins may be variously configured to effect the aforesaid impalement and organ contact, and the number of and spacing between pins is a matter of mechanical choice and design.
In use of the improved anastomotic device of FIG. 1A through FIG. 4, a tubular section is inserted through the rear center, or backside, of a first annular member to a predetermined depth and then retracted to effect impalement. A second tubular part is likewise manipulated with respect to the second member. The members are then assembled, as illustrated in FIG. 4, whereupon each pin enters the opposed tubular part to further maintain retention and patency of the lumen.
Only a male member 18A is shown in the species of invention illustrated in FIGS. 5A, 5B. This embodiment of the invention is identical to that of FIGS. 1-4, except that the male and female annuli are each slotted, as at 18, between radial sections upon which the retaining pins are mounted; the slots extending from the inner diameters. The depth and width of said slots require only that the radial sections have sufficient rigidity for the tubular retention purpose.
The species of invention illustrated in FIG. 6 is identical to that of FIGS. 1A-4, except that the device members are not configured as annuli but are presented as strips 19A, 19B. In use, the male and female strips of predetermined lengths may be assembled with respect to luminal structure or may be utilized to close elongated openings in an anatomical wall.
The radial section of FIG. 7 and partial perspective of FIG. 8 illustrate a fourth species of invention that is very similar to that of FIGS. 1A-4, is used in like manner, but is of a more severe design. Thus, male and female annuli 20A and 20B, respectively, are retained in assembly through a frictional fit between a simple annular slot 21B into which is keyed tenon 21A. Element 21A may be continuous. The inwardly extending annular walls of said annuli are simple planar elements 22A, 22B. From the inner peripheries of said planar elements extend pluralities of retaining pins 16A, 16B which are in functional disposition as in FIGS. 1A-4.
FIGS. 9A, 9B illustrate a fifth embodiment of the invention which is somewhat similarly configured as that of FIGS. 1A-4 or that of FIGS. 5A, 5B, depending on whether the aforenoted channel-forming means 14A, 14B is of continuous or slotted configuration, and materially differs only as to pin means and newly presented retaining means associated with said pins.
As in FIGS. 1A-5B, in this fifth embodiment, each annulus has a plurality of retaining pins disposed about the organ-contacting periphery thereof; the pins of each series being spaced from one another and from the pins of the opposed series with which they alternate. In this instance, however, each pin extends generally normal to the planar surface of the respective annulus, passes through each wall of the structures to be connected and then passes through pin retention means formed in the opposed annulus means.
For brevity, only one such combination of pin and retention means need be shown. Thus, in FIGS. 9A, 9B, pin 23 extends from, and generally normal to, the male member, passes through walls of structures to be connected (shown in broken line) and then through pin retention means 24. To effect such retention, each pin is peripherally notched or slotted at its distal end (as at 25 of FIG. 9B) and operatively associates with triangularly shaped, flexible panels that are formed by criss-crossing slits 26, 27, disposed in a thinned and aligned section of the opposed annulus.
Obviously, the inventive embodiment of FIGS. 7, 8 and that of FIGS. 9A, 9B may be presented in strip form, analogous to that of FIG. 6.
The sixth embodiment of the invention (10A, 10B, 10C, 10D), which is adaptable for either intraluminal joinder or for closure of an elongated opening, requires a single flexible strip 30. On one face of said strip, first and second pluralities of retaining pins 31, 32 extend from a respective intermediate transverse location, near an associated respective longitudinal strip edge 33, 34, to substantially transversely across said strip; each plurality of pins being generally aligned. The retaining pins of each plurality are spaced from one another and spaced, in the alternate, from the retaining pins of the opposed plurality.
In separate longitudinal alignment, near said respective edges are first and second series of spaced and alternating apertures 35 (see the incomplete sectional view of FIG. 10D) and relatively short retaining pins 36 that extend generally normal to said strips. The short pins of the first series are in transverse alignment with the short pins of the second series, and the respective apertures are similar by aligned. Further, the transversely aligned pairs of pins and apertures are each intermediate of succeeding retaining pins 31, 32.
In elongate use, the strip is flexed along its longitudinal axis (note the partial flexure in the sectional view of FIG. 10B), and the anatomical parts to be joined are attached in sequence to pins 31, 32. When the strip is subsequently unflexed, the several parts assume the association as illustrated in the sectional view of FIG. 10C; wherein the short pins 36 reinforce retention of the parts joined.
When the composite strip means 30 is to be used in annular form, a requisite length of said strip is so designed that at one end is disposed a said pair of short pins and, at the other strip end, is disposed a said pair of apertures. In use as an annulus, said longitudinally and transversely aligned pairs of pins and apertures operatively associate to retain said annular form.
FIGS. 11A, 11B, the seventh embodiment of invention, essentially consist of a tubular member 38 that is linear if intended for closure of an elongated anatomical opening and annular if an anastomotic device. The member is relatively lightly resilient and coextensively slitted as at 39 in a line parallel to its axis or center line. Along each edge defining said slit extend a spaced plurality of retaining pins 40, 41 which extend in the path defined by the tubular structure, and each pin alternates with, and is spaced from, each respective pin that extends from the opposed edge defining such slit.
Further, each said edge is notched 42 to the extent of receiving therein a respective one of the pins extending from the opposed edge. There may be a light frictional fit between said operatively associated pins and notches.
In use, the tubular device is widened at the slit, the anatomical structures slightly flexed and attached, and the force of widening removed whereat the memory imparted in the tubular device effects closure of same or, if insufficient memory, then the tube is manipulated to effect a retained closure by means of said pins and notches.
The retaining pins may, of course, be configured to lie outside of the tubular path and to enter an anatomical wall and extend into an abutting anatomical wall, as described with respect to foregoing embodiments of the invention.
The materials of fabrication are flexible, compatible with that of the human body, and, where practical, are preferably of an absorbable such as polyglycolic or polylactic materials. Further, such latter materials of fabrication may be treated or coated in order to control the time of material dissolution, as is known in the art.
The embodiments shown and described are only illustrative he present invention and not to be construed as definitive thereof; Since once apprised of the invention, changes in structure would be readily apparent to one skilled in the art. Hence, the present invention includes all modifications of structure encompassed within the spirit and scope of the following claims. | Elongated, flexible strip, for linear or tubular surgical joinder has pluralities of primary retaining pins that extend in opposed directions and are substantially parallel to the strip face. The pins are adapted to pierce a respective tissue, extend therealong, and then extend into the opposed tissue of a surgical opening. Short retaining pins extending normal to the strip are adapted to inhibit withdrawal of the primary retaining pins. Apertures at one end of the strip operatively associate with end ones of the short pins to configure the strip for anastomosis. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to railway hopper vehicles and particularly to door operating mechanisms for longitudinally disposed bottom discharge doors.
2. Description of the Prior Art
The prior art discloses several latching devices employing claw-like latches similar to those of the subject invention. The subject invention presents a novel arrangement of clawlike latches and other components for use in a railway hopper car discharge mechanism. It improves upon the prior art by providing a mechanism which latches and then draws closed the discharge gates, providing an effective seal and overcoming the problem of warped or ill-fitted discharge doors to provide continued dependable service.
SUMMARY OF THE INVENTION
The door operating mechanism of the present invention is suitable for use on a center-sill, side dump railway hopper car with longitudinally mounted discharge doors. The mechanism is situated beneath the center hood of the car and includes a tension rod disposed along the longitudinal center-line of the car beneath the center sill. The tension rod is operatively connected to a plurality of bell cranks, each of which operates two transversely opposite latches. Each latch comprises a pair of hook-shaped members horizontally guided between a pair of vertical stop members or dowel pins. Each pair of hook-shaped members act together to engage a vertically disposed latch catch or blade rigidly affixed to the bottom edge of the discharge door. Operating rods connect each bell-crank with its corresponding latches, each pair of oppositely opening doors having two bell crank assemblies with two latch mechanisms per door. The operative rods are disposed in such a manner as to be in an over-center position with respect to the bell cranks when in the closed position ensuring positive locking of the doors.
Each end of the longitudinal tension rod is connected by a suitable linkage to an operating mechanism actuated by a trackside cam. The linkages include a spring-tensioned flexible element so that operation of the tension rod by one of the linkages is not affected by the other linkage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view of a railway hopper having longitudinal bottom discharge doors in the closed position;
FIG. 2 is a plan view in partial cutaway of a railway hopper showing the operative components of the present invention;
FIG. 3 is a transverse fragmentary sectional view taken substantially along lines 3--3 of FIG. 1;
FIG. 4 is a perspective view of the latching mechanism of the present invention in the closed position taken substantially along lines 4--4 of FIG. 2;
FIG. 5 is a perspective view of the latching mechanisms of the present invention in the open position taken substantially along lines 4--4 of FIG. 2;
FIG. 6 is a fragmentary plan view of the latching mechanisms of the present invention in the closed position;
FIG. 7 is a fragmentary plan view of the latching mechanism of the present invention in the open position;
FIG. 8 is a fragmentary plan view of one of the latches of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a railway hopper car 1 is shown including the usual transversely spaced side walls 2 and assoicated end slope sheets 3. The hopper car 1 includes longitudinally extending center sill 4 and is supported by the usual wheeled trucks 5 which ride on tracks 6. The interior of the car 1 is divided into two longitudinally spaced hoppers 7 divided transversely at the center of the car by center crossridge partitions 8. Each hopper 7 includes two oppositely opening longitudinal discharge gates or doors 9 which are connected by door hinges 10 to longitudinally extending side sills 11 for divergent opening movement.
Referring to FIG. 2, the operative components of the present invention are shown in place in hopper car 1. Longitudinally extending actuating or tension rod 12 is shown positioned beneath the hoppers 7. Tension rod 12 is pivotally connected to bell cranks 13 which are spaced longitudinally beneath the hoppers 7. Operating rods 14 connect each bell crank 13 with its respective latch mechanisms 15. At each end of tension rod 12 is attached a partially slack flexible linkage 16 which extends around a rotatable sheave 17. Flexible linkages 16 are also each connected to a tension lever 18 capable of pulling on flexible linkage 16 when lever 18 is engaged by trackside cam 19. Tension springs 20 are adjusted to permit independent operation of tension rod 12 from either end of the car without affecting operability from the other end of the car.
Referring to FIG. 3, the position of the latch mechanisms 15 and their respective bell crank 13 is shown relative to discharge doors 9. The articulated shape of discharge doors 9, together with partition sheet 8, cross-ridge slope sheets 21, end slope sheet 3 (not shown in FIG. 3) and longitudinal hood 22 define the shape of hopper 7. Center sill 4 is disposed beneath the longitudinal hood 22, and cross-ridge 23 is positioned thereunder. Cross-ridge 23 supports bell crank bracket 24 from which extends bell crank pivot 25. As best shown in FIGS. 3,4 and 5 bell crank 13 is pivotally supported by bell crank pivot 25. Tension rod 12 is pivotally connected to bell cranks 13 by tension rod pivots 27. Operating rods 14 are pivotally connected to bell crank 13 by rod pivots 26 and extend transversely outward therefrom.
Each operating rod 14 is pivotally connected to each latch mechanism 15 by means of latch pivot 28. Each latch mechanism 15 includes a latch hanger plate or saddle 34, two vertically disposed stop members or latch dowel pins 30 extending down and supported therefrom, two hook-shaped members generally designated as 29 horizontally movably disposed between pins 30, a latch support plate 31 rigidly attached to the lower ends of pins 30, and a vertically disposed latch catch or blade 32 rigidly affixed to the discharge door 9.
FIG. 4 shows the latching mechanism of the present invention in the closed and locked position. Latch blade 32 is positively engaged by hook-shaped members 29 thereby securing discharge door 9 in a closed position. Operating rods 14 are held in the locked position due to the overcenter configuration of rod pivots 26 relative to bell crank pivot 25.
FIG. 5 illustrates the operation of the present invention as it moves to the open position. Tension rod 12 moves in the direction indicated by the arrow, causing bell crank 13 to rotate as indicated. Operating rods 14 and rod pivots 26 move out of their overcenter configuration, the rotation of bell crank 13 causing rods 14 to move divergently outward. As each operating rod 14 moves outward, it acts through latch pivot 28 to move hook-shaped members 29 outward between stop members or dowel pins 30. As members 29 move outward, each engages one of the dowel pins 30, stopping the outward movement of members 29 and causing them to divergently rotate about dowel pins 30. As members 29 continue to open, latch blade 32 is disengaged, allowing discharge door 9 to swing open.
FIGS. 6 and 7 illustrate the configuration of the latch mechanism in the closed and open positions, respectively. The overcenter locked configuration of rod pivots 28 relative to bell crank pivot 25 is best shown in FIG. 6.
FIGS. 6, 7 and 8 all show the various reactive portions of hook-shaped members 29. Each member 29 includes a latch keeper 33, a dowel pin arm 35 and a latch lobe 36.
As best shown in FIG. 7, movement of tension rod 12 in the direction of the solid arrow rotates bell crank 13 as indicated. This causes operating rods 14 and hook-shaped members 29 to move outward. As members 29 move outward the dowel pin arm 35 of each member 29 engages one of dowel pins 30, which acts to stop further outward movement of members 29. As operating rods 14 continue to move outward, members 29 are caused to rotate about dowel pins 30. This action causes each pair of members 29 to divergently open, disengaging latch blade 32 from latch keepers 33, allowing gravity to open the discharge doors of the hopper car.
FIG. 8 illustrates the action of the latch mechanisms as the discharge doors close. As the doors are moved to the closed positions by means of suitable converging door closing cams 37 (shown in FIG. 2), latch blade 32 pushes against latch lobes 36 of hook-shaped members 29. This action causes members 29 to convergently rotate, causing latch keepers 33 to again engage and secure latch catch or blade 32. Tension rod 12 is now moved in the direction indicated by the phantom arrow in FIG. 7, rotating bell crank 13 as shown by the phantom arrows. Operating rods 14 and members 29 are drawn toward the center-line of the car, thereby securing positive engagement of latch blades 32 by latch keepers 33 of members 29. Operation is complete when rod pivots 28 return to their overcenter configuration relative to bell crank pivot 25 as shown in FIG. 6.
OPERATION
As loaded railway hopper car 1 travels along tracks 6, a trackside cam 19 is engaged by tension lever 18. Rotation of tension lever 18 causes flexible linkage 16 to pull on tension rod 12. Movement of tension rod 12 produces simultaneous rotation of all bell cranks 13. As each bell crank 13 rotates, operating rods 14 are moved out of their overcenter locking configuration and continue to move away from the center line of the car. As each operating rod 14 moves outward, it moves its pair of hookshaped members 29 outward also, until dowel pin arm 35 of each member 29 engages one of stop members or dowel pins 30. Upon engagement, the outward movement of members 29 is stopped, and as each operating rod 14 continues to move outward, each member 29 rotates about one of the dowel pins 30, causing latch keepers 33 to divergently open, releasing latch catches or blades 32 and allowing gravity to swing discharge doors 9 open.
As the railway hopper 1 continues to move along tracks 6, discharge of the lading is completed, and discharge doors 9 are moved back to the closed position as they engage converging door closing cams 37, mounted along the track. As doors 9 are closed, each latch blade 32 engages the latch lobes 36 of its respective latch mechanism 15. As door cams 37 push inward on doors 9, each latch catch or blade 32 pushes inward on latch lobes 36, causing hook-shaped members 29 to convergently rotate about dowel pins 30, bringing latch keepers 33 into positive engagement with each latch catch 32.
As the railway hopper 1 continues along tracks 6, another tension lever 18 is caused to rotate by means of a trackside cam (not shown), acting through a flexible linkage 16 to cause tension rod 12 to move to the closed position. As tension rod 12 moves, all of bell cranks 13 are simultaneously rotated causing operating rods 14 to move inward, drawing hook-shaped members 29, latch blades 32 and discharge doors 9 toward the center line of the car. As tension rod 12 completes its closing movement, bell cranks 13 rotate back to their closed and locked position, and operating rods 14 are again in an overcenter locking configuration. The discharge cycle is now complete, with operating rods 14 and members 29 securely holding discharge gates 9 closed and locked. | A door operating mechanism for a bottom dump railway hopper car including a plurality of longitudinally mounted, divergently opening discharge doors held in the closed position by a plurality of longitudinally spaced claw-like latches. Each pair of transversely opposite latches includes operating rods connecting each latch to a bell-crank positioned beneath the longitudinal hood of the car. The bell-cranks are operatively connected to a longitudinally disposed tension rod, which includes linkages at either end for actuation of the mechanism by trackside mounted cams. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel apparatus for uniformly decomposing compressed tablets into a uniform size powder form. More particularly, the present invention is directed to a hand held device or apparatus which controllably crushes and shaves tablets in a compressed form using a minimum amount of manual force so as to deposit the decomposed tablet powder directly into a universal patient cup of the type standardized for use in hospitals.
2. Description of the Prior Art
The present invention relates to an apparatus for solving a number of universally recognized problems. It has long been recognized that one of the preferred ways of administering medication is orally in tablet form. Medication in tablet form is the least expensive form in which to manufacture and package medication and is a preferred non-invasive delivery method. Further, compressed tablet form medication is the best form to avoid tampering.
There are several recognized problems associated with administering medication in tablet form. A principal known problem is that a large number of people are subject to gag reflex response which will not permit them to swallow a tablet in solid form. A large number of bedridden patients or patients disposed in a reclined position are also not capable of swallowing tablets in solid form or in granular form. Persons or patients having to use nasalgastrological feeding tubes or other types of feeding tubes require that their medication be presented in a solution or liquid form. Medication has heretofore been taken in liquid form through a straw or in a powdered form when mixed with food. The above problems that exist with human patients also exist in the field of veterinary medicine.
Heretofore, the preferred solution to the abovementioned problems of administering oral medication in tablet form is to grind, abrade (comminute) and compress fracture (crush). Heretofore, devices and apparatus for decomposing tablets in fractured particle form or in granular or in powder form have been classified in U.S. Class 241, Subclasses 168, 169 and 273 with comminution or defracture devices.
Typical of such crushing devices is shown in U.S. Pat. No. 2,892,595 which shows a pair of plastic nesting conical mortar and pestle assemblies. The problem with such crushing devices is similar to the well known pharmacists hard stone-like mortar and pestle which cannot generate the necessary forces to fracture and decompose ultra-hard tablets such as calcium gluconate, etc. Such crushing devices leave particles on both assemblies that are not easily dislodged when it is necessary to transfer the crushed tablet in a glass or receptacle for consumption.
Typical of such grating devices is shown in U.S. Pat. No. 2,804,896 which shows a household food grater or slicer having a hollow spool or cylinder provided with rows of sharp edge grating apertures formed therein. The article of food to be grated is placed in a hopper and a shaped follower is manually pressed down on the top of the food. This type grating device leaves a substantial amount of ungrated food in the hopper, apertures and the hollow spool, thus, cannot be used for comminuting medication in its present form or in a modified form without wasting a portion of the prescribed medication.
U.S. Pat. No. 4,209,136 shows a device for chopping and crushing medicinal tablets which device is adapted from a food chopper. This chopping device will reduce tablets to a granular form by a crushing or chopping action but leaves medication on the crusher foot and in the container when transfer is made to a glass or receptacle when used for consumption.
These and other devices are found in Class 241 which are not suitable for grinding or slicing medication in tablet form to provide a powder of predetermined size quickly dissolvable for use with feeding tubes or to be administered with solid foods with little or no waste involved in either case.
It would be desirable to provide an apparatus for decomposing compressed tablets to a powder in a predetermined size form which does not waste the medication.
SUMMARY OF THE INVENTIONS
It is a primary object of the present invention to provide a novel apparatus for decomposing compressed tablets into predetermined powder size and depositing the powder directly into a universal patient cup for direct use by a patient.
It is another primary object of the present invention to provide a novel apparatus for decomposing compressed tablets into a powder form with a minimum of physical effort and time leaving a minimum of residue within the apparatus.
It is another primary object of the present invention to provide a device for pre-fracturing ultra hard tablets to insure rapid and uniform decomposition into a powder form.
It is another principal object of the present invention to provide a novel device for reducing a plurality of the same or different tablets to a predetermined size powder form.
It is another object of the present invention to provide a novel apparatus for decomposing tablets employing a rotor which slices of shaves the hard tablets with a minimum of effort.
It is another object of the present invention to provide a novel apparatus for decomposing tablets which may be assembled to suit either left handed or right handed persons who operate the device.
It is yet another object of the present to provide a novel apparatus for decomposing tablets which may be destroyed after use or recycled through a controlled environment.
According to these and other objects of the present invention, there is provided a apparatus and method for decomposing hard tablets into a powder form having a predetermined maximum size which includes loading the tablets to be reduced to powder in a hopper of a housing and providing an imperforate rotor in the housing having protruding helical shaped cutting ribs extending therefrom. The tablets are pressed against the rotor and the helical cutting ribs while the rotor is rotated to simultaneously crush and shave powder particles from the tablets which are restrained in the hopper of the housing until crushed and shaved to the predetermined size defined by the height of the helical shaped cutting ribs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in elevation of a preferred embodiment tablet decomposing apparatus according to the present invention;
FIG. 2 is a front view of the apparatus shown in FIG. 1;
FIG. 3 is a partial top view showing the rotor and crank mounted in the housing of FIGS. 1 and 2 and showing a pre-fracturing recessed trough in the handle of the housing;
FIG. 4 is an enlarged view of a rotor showing dual anticlog slicing ribs according to the preferred embodiment of the present invention;
FIG. 5 is an enlarge view showing another rotor having dual cutting ribs which have a tendency to clog;
FIG. 6 is an enlarged view of a rotor having a continuous spiral cutting rib and a cleaning brush of the type which mounts in the housing juxtaposed the slicing ribs;
FIG. 7 is a front view and partial section of the motorized version of the apparatus shown in FIGS. 1 through 6; and
FIG. 8 is an enlarge schematic view of a continuous spiral slicing rib prior to slicing and cutting a tablet which is captured between the presser foot and one of the rotors of the apparatus from a crushing action.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refer now to FIG. 1 showing a side view in elevation of a preferred embodiment tablet decomposing apparatus 10 which comprises a housing assembly 11, a pressor foot assembly 12 and a rotor and crank assembly 13 mounted in the housing 11. The housing 11 is provided with a tapered feed hopper 14, 14A in which tablets may be placed directly or pre-crushed (pre-fractured) by placing the tablet in the pre-fracturing recess 15 and crushing and fracturing the tablets placed in the pre-fracturing recess 15 by engaging them with the pre-fracturing blade 16 mounted on the pressor foot assembly 12. Blade 16 may be made from a piece of sharp metal or integrally molded as a blade as part of the assembly 12. The pressor foot 17 is provided with a partial cylindrical shape which is adapted to match and fit the tops of the slicing ribs (not shown) which rotate in the cylindrical plane 18. As will be explained in more detail hereinafter, tablets caught between the pressor foot 17 and the plane of revolution 18 of the slicing ribs will be sliced and pulverized while being held by the forward portion of the feed hopper 14. Discharge chute 19 is shown having the same width as the diameter of the cylindrical plane 18 of the slicing ribs and is larger than the opening of the tapered feed hopper 14 at its engagement point with the slicing rotor. A patient's cup 21 is shown held in place against the bottom surface 22 of the housing 11. The patient's cup 21 is a standard plastic cup having different types of calibrations or graduations thereon. Normally the cup is provided with graduations up to one fluid ounce, graduations up to eight drams, graduations up to two tablespoons, graduations up to 30 cubic centimeters and graduations up to 30 milliliters. Such cups are known as universal patients' cups and are used throughout the world. Since the cup 21 is standard and of uniform size throughout the world, it readily fits into an annular tapered ring provided as an extension on the housing assembly 11. In the process of decomposing tablets, the size of the powder can be controlled by controlling the height of the slicing ribs as will be explained hereinafter. Since a very fine powder traps below the top of the slicing rib, a cleaning brush (not shown) may be inserted in the brush recess 24 and forms an effective means for dislodging powder. A thumb rest 25 is provided on pressor foot assembly 12 and is positioned therealong to permit a person holding the decomposing apparatus 10 in one hand to apply sufficient pressure on the pre-fracturing blade 16 and pressor foot 17 to completely decompose tablets in the decomposing apparatus.
Refer now to FIG. 2 showing a front view of the apparatus 10 shown in FIG. 1. The patient's cup 21 is shown mounted in the annular tapered ring 23 which has an opening 26 which permits the top of the patient's cup 31 to be squeezed at the top and slid into place tightly against bottom surface 22. The flexing of cup 21 tightly holds the cup 21 against the surface 22 when released.
The crank and rotor assembly 13 is shown having a rotatable knob 27 which snaps through recess 28 during assembly. Similarly a end cap 29 having an anti-friction flange 31 snaps into recess 32 and urges the opposite anti-friction flange 31A into engagement with the side of the housing 11. Housing 11 is provided with cylindrical bearing recesses 33 which are adapted to receive the bearings on the rotor in a manner which provides a seal and yet provides rotatable movement as will be explained hereinafter.
Refer now to FIG. 3 showing a top view of the housing assembly 11 with a crank and rotor assembly 13 mounted therein and the pressor foot assembly 12 removed. The pre-fracturing recess 15 is shown tapered and becoming progressively deeper as it approaches the tapered feed hopper 14 having a tapered side wall 14A. A hinge extension 34 is provided on the handle of the housing assembly 11 and adapted to receive a pin in the recess 35 to pivotally mount the pressor foot assembly 12 thereon. When using modern injection molded techniques, it is possible to eliminate the hinge extension 34 and substitute a flexible and narrow molded sheet of plastic for the hinge 34 and pin 35. Before referring to details of the crank and rotor assembly 13 it will be understood that the shaving means 36 which completely fill the hopper 14 comprise raised ribs or slicing means on an imperforate cylinder which completely fills the hopper from wall to wall.
Refer now to FIG. 4 showing an enlarged view of the shaving means 36 on a crank and rotor assembly 13. Cylindrical bearings 33A and 33B fit snugly but rotatably in the bearing recesses 33 shown in FIGS. 2 and 3. Shaving means 36 comprise a pair of raised ribs 37 that are discontinuous. The forward edges of ribs 37 are indicated at the lead line of the numerals 37 and are sharp protruding edges which cut or shave the bottom of a tablet which is placed in the tapered feed hopper 14. As will be explained hereinafter, the trailing edges 37A may be tapered to prevent any possible buildup of powder from the tablets. When the rotor is rotated clockwise in the direction of the arrow, the leading or cutting edge 37 will cause powder from the tablet to collect below the top of the rib and shift to the right to the end point 38. As the powder leaves the end point 38 of the rib 37, it soon engages the next leading edge 37 of the companion rib 37 and is then shifted to the right until it either slips by the end 38 or is deposited in the discharge chute 19. It will be understood that the crank and rotor assembly 13 may be injection molded and is preferably made as a hollow cylindrical form in which the shaving means 36 is an imperforate part of the cylindrical. Thus any powder that is sliced from a tablet is shifted to the left and back to the right and to the left and back to the right until it is discharged in the discharge chute 19 as is clearly shown in FIGS. 1 through 3.
Refer now to FIG. 5 showing another form of dual rib shaving means. The leading edges of this dual spiral rib configuration tend to trap powder in the crotch of the V shown in the center of the shaving means 36. However, the nature of this device tends to move the powder shaved from the tablets towards the center of the discharge chute 19 and has been found to be a Very effective shaving means for most tablets. When used in conjunction with the cleaning brushes and combs to be described hereinafter, this dual rib configuration is extremely effective and when used in conjunction with tapered trailing edges of the ribs little or no residue is accumulated even without the cleaning brushes. Rotors made from hard glass-like finish plastic do not tend to clog.
Refer now to FIG. 6 showing a singular helical rib 39 having leading cutting edges 37 and tapered trailing edges 41. While this single helical rib is extremely effective in slicing tablets by removing portions at no more than the height H of the rib 39, it tends to move the powder to the right and traps powder against the side of the rib 39 which engages the right most bearing 33A, however, deposits which form in this V shaped cavity can be easily removed by a resilient brush 41 which cleans the cavities below the tops of the ribs when properly inserted in the brush recess 24 shown in FIG. 1. It will be understood that the brush 41 may be replaced with a resilient comb 42 or resilient comb shaped brush 42 as the case may be.
Refer now to FIG. 7 showing a front view of a motorized version of the decomposing apparatus shown in FIGS. 1 to 6. The major modification required for simplification or a motorized version is to change the axial direction of the shaving means 36 by 90° so that the shaft 42 of the motor 43 in housing 44 can directly couple to the rotor means 13A,36 thus replacing the need for a crank arm. The motor 43 is preferably driven by a rechargeable battery pack 45. In the preferred embodiment of the motorized version an actuation switch 46 is provided in the thumb area and completely clear of the pressor foot assembly 12A (not shown). It will be appreciated that the rotor assembly 13A may be provided with a cap having an anti-friction flange 31 which is adapted to hold the rotor assembly in place against the housing 44 and may be inserted in the housing assembly from the flange 31 end to engage a spline or recess in the shaft 42. The side walls 14B of the hopper are shown having a taper, thus, the pressor foot (not shown) is provided with a similar taper and cylindrical shape so as to engage firmly against the slicing or cutting ribs of the rotor.
Refer now to FIG. 8 showing an enlarge schematic view of a continuous spiral slicing rib 39 of a rotor assembly 13 mounted in a housing assembly 11 and having a curved pressor foot 17 engaging a tablet 47 between the pressor foot and the rotor surface 48. The force of the pressor foot 17 is seldom great enough to permit the leading edge 37 of the rib 39 to make a slice from the tablet 47 which is as thick as the height H of the rib 39. This is to say that the slicing action of the leading edge 37 actually shaves portions from the tablet 47 which never exceed the height H. The tablet 47 is urged by the inclined or helical direction of the rib 39 into engagement with a side of the housing 11 as shown. As portions of the tablet 47 are shaved or removed, the force of the pressor foot 17 will eventually cause the tablet to be crushed or fractured which further enhances the powdering and decomposition procedure even if the tablet has not been pre-fractured using the prefracturing means 15, 16 described hereinbefore. It will be appreciated that the diagonal or helical direction of the cutting edge 37 enhances the shaving action and reduces the force required to rotate the rotor, however, various forms of ribs have been considered. A horizontal rib or protrusion provided on the rotor 13 is not as effective as a helical shape. If the ribs are placed too close together then the tablet 47 does not have adequate space to drop between the helical ribs and perform the desirable shaving action. Other forms and shapes of ribs are operable but are not as effective as the helical shape described herein as the preferred embodiment of the present invention.
Having explained an anti-clogging or self cleaning dual rib configuration and several modifications thereof, it will be appreciated that the ribs are in fact raised cutting blades or slicing blades as distinguished from recesses which could easily become clogged. The helical or spiral shape only enhances the shaving action.
The decomposing apparatus described in detail hereinbefore is preferably made of the three components or assemblies 11, 12 and 13 described hereinbefore and are made by injection molding so that the apparatus may be sold cheap enough to permit it to be used as a throw away apparatus after use. In the preferred mode of operation, a decomposing apparatus is assigned to a patient in a hospital or in a home or other facility. Once the patient is dismissed, the apparatus may be given to the patient. It is up to the administering and prescribing doctors to prevent intermixing tablets in chemical form which could be harmful. In such cases it would be desirable to use a different color apparatus for chemicals which are dangerous so as to visually warn the person or staff administering the medication that the decomposing apparatus is only used for certain drugs and not for the general run of drugs which could be intermixed.
A feature of the present invention is that it may be made for right handed persons or left handed persons by reversing the crank and rotor assembly in the standard housing. This also requires a reverse helical shape so that the leading edge cuts in the direction in which the left handed or right handed model would ordinarily be turned. Further, the motorized version shown in FIG. 7 has been made so that the rotor-shaving means is completely removable as a unit and may be cleaned and reused by standard cleaning and/or sterilization procedures. It will be appreciated that the universally standard patient's cup 21 fits so tightly against the bottom surface 22 that n spillage will occur even when the apparatus is accidentally dropped after decomposing a tablet or tablets which are now contained in the patient's cup 21. In the preferred embodiment of the present invention it was found that the height H of the slicing rib 39 when made approximately 1/30th of an inch produced a powder so fine that it met all presently known requirements for all different types of patients and still permitted the apparatus to decompose several tablets in less than one minute, thus, the decomposing apparatus is known to perform an extremely desirable function as well as paying for itself in the saving of time of skilled personnel.
While the novel decomposing apparatus was designed to reduce compressed tablets to a powder of a predetermined size it has been used to decompose peppercorns and coffee beans, thus, has a desirable secondary use for powdering hard and semi-hard condiments and food items. Powdered custom blend coffee may be deposited directly into a filter paper holder of the type used for a single cup of coffee made in a microwave oven or a larger filter of the type used in coffee machines. Thus, the preamble of the claims is not intended to restrict the claims to the preferred mode of use. | Apparatus for decomposing hard compressed tablets into powder includes a housing having a hopper for receiving the tablets therein and a discharge chute in the housing for discharaging the decomposed powdered tablets directly into a patient's cup. The housing is further provided with a cylindrical aperture therethrough which is adapted to receive an imperforate rotor in the cylindrical aperture. The imperforate rotor is provided with helical blades which protrude from said imperforate rotor means for decomposing said hard compressed tablets by a slicing and cutting action which controls the size of the powder by the height of the slicing blades. | 8 |
STATEMENT OF RELATED APPLICATIONS
This patent application is based on and claims the benefit of German patent application number 10 2010 020 693.8 having a filing date of 17 May 2010, which is incorporated herein in its entirety by this reference.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a door for closing an opening in a wall, preferably a wall which separates two different temperature zones from one another, in particular one belonging to a cold store, having a door leaf, which can be moved in front of the wall opening, and having a heater for heating at least one door component. The invention also relates to a door leaf for such a door. The invention additionally relates to a winding-up shaft for winding up a door leaf or part of the leaf of a rolling door for closing a wall opening, wherein the winding-up shaft, for winding up at least one web of the door leaf, has a suitable winding surface.
2. Prior Art
In particular in conjunction with the use in cold stores, it is known to heat components of doors. The heating here serves predominantly to avoid the formation of ice on various door components. Such ice formation usually results in malfunctioning of the door.
German patent number DE 196 25 215 C2 discloses a rolling door in which warm air coming from a heating device arranged in the upper region of the door flows through side parts of the rolling door, in which the lateral edges of the rolling-door leaf are guided. In addition, lower regions of the side parts contain openings through which the warm air can penetrate laterally into the rolling-door leaf when the rolling door is closed. The rolling-door leaf is formed from webs which enclose an interspace into which the warm air can penetrate. The warm air can rise upwards within this interspace and also heat the rolling-door leaf in the process.
One disadvantage with this solution is that the warm air, as it passes through the side parts, has already lost heat energy as soon as it reaches the interspace of the rolling-door leaf. Most of the rolling-door leaf, therefore, is heated possibly only to an insufficient extent and is kept ice-free only to an insufficient extent. In addition, it is also the case that, with the rolling door open, the warm air escapes from the openings and is then discharged ineffectively to the surroundings.
A fundamental disadvantage of rolling doors with flexible webs is that the operation of winding up these webs onto the winding-up shaft gives rise to unbalances. Despite the usually rotationally symmetrical winding surface of the winding-up shaft, the masses of the rotating overall structure made of the winding-up shaft and already partially wound-up rolling-door web are no longer distributed in a rotationally symmetrical manner in relation to the axis of rotation of the shaft. The already wound-up portion of the rolling-door web causes this non-symmetrical mass distribution.
BRIEF SUMMARY OF THE INVENTION
Taking this as the departure point, it is an object of the present invention to specify a door, a door leaf and a winding-up shaft of the type mentioned in the introduction which are particularly reliable to use.
This object is achieved by a door for closing an opening in a wall, preferably a wall separating two different temperature zones from one another, in particular one belonging to a cold store, having a door leaf, which can be moved in front of the wall opening, and having a heater for heating at least one door component, characterized in that the leaf of the door has arranged on it at least one preferably electrically operated door-leaf-heating device, preferably a radiant heater, which runs at least more or less parallel to the front side or rear side of the door leaf and by means of which the door leaf and/or the surroundings of the door leaf can be heated at least in certain regions. This object also is achieved by a door leaf for a door, having a preferably electrically operated door-leaf-heating device, preferably a radiant heater, which runs parallel to the front side or rear side of the door leaf and by means of which the door leaf and/or the surroundings of the door leaf can be heated at least in certain regions.
Accordingly, a door according to the invention for closing an opening in a wall is characterized in that the leaf of the door has arranged on it at least one preferably electrically operated door-leaf-heating device and preferably a radiant heater, which runs at least more or less parallel to the front side and/or rear side of the door leaf and by means of which the door leaf and/or the surroundings of the door leaf can be heated at least in certain regions.
For the first time, therefore, it is the case that the leaf of doors is heated directly by a heating device assigned to the door leaf or arranged on the door leaf. This has the advantage over prior-art solutions that the heat is generated directly wherever it is required, that is to say on the door leaf, for de-icing purposes or for avoiding the formation of ice on the door leaf. The concept according to the invention of arranging the heating device directly on or in the door leaf can be used particularly preferably for rolling doors, in particular for high-speed rolling doors for cool stores. As an alternative, however, it is basically also conceivable to provide such door-leaf-heating devices for various other doors, for example for sliding doors.
As far as the door-leaf-heating device is concerned, it comprises at least one, usually more than one, heat generator. The heat generator or generators is or are advantageously designed such that they convert electric current into heat. Accordingly, the door-leaf-heating device in this case is supplied with electrical energy by a source of electrical energy or a power source. The power source here is usually arranged outside the door leaf, wherein an electrically conductive connection between the door-leaf-heating device and the separate power source is created via suitable electrical connecting means. The source of electrical energy is usually a conventional mains connection or has such a connection, although it may also be a (storage) battery, a generator or some other generator of power.
The door-leaf-heating device is expediently designed as a so-called electric radiant heater. Such a radiant heater usually comprises a multiplicity of heat generators which are arranged in a sheet-like structure, are each designed as electrical resistors and heat up when current flows.
In an advantageous embodiment of the invention, the door leaf has a plurality of layers, wherein the door-leaf-heating device is integrated in at least one layer. Expediently, at least one layer is formed by insulation made of heat-insulating material. This insulation ensures sufficiently good thermal separation of various temperature zones which the door is usually intended to separate from one another.
With the door installed as intended, the door-leaf-heating device is advantageously arranged, in relation to the insulating layer, on the side which is directed towards the colder temperature zone. As a result, the heating energy can act predominantly in the direction of the colder zone, i.e. in the direction of that side of the door leaf on which there is the greater risk of ice formation.
Of course, it is additionally also possible, in principle, for a heating device to be arranged on the other side of the insulating layer. This is recommended, for example, when there is also a risk of ice formation on that side of the door leaf which is adjacent to the warmer temperature zone. This would be conceivable, for example at least in theory, when the door closes an opening in an outer wall of a cold store. In the presence of low temperatures in winter, it is then not possible to rule out the possibility of that side of the door leaf which is oriented outwards, towards the surroundings of the cold store, also otherwise icing up.
In a further embodiment of the invention, the outer sides of the door leaf are formed by two spaced-apart layers, preferably made of plastics material, for example PVC. The at least one door-leaf-heating device and/or the insulating layer here are/is preferably arranged between these outer layers.
If the door is designed as a rolling door, preferably as a high-speed rolling door, the leaf of the rolling door advantageously has at least one flexible door-leaf web which can be wound up onto a winding-up shaft. The rolling door, however, usually has a plurality of such webs. At least one of the webs then comprises the door-leaf-heating device, preferably a radiant heater.
The web in which the door-leaf heater, preferably the radiant heater, is integrated may also comprise, in addition, an insulating layer. The insulating layer, however, may also be formed separately as a web in its own right.
According to a particular embodiment of the invention, the leaf of the rolling door comprises at least three flexible webs which are not connected to one another, namely two spaced-apart outer webs, which form the outer sides of the door leaf, and a radiant-heater web, which is arranged between the outer webs. These webs may then be wound up, for example, onto a common winding-up shaft. However, it is also possible to provide two or more winding-up shafts, wherein some of the webs are assigned to the one winding-up shaft and the rest of the webs are assigned to the other winding-up shaft. As far as the outer webs are concerned, they preferably each have a layer of plastics material and/or a layer of heat-insulating material.
In a further embodiment of the invention, the door leaf has at least five such flexible webs which are not connected to one another. In this embodiment, once again, two spaced-apart outer webs are provided. Two spaced-apart insulating webs made of heat-insulating material are arranged in the interspace between the outer webs. In addition, a radiant-heater web is arranged between one of the outer webs and the adjacent insulating web. It is expedient for the radiant-heater web here—as already explained above—to be arranged, in relation to the aforementioned insulating web, on the side which is directed towards the colder temperature zone.
The door leaf expediently has a lower termination part, on which the lower end regions or the lower end edges of the individual webs of the door leaf are fastened.
It is possible here for the termination part to have one or more contact sensors, in particular a contact strip, which, under mechanical action, emits a signal to a control unit of the door, this signal triggering the door to stop and/or to reverse its movement direction.
In a further embodiment of the invention, the door has two side parts, which are arranged on the wall-opening sides and in which a lateral periphery or a lateral edge of the door leaf is guided in each case. This lateral periphery, or this lateral edge, runs at least more or less vertically in the installed state of the door in each case.
The door preferably has an upper casing with an interior in which are arranged the at least one winding-up shaft and/or one or more other components, for example a control unit for controlling the door and/or a drive for driving the at least one winding-up shaft. The interior of the upper casing is in air-channelling connection with a cavity of the door leaf which can be heated by the door-leaf-heating device, and therefore heated air located in the cavity of the door leaf can flow into the upper-casing interior.
For example, in the case of the above described embodiment of the invention with the rolling-door leaf having a plurality of webs, some of the heat from the radiant heater will penetrate into the interspace between outer webs, and possibly also into the interspace between the insulating layers, and will rise upwards and flow into the upper-casing interior.
The upper-casing interior is advantageously in air-channelling connection in each case with an interior of the side parts, and therefore heated air can flow out of the upper-casing interior into the respective side-part interior.
The object according to the invention is also achieved by a further independent special feature of the invention, namely by a winding-up shaft for winding up a door leaf or parts of a leaf of a rolling door for closing an opening in a wall, wherein the winding-up shaft, for winding up at least one web of the door leaf, has a suitable winding surface, characterized in that the winding surface, for the purpose of avoiding or reducing unbalances during the operation of winding up the door-leaf web, has a first surface region which, in relation to the axis of rotation of the winding-up shaft, is arranged further inwards in the radial direction than a second surface region.
Such a winding-up shaft has a winding surface which, for the purpose of avoiding unbalances during the operations of winding up and unwinding at least one door-leaf web, has a first surface region which, in relation to the axis of rotation of the winding-up shaft, is arranged further inwards in the radial direction than a second surface region. This means that, with the door leaf, in particular the upper edge thereof, fastened suitably on the winding-up shaft, the overall structure made up of the door-leaf web and the winding-up shaft deviates from the ideal rotationally symmetrical shape to a lesser extent than would be the case if use were made of conventional, rotationally symmetrical, in particular cylindrical, winding surfaces.
Accordingly, the winding surface is preferably designed such that, with the door leaf wound up in part, the overall structure made up of the winding-up shaft and partially wound-up door leaf is at least more or less rotationally symmetrical in relation to the axis of rotation of the winding-up shaft, in particular it is at least more or less cylindrical.
The upper edge of the door-leaf web, for this purpose, can be fastened in or on the radially further inward region of the winding surface. With an appropriate design of the winding-up shaft, it is then possible to achieve a situation where the radial distance between the radially outward surface or side of the door-leaf web in this fastened region and the axis of rotation of the winding-up shaft is more or less identical to the distance of that surface region which is offset by 180° in relation to the fastening region.
The radially further inward surface region of the winding surface, in a first circumferential direction of the winding-up shaft, preferably merges in an essentially transition-free manner into the radially further outward surface region, preferably in that—as seen in cross section—the respective radial distances of the winding surface from the axis of rotation increase continuously, at least in certain sections, preferably along the entire circumference in this first circumferential direction from the radially further inward region to the radially further outward region.
In the other, opposite circumferential direction, the radially further inward surface region and the radially further outward surface region are preferably connected to one another by an offset. The offset runs preferably at an angle, in particular more or less perpendicularly, to those regions of the winding surface which are adjacent to the offset. The height, or the corresponding dimension, of the offset here is expediently equal to or greater than the thickness of the door-leaf web which can be wound up onto the winding-up shaft. In the case of a plurality of door-leaf webs which can be wound up onto the winding-up shaft, the height of the offset here is expediently equal to or greater than the sum of the thicknesses of the individual door-leaf webs.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features of the present invention can be gathered from the accompanying patent claims, from the following description of a preferred exemplary embodiment and from the accompanying drawings, in which:
FIG. 1( a ) shows a schematic front view of a door according to the invention with the upper part separated from the side parts,
FIG. 1( b ) shows a side view, partly in section, of the door from FIG. 1( a ),
FIG. 1( c ) shows a horizontal longitudinal section through the door from FIGS. 1( a ) to 1 ( b ),
FIG. 2( a ) shows a vertical section through the leaf of the door from FIGS. 1( a ) to 1 ( c ) in the unwound state,
FIG. 2( b ) shows a front view of the door leaf from FIG. 2( a ),
FIG. 3 shows the detail A from FIG. 2( a ),
FIG. 4 shows a cross section through the upper part of the door from FIGS. 1( a ) to ( c ), and
FIG. 5 shows a schematic illustration of a winding-up shaft of the door from FIGS. 1 to 4 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 to 5 show a door 10 according to the invention, namely a so-called high-speed rolling door.
The door 10 serves for the temporary closure and/or release of an opening (not illustrated) in a wall (not illustrated), for example in an outer wall of a building, preferably of a deep-freeze store.
Temperatures of well below zero prevail in such a deep-freeze store. Deep-freeze stores make use of high-speed rolling doors in order for it to be possible for the times during which the closable openings are released, in order to allow for example fork-lift trucks to pass through the openings, to be kept as short as possible. This is because, with the door open, a large amount of heat energy penetrates into the deep-freeze store on account of the usually pronounced temperature gradient between the interior of this store and the exterior surroundings. This is to be avoided. One problem with such high-speed rolling doors in deep-freeze stores is that the individual components of the doors ice up quickly. Icing up may result in malfunctioning.
Icing up is largely avoided in the case of the door 10 according to the invention.
The door 10 has side parts 12 , 14 , which are installed in the region of the vertical peripheries or sides of the wall opening (not illustrated). For this purpose, the side parts 12 , 14 have self-supporting carrying or installation framework structures (not shown specifically).
The upper region of the wall opening has arranged in it an upper part or an upper casing 16 which runs parallel to the upper edge of the wall opening and, in the installed state, is (also) borne by the side parts 12 , 14 . In other words, the upper part 16 connects the side parts 12 , 14 by resting on the upper sides of the side parts 12 , 14 .
The interior of the upper part 16 contains various subassemblies of the door 10 , for example two winding-up shafts 18 , 20 , which are spaced apart horizontally and parallel to one another. Individual webs of a flexible door leaf 22 are wound up in each case onto these winding-up shafts 18 , 20 in order to open the door 10 and unwound therefrom in order to close the same.
In order to make the winding-up shafts 18 , 20 rotate in a suitable manner, in addition, a gear-mechanism device 24 with various driving gearwheels 26 is arranged in the upper part 16 . Also present in the upper part is a preferably electric drive motor (not illustrated). It also contains a control unit, which controls, inter alia, the drive movements of the winding-up shafts 18 , 20 .
The door leaf 22 has individual webs 28 a - 28 e which are not connected to one another. The webs 28 a - e , in the unwound state of the door leaf 20 , extend essentially over the entire free surface area of the wall opening, this surface area running between the side parts 12 , 14 and the upper part 16 . The webs 28 a , 28 b here are assigned to the winding-up shaft 18 and the webs 28 c , 28 d and 28 e are assigned to the winding-up shaft 20 . In other words, the webs 28 a , 28 b are wound up, if required, on the winding-up shaft 18 and the webs 28 c , 28 d , 28 e are wound up on the winding-up shaft 20 .
The front side 30 of the door leaf 22 is formed by the outer web 28 e , and the rear side of the door leaf 22 is formed by the outer web 28 a . The material of the two outer webs 28 a , 28 e in each case here is plastics material, preferably PVC.
In the installed state, the door leaf 22 is oriented such that the front side 30 or the outer web 28 e is directed into the interior of the cold store (not illustrated), that is to say faces in the direction of the temperature zone which is colder than the exterior surroundings of the building.
The webs 28 b , 28 c are spaced apart from one another in the interspace between the front side 30 and the rear side 32 or between the outer webs 28 a , 28 e.
The webs 28 b and 28 c are designed as insulating webs, i.e. they consist, in the present case, of suitable flexible, heat-insulating material.
The web 28 d is positioned between the insulating web 28 c and the outer web 28 e , or the front side of the door leaf 22 , at a distance in each case from the aforementioned webs 28 c , 28 e . All of the webs 28 a - 28 e , in the closed state of the door 10 , run essentially parallel to one another.
The web 28 d comprises a door-leaf-heating device. In the present case, the entire web 28 d is designed as an electric radiant-heater web.
Electric radiant heaters are known in the prior art. They are based essentially on heat being generated by electrical resistors which form heat generators. These resistors have electric current flowing through them as required, as a result of which they give out heat in a known manner. Such radiant heaters with a sheet-like structure may be, for example, known carbon radiant heaters.
The radiant-heater web 28 d is connected to a source of electric current (not illustrated) via suitable connections and suitable lines for conducting electric current. In the present case, the radiant-heater web 28 d is connected to a transformer (not illustrated) or a power supply unit, which in turn is connected to a conventional mains connection of a higher-voltage mains system.
The aforementioned control unit can be used to control the supply of power to the radiant-heater web 28 d , in particular the intensity of the current supplied and/or the duration and/or the corresponding points in time at which the power is supplied.
The electric radiant-heater web 28 d ensures that the adjacent outer web 28 e is heated on a permanent basis or as required. This effectively prevents the situation where ice can form on this outer web 28 e.
A specific secondary effect is the fact that the radiant-heater web 28 d likewise heats at least to a slight extent in each case the air in the interspaces between the individual webs 28 a to 28 e . The heated air rises upwards, in the interspaces, into the upper casing 16 and ensures that the relevant subassemblies, for example the gear-mechanism device 24 , the driving gearwheels 26 , the control unit (not illustrated) and the drive motor (not illustrated) also remain free of ice.
The lower edges 34 , 36 of the outer webs 28 a , 28 e are fastened on a common, lower termination part 38 . This termination part 38 , in the present case, is designed as an elongate plastics-material profile which, in the closed state of the door 10 , forms the lower termination of the door. In other words, the termination part 38 preferably has its underside 40 resting on the ground, which bounds the building opening in the downward direction, or alternatively it hangs just above the ground, at a small distance therefrom.
The vertical, lateral edges 42 , 44 of the door leaf 22 , namely the lateral edges of the outer webs 28 a , 28 e , are guided in corresponding vertical guides of the side parts 12 , 14 , these guides not being shown explicitly in the drawings.
Provision may also be made, if appropriate, for electric radiant heaters or other heating devices to be arranged on the side parts 12 , 14 , and to be positioned such that at least the guides of the side parts 12 , 14 are heated.
For the purpose of weighting the insulating layers 28 b , 28 c , in addition, steel profiles 46 , 48 , which are U-shaped in section, are arranged at the ends of these layers.
For the purpose of absorbing impact which may arise, for example, from fork-lift trucks accidentally colliding with the door leaf 22 , both the front side 30 and the rear side 32 of the door leaf 22 have arranged on them respective bumpers 47 and 49 , the latter running parallel to these sides in each case. These bumpers 47 , 49 are preferably formed from elastic material, in particular from rubber, elastic plastics material or the like. They extend in each case preferably more or less parallel to the cold-store floor, essentially from the one lateral door-leaf edge 42 to the other lateral door-leaf edge 44 , wherein they maintain a small distance from the door-leaf edges 42 , 44 . In concrete terms, they are each fastened on the respective outer sides of the termination part 38 of the door leaf 22 , and in the present example they are connected thereto in a form-fitting manner.
A further special feature of the invention relates to the winding-up shafts 18 , 20 :
FIG. 1 illustrates the winding-up shaft 18 in the form of a schematic diagram. The explanations which follow also apply analogously to the winding-up shaft 20 .
The winding-up shaft 18 has a winding surface 50 which, in contrast to the prior art, is not cylindrical, i.e. is not rotationally symmetrical in relation to the axis of rotation, which is directed perpendicularly to the plane of the drawing. Rather, the winding-up shaft 18 has at least a first surface region 52 , which is spaced apart radially from the axis of rotation by a smaller distance than at least a second surface region 54 .
In the present example, in a first circumferential direction, namely in the clockwise direction (arrow 58 ), the first surface region 52 and the second surface region 54 are connected to one another in a continuous and transition-free manner. Accordingly, these regions merge into one another in a transition-free manner.
For this purpose, correspondingly, the distance of the winding surface 50 increases continuously in this circumferential direction from the surface region 52 to the surface region 54 .
As seen in the opposite circumferential direction, i.e. in the anticlockwise direction (arrow 60 ), the surface regions 52 , 54 are connected to one another by an offset 56 . This offset 56 in the winding surface 50 runs more or less radially, but at least at an angle to the surface regions 52 , 54 , and runs longitudinally along the entire winding-up shaft 18 .
The height or the corresponding radial dimension of the offset 56 , in the present case, is somewhat greater than the sum of the thicknesses of the door-leaf webs 28 a , 28 b which can be wound up onto the winding-up shaft 18 . This can be seen particularly clearly in FIG. 4 .
The upper edges of the door-leaf webs 28 a , 28 b are fastened in the surface region 52 in a manner which is not illustrated, and therefore the door-leaf webs 28 a , 28 b which can be wound up have their upper edges in each case butting against the offset 56 . These edges here run perpendicularly to the plane of the drawing, parallel to the offset 56 .
The specific design of the winding surface 50 serves for avoiding unbalances during the operations of winding up and unwinding the door-leaf webs 28 a , 28 b . The overall structure made up of the door-leaf webs 28 a , 28 b and the winding-up shaft 18 deviates from the ideal rotationally symmetrical form, during the winding-up and unwinding operations, to a lesser extent than would be the case if use were made of conventional, rotationally symmetrical, in particular cylindrical, winding surfaces.
The same applies analogously—as already indicated above—to the winding-up shaft 20 and the door-leaf webs 28 c , 28 d , 28 e which can be wound up thereon.
LIST OF DESIGNATIONS
10 Door
12 Side part
14 Side part
16 Upper part
18 Winding-up shaft
20 Winding-up shaft
22 Door leaf
24 Gear-mechanism device
26 Driving gearwheel
28 a - 28 e Webs
30 Front side
32 Rear side
34 Edge
36 Edge
38 Termination part
40 Underside
42 Vertical, lateral edge
44 Vertical, lateral edge
46 Steel profile
47 Bumper
48 Steel profile
49 Bumper
50 Winding surface
52 First surface region
54 Second surface region
56 Offset
58 Arrow
60 Arrow | A door for closing an opening in a wall, preferably a wall which separates two different temperature zones from one another, in particular one belonging to a cold store, having a door leaf ( 22 ), which can be moved in front of the wall opening, and having a heater for heating at least one door component. | 4 |
[0001] This application is related to U.S. provisional patent application Ser. No. 61/126,443, filed May 5, 2008, from which priority is claimed under 35 U.S.C. §119(e)(1) and which is incorporated herein by reference in its entirety.
[0002] This invention was made with government support under P01AG20641 awarded by National Institute on Aging/National Institutes of Health and R01AA016676 awarded by National Institute on Alcohol Abuse and Alcoholism/National Institutes of Health. The government has certain rights in the invention. Additional support was provided by Arkansas Biosciences Institute (Arkansas Tobacco Settlement Fund).
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally concerns a method for quantifying a polymorphism or site-specific DNA methylation in a single cell, a virus, a multicellular organism, or a population of viruses, cells or organisms.
[0005] Moreover, the present invention more specifically concerns a process to quantify the amount of a nucleotide signal in a sequencing electropherogram. This method is particularly useful to quantify signals of bases that are unusual in the sequence and for which there are few (or no) examples in the sequence to use as internal standards. An example of this is the widely used bisulfite genomic sequencing method where cytosine peaks are underrepresented. The method and process accurately quantifies a thymine peak comigrating with a cytosine peak.
[0006] The present invention particularly concerns an improved bisulfite genomic sequencing (BGS) analysis method that quantifies methylation at any particular site by subtracting the thymine signal at that site from the average signal of 10 surrounding thymine peaks. Inventor calls this method “Mquant.”
[0007] 2. Description of Related Art
[0008] This invention revolves around the pressure applied to the genome of an organism by environmental forces. This pressure is believed to act upon and drive the stoic hereditary genome defined by the DNA sequence, and is known as epigenetics.
[0009] First introduced by Conrad Waddington in 1942, the term “epigenetics” was used to describe “the branch of biology which studies the causal interactions of genes with their environment, which bring the phenotype into being” (1). However, conceptual origins of epigenetics date back to Aristotle. The field of epigenetics has emerged to bridge the gap between nature and nurture.
[0010] Epigenetics refers to modifications to DNA and chromatin that persist from one cell division to the next regardless of a lack of change in the underlying DNA sequence. Transgenerational inheritance is shown by some epigenetic changes, indicating that these changes can be passed from one generation to the next. Epigenetics is involved in cellular differentiation, allowing distinct cell types to have specific characteristics even as they share the same DNA sequence. Imprinting, bookmarking, gene splicing, paramutation, X chromosome inactivation, reprogramming, position effect, histone modifications and heterochromatin, some carcinogenesis, maternal effects, and transvection are some examples of epigenetic processes. The epigenome refers to the overall epigenetic state of a cell while the epigenetic code refers to epigenetic features such as DNA methylation and histone modifications that create different phenotypes in different cells.
[0011] Epigenetic inheritance systems mechanics are still incompletely understood, but our current understanding has uncovered at least 4 mechanisms by which epigenetic changes persist over time. These include RNA transcripts, cellular structures, DNA methylation/chromatin remodeling, and even prions.
[0012] Methylation, on a DNA level, is the addition of a methyl group to a cytosine residue to convert it to 5-methylcytosine. Methylation of DNA occurs at CpG sites, where cytosine (C) lies next to guanine (G). The CpG sites are in regions near the promoters of genes. These regions are known as CpG islands. The state of methylation of CpG islands is critical to both gene activity and gene expression.
[0013] Identification and characterization of DNA methylation came later in 1948 (2). This was the first epigenetic mark to be discovered. Cytosine is the predominant target for DNA methylation in the mammalian genome. An enzymatic attachment of a methyl group to the 5 position of the pyrimidine ring produces 5-methylcytosine (3), which has sometimes been referred to as the fifth base of genomic DNA.
[0014] Methylation adds four atoms to cytosine, one of the four DNA bases. Cytosine is also part of deoxycytidine which is one of the four DNA nucleosides. The body naturally uses methylation to turn genes on and off. The additional atoms block the proteins that transcribe genes. But, when something goes awry, methylation can unleash a tumor by silencing a gene that normally keeps cell growth in check. Removing a gene's natural methylation can also render a cell cancerous by activating a gene that is typically “off” in a particular tissue.
[0015] Although by some methods and for some biological functions 5-methylcytosine is indistinguishable from cytosine within the structure of the DNA molecule, where both base-pair with guanine, the presence of the methyl group has considerable biological implications for DNA function (4). Alterations in DNA methylation affecting target sequences within the transcriptional control regions of genes produce changes in gene expression, with hypomethylation leading to increased expression and hypermethylation leading to decreased expression. In contemporary terms, epigenetics refers to modifications of the genome that are heritable during cell division but do not involve a change in the DNA sequence (4). Thus, epigenetics describes heritable changes in gene expression that are not simply attributable to nucleotide sequence variation (5). It is now recognized that epigenetic regulation of gene expression reflects contributions from both DNA methylation and complex modifications of histone proteins and chromatin structure (6). Nonetheless, DNA methylation plays a central role in nongenomic inheritance and in the preservation of epigenetic states, and remains the most accessible epigenomic feature because of its inherent stability (4). Thus, DNA methylation represents a target of fundamental importance in the characterization of the epigenome, in defining the role of epigenetics in disease pathogenesis, and in the development of useful molecular tools for diagnostic testing and prediction of prognosis in neoplastic and non-neoplastic diseases (7-9). Ogino et al (10) investigated one such molecular tool, sodium bisulfite conversion of DNA followed by MethyLight real-time polymerase chain reaction (PCR), and described the factors that influence the variability of quantitative analysis. However, to fully understand these results, it is important to comprehend the importance of DNA methylation in cancer and the significance of such information to cancer diagnosis and prognosis.
[0016] Sequencing the human genome was far from the last step in explaining human genetics. Researchers still need to figure out which of the 20,000-plus human genes are active in any one cell at a given moment. Chemical modifications can interfere with the machinery of protein manufacture, shutting genes down directly or making chromosomes hard to unwind. Such chemical interactions constitute a second order of genetics, i.e., epigenetics.
[0017] Methylation of cytosines in DNA is an epigenetic modification in vertebrates, higher plants and some other eukaryotes. It is strongly associated with gene silencing, and its gene- and site-specific quantification is important to understand epigenetic changes in biology including in development, behavior, cancer and aging (11-18).
[0018] Site-specific DNA methylation can be quantified by numerous methods, most of which use restriction digestion and/or bisulfite treatment (19-23). However, there are difficulties and/or disadvantages associated with the methods described heretofore. Some of these methods are limited to just one or a few sites. Several methods use genomic sequencing to quantify methylation over stretches of DNA up to a few hundred nucleotides. Each of these methods require specialized techniques and/or equipment not widely used or widely available (20, 23, 26, 28, 29). Bisulfite genomic sequencing (BGS) and related bisulfite based techniques (19, 34) are among the most useful methods to detect DNA methylation. Capillary electrophoresis methods producing four-dye-trace electropherograms are widely used to detect methylation with BGS. But, this method is not quantitative without subcloning, sequencing and averaging each sample (35-37) or without use of complex, specialized algorithms (26). Recently, Dikow et al. (22) described a simple way to quantify DNA methylation from BGS four-dye-trace electropherograms, but they show the maximum mean signal generated to be just over 80% methylation (that is known not to be the case), and they suggest that quantification by bisulfite treatment may be intrinsically problematic. They presented data showing that a specialized, nonbisulfite technique (22, 27) was more accurate approach.
[0019] In addition to DNA methylation and epigenetics, important variations occur in nucleic acid sequences themselves. These variations, often called polymorphisms, affect the coding, activity, splicing etc. of nucleic acids including DNA and RNA. Polymorphisms can be measured in populations of animals, plants and viruses, and are often studied to understand why some individuals or populations have certain phenotypes or have certain characteristics to a different degree than other individuals or populations.
[0020] Citation of any document herein is not intended as an admission that such document is pertinent prior art, or considered material to the patentability of any claim of the present application. Any statement as to content or a date of any document is based on the information available to applicant at the time of filing and does not constitute an admission as to the correctness of such a statement.
SUMMARY OF THE INVENTION
[0021] The primary object of this invention is to provide an uncomplicated, cost-effective and accurate method for quantifying the levels of cytosine methylation in genomic DNA.
[0022] Another object in accordance with the present invention is to provide a method to quantify methylation on multiple independent CpG sites from analysis of a single sequencing run.
[0023] Yet, another and highly preferred object is a method that works well over the entire range of methylation levels, making it suitable for analyses of hypo- and hypermethylation and of methylation associated with imprinting.
[0024] Still, another highly preferred object of this invention is to define a quantification method that is amenable to robotic or manual high throughput methods, such as, for example, would be suitable for screening for deleterious effects, diagnosis, treatment modalities and prognosis of cancer.
[0025] Yet another preferred object is to quantify polymorphisms that occur in nucleic acid sequences themselves (without any bisulfite treatment). A particularly preferred object is to quantify polymorphisms where few or no other examples of one of the polymorphic nucleosides, nucleotides or bases exist in the sequence.
[0026] A further, most preferred object is to provide a method that uses less than the DNA needed for other, known, analysis methods, making it more suitable for determining methylation or polymorphisms in extremely small samples, for example, paraffin sections, and so forth. Other uses will become apparent to one familiar with the art.
[0027] In accordance with these objects, this invention contemplates a preferred method to quantify cytosine methylation at a particular target CpG site in DNA of a virus, cell or organism. The method involves performing bisulfite genomic sequencing, wherein a DNA sample extracted from a virus, cell or organism is treated with sodium bisulfite to convert cytosine to uracil, and a selected fragment of this treated DNA is amplified. 5-methylcytosine is unaffected by the bisulfite treatment. The treated DNA fragment is then amplified by PCR (a term known to those familiar with the art).
[0028] The contemplated method further involves performing a sequence analysis of the PCR amplificate from an electropherogram, wherein the area under a peak is measured in a plurality of peaks at either side of the target CpG site to determine the mean T area (T bar) surrounding the site. The method further contemplates subtracting the area of the T at the target CpG site from the mean T area. The difference obtained is termed delta T, and the proportional level of methylation is calculated as a quotient of delta T/T bar.
[0029] A more specific and preferred embodiment of this invention is an improved method, extending a known method to quantify DNA methylation at a particular site from bisulfite genomic sequencing using data from four-dye-trace value electropherograms from fluorescent dye terminator sequencing.
[0030] The improvement of the known method involves selecting a target CpG site and determining the mean T area (T bar) from a plurality of Ts surrounding the target CpG site. Also involved in this improvement are the steps of subtracting the area of the T at the target CpG site from T bar, wherein the subtracting yields delta T, and calculating the level of methylation on the site as the proportion of (delta T)/(T bar). The Ts surrounding the target CpG site may number 2-20. However, the preferred number of Ts surrounding the target CpG site is 10 or more. The Ts used to calculate T bar preferably have a T signal-to-noise ratio of 10 or better with respect to their secondary peak, and are at least 10 times the area of their secondary base (C, G or A). Preferably, an equal number of T's from each side of the target CpG are used, and preferably the number comprises 5 on each side. The calculation may be stated as 100×(delta T)/(T bar), representing the percentage of methylation.
[0031] A most preferred embodiment in accordance with this invention is an algorithm for quantifying DNA methylation at a particular site from bisulfite genomic sequencing, using data from four-dye-trace trace value electropherograms from fluorescent dye terminator sequencing. The algorithm involves choosing the target CpG site, determining the mean T area (T bar) from 10 Ts surrounding the target CpG site provided that Ts used to calculate T bar are at least 10 times the area of their secondary base (C, G or A), the Ts used to calculate T bar have a T signal-to-noise ratio of 10 or better with respect to their secondary peak, and an equal number of T's from each side of the target CpG (i.e. 5 on each side) are used. The algorithm further requires subtracting the area of the T at the target CpG site from T bar to yield delta T (i.e. T bar−CpG T=delta T), and calculating the level of methylation on the site as the proportion, (delta T)/(T bar), or the percentage, 100×(delta T)/(T bar).
[0032] When there are not 10 peaks in close proximity to the specific CpG site, any number from 2-20 can be used for calculation without seriously affecting the calculation; however, 10 (5 flanking each side) are preferred. In some embodiments the 2-20 closest peaks (not necessarily symmetrical and not necessarily the same number on each side) can be used for calculation without seriously affecting the calculation; however, 10 (5 flanking each side) are preferred.
[0033] Another preferred embodiment uses a generalized form of the algorithm for quantifying a base, nucleoside or nucleotide at a particular polymorphic site from electropherogram trace values. The algorithm involves choosing the target polymorphic site and a nucleotide N1, to be quantified, and a second polymorphic nucleotide at the polymorphic site (N2p), and determining the mean N2 area (N2 bar) from 10 N2 nucleotides surrounding the target polymorphic site using an equal number of N2s from each side of the target polymorphic site (i.e. 5 on each side). The algorithm further requires subtracting the area of the N2 at the target polymorphic site (N2p) from N2 bar to yield delta N2 (i.e. N2 bar−N2p=delta N2), and calculating the level of N1 on the polymorphic site as the proportion, (delta N2)/(N2 bar), or the percentage, 100×(delta N2)/(N2 bar).
[0034] A more preferred embodiment of the generalized form of the algorithm uses 10 N2 nucleotides to determine the mean N2 area (N2 bar) that are at least 10 times the area of their secondary nucleotide (base) such that the N2s used to calculate N2 bar have an N2 signal-to-noise ratio of 10 or better with respect to their secondary peak. In some embodiments the 2-20 closest N2 peaks (not necessarily symmetrical and not necessarily the same number on each side) can be used for calculation without seriously affecting the calculation; however, 10 (5 flanking each side) N2 peaks are preferred.
[0035] Still further embodiments and advantages of the invention will become apparent to those skilled in the art upon reading the entire disclosure contained herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 shows a gel electrophoresis run for quantification of DNA methylation by COBRA (32, 33), a scan of this gel and a corresponding electropherogram from the same amplificate analyzed by Mquant. A) A bisulfite PCR product was digested with HpyCH4IV (ACGT) to give three bands of 372, 248 and 124 bp. The 372 bp band is undigested DNA (representing unmethylated DNA that now has an ATGT site). The smaller bands represent methylated DNA whose single HpyCH4IV site was cleaved. The digested DNA lane is marked Hpy and the undigested DNA lane is marked U. B) A scan of the digested lane of this gel. C) The peak areas of the 372 and 248 bp bands from four determinations were quantified and their relative peak areas are shown (with 372 bp areas normalized to 100). D) The T trace of the electropherogram was analyzed by Mquant as described in the text. E) The relative copy numbers of the 372 and 248 bp bands were used to calculate the percent DNA methylation (5MC) of the original DNA. The percent methylation by Mquant is also shown. Analyses of this individual PCR amplificate gave a mean percent methylation (+/−SD) by COBRA of 34.6+/−5.2% with a CV of 15% (n=4) and a mean percent methylation by Mquant of 38.4+/−6.8 with a CV of 18% (n=4). The differences in the two methods for this amplificate are not statistically significant (p=0.40) and are <4% methylation (35 versus 38%).
[0037] FIG. 2 a is a plot of the percent DNA methylation on the CpG of an ACGT site from 19 different DNA samples determined by COBRA versus the percent methylation on this same site determined by peak areas on forward sequence electropherograms. The results of the two methods were highly correlated (R=0.95, P<10-09) and in good agreement (estimate±standard error=0.98±0.079 for slope, and 0.012±0.031 for y-intercept). The average percent methylation measured by COBRA and Mquant were both 32%.
[0038] FIG. 2 b shows A Bland-Altman plot of the data shown in FIG. 2 a . The vertical axis shows the difference in methylation values measured by the two methods (Mquant minus COBRA), whereas the horizontal axis shows the average methylation value measured by the two. The mean (SD) of the difference between methods was +0.72% (7.6%), indicating little evidence of bias between the methods (P=0.68). The center dashed horizontal line shows the mean difference, while the outside horizontal lines show the 95% LoA's (at −14.4%, +15.9%).
[0039] FIG. 3 demonstrates gel electrophoresis for quantification of DNA methylation by COBRA, a scan of this gel, and a corresponding electropherogram from the same amplificate analyzed by Mquant. A) A bisulfite PCR product was digested with Taqalphal (TCGA) to give three bands of 307, 190 and 117 bp. The 307 bp band is undigested DNA (representing unmethylated DNA that now has a TTGA site). The smaller bands represent methylated DNA whose single Taqalphal site was cleaved. The peak areas of the 307 and 190 bp bands were quantified and their relative copy numbers were calculated and used to calculate the percent methylation of the original DNA. The digested DNA lane is marked Taq and the undigested DNA lane is marked U. B) A scan of the digested lane of this gel. C) The peak areas of the 307 and 190 bp bands from five determinations were quantified and their relative peak areas are shown (with 307 bp areas normalized to 100). D) The T trace of the electropherogram was analyzed by Mquant as described in the text. E) The relative copy numbers of the 307 and 190 bp bands were used to calculate the percent DNA methylation of the original DNA. The percent methylation by Mquant is also shown. Analyses of this individual PCR amplificate gave a mean percent methylation (+/−SD) by COBRA of 95.7+/−2.1 with a CV of 2.2% (n=5) and a mean percent methylation by Mquant of 91.7+/−1.0 with a CV of 1.1% (n=5). The differences in the two methods for this amplificate are statistically significant (p<0.01, marked with an asterisk in E)) but differ by only 4% methylation (96 versus 92%). The standard deviation (shown as error bars) is large in C) because it includes the variation (2.1%) in the percent of unmethylated site (4.3%).
[0040] FIG. 4 a is a plot of the percent DNA methylation on the CpG of a TCGA site from 29 different DNA samples determined by COBRA versus the percent methylation on this same site determined by peak areas on forward sequence electropherograms. The results of the two methods are highly correlated (R=0.91, P=7.0×10-12), but in rather poor agreement (estimate±standard error=0.84±0.073 for the slope, and 0.009±0.048 for the y-intercept). The average percent methylation measured by COBRA and Mquant were 61% and 52% respectively.
[0041] FIG. 4 b shows a Bland-Altman plot of the data shown in FIG. 4 a . The vertical axis shows the difference in methylation values measured by the two methods (Mquant minus COBRA), whereas the horizontal axis shows the average methylation value measured by the two. The mean (SD) of the difference between methods was −8.9% (10.3%), indicating statistically significant evidence (P<0.0001) of a bias toward lower values as measured by Mquant compared to COBRA. The center dashed horizontal line shows the mean difference, while the outside horizontal lines show the 95% LoA's (at −29.5%, +11.7%).
[0042] FIG. 5 shows gel electrophoresis for quantification of DNA methylation by COBRA, a scan of this gel, and a corresponding electropherogram from the same amplificate analyzed by Mquant. A) A bisulfite PCR product was digested with Acil (GCGG) to give three bands of 372, 242 and 130 bp. The 372 bp band is undigested DNA (representing unmethylated DNA that now has a GTGG site). The smaller bands represent methylated DNA whose single Acil site was cleaved. The peak areas of the 372 and 242 bp bands were quantified and their relative copy numbers were calculated and used to calculate the percent methylation of the original DNA. The digested DNA lane is marked Aci and the undigested DNA lane is marked U. B) A scan of the digested lane of this gel. C) The peak areas of the 372 and 242 bp bands from four determinations were quantified and their relative peak areas are shown (with 372 bp areas normalized to 100). D) The T trace of the electropherogram was analyzed by Mquant as described in the text. E) The relative copy numbers of the 372 and 242 bp bands were used to calculate the percent DNA methylation of the original DNA. The percent methylation by Mquant is also shown. Analyses of this individual PCR amplificate gave a mean percent methylation (+/−SD) by COBRA of 82.0+/−1.0 with a CV of 1.2% (n=4) and a mean percent methylation by Mquant of 90.9+/−2.5 with a CV of 2.7% (n=4). The differences in the two methods for this amplificate are statistically significant (p<0.003, marked with an asterisk in E)) but only differ by 9% methylation (82 versus 91%).
[0043] FIG. 6 a is a plot of the percent DNA methylation on the CpG of a GCGG site from 13 different DNA samples determined by COBRA versus the percent methylation on this same site determined by peak areas on forward sequence electropherograms. The results of the two methods are highly correlated (R=0.98, P=2.7×10-9) and in reasonably close agreement (estimate±standard error=1.07±0.062 for the slope, and −0.026±0.044 for the y-intercept). The average percent methylation measured by COBRA and Mquant were 61% and 63% respectively.
[0044] FIG. 6 b is a Bland-Altman plot of the data shown in FIG. 6 a . The vertical axis shows the difference in methylation values measured by the two methods (Mquant minus COBRA), whereas the horizontal axis shows the average methylation value measured by the two. The mean (SD) of the difference between methods was +1.6% (8.1%), indicating little evidence for bias between methods (P=0.48). The center dashed horizontal line shows the mean difference, while the outside horizontal lines show the 95% LoA's (at −14.6%, +17.8%).
[0045] FIG. 7 is an example of an electropherogram of bisulfite treated and PCR amplified mouse Peg 10 gene (47). This gene is imprinted and has intermediate levels of methylation on many CpG sites.
[0046] FIG. 8 is an example of an electropherogram of bisulfite treated and PCR amplified human telomerase reverse transcriptase gene (TERT) (48). In some cell types the gene has high levels of methylation on multiple CpG sites.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
1. Introduction
[0047] Having assigned such key roles to cytosine methylation, it is no wonder that there is a huge interest in developing procedures to analyze DNA methylation, and especially to have the ability to do it rapidly, cost-effectively, accurately, and with great sensitivity. The potential for large scale screening for disease, identifying the causes, stages, prognoses and designing treatment modalities is very inviting. Not surprising then, that there are many different approaches to quantitate DNA methylation (10-18, 47). Leading the charge and popularity, many of these approaches involve bisulfite treatment of DNA.
[0048] These new methods have to be validated as to their effectiveness against well-known and respected methods in existence. Provided herein and below are examples of such verification of the new method that is the subject of this invention.
Materials and Methods
[0049] DNA Extraction and In Vitro Methylation
[0050] DNA was extracted from mouse tissues using an Epicentre MasterPure DNA purification kit (Epicentre Biotechnologies, Madison, Wis.) according to the manufacturer's recommendations with minor modifications. Inventor added a phenol (Amresco, Solon Ohio) extraction step and a 1-bromo-3-chloropropane (Molecular Research Center, Inc. Cincinnati, Ohio) extraction step just prior to isopropanol precipitation. Purified DNA was washed with tris-EDTA buffer in Montage centrifugal filters (Millipore, Bedford, Mass.). In some cases DNA was methylated in vitro with SssI (CpG) methylase according to the manufacturer's instructions (New England Biolabs Inc, Ipswich, Mass.) except that DNA was washed in a centrifugal filter and reacted a second time (21) to assure complete methylation.
[0051] Bisulfite Modification of DNA
[0052] DNA was sodium-bisulfite modified with an Epitect Kit (Qiagen, Valencia, Calif.) according to the manufacturer's instructions. For each bisulfate modification Inventor used 300 ng of DNA. Inventor stored bisulfite-treated DNA at −20° C.
[0053] PCR
[0054] PCR was performed using a Hot Star Taq DNA polymerase kit (Qiagen, Valencia, Calif.). Each 25 ul PCR reaction included 0.65 units of Hot Star Taq polymerase, 0.22 mM Promega dNTP mix (Promega, Madison, Wis.), and 0.8 uM of each primer. The sequences amplified were from the mouse Avy allele of agouti (38) (Genbank AR302985). Bisulfite modified genomic DNA was amplified by nested PCR using two sets of primers for the Avy allele similar to that described by Rakyan et al. (39).
[0055] The first PCR reaction was carried out with 10 ng of DNA using the amplification profile: 1 cycle at 80° C. for 1 min, 1 cycle at 94° C. for 1 min; 2 cycles at (95° C. for 1 min, 64° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 63° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 62° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 61° C. for 1 min, 72° C. for 1 min); 40 cycles at (95° C. for 1 min, 60° C. for 1 min, 72° C. for 1 min); 72° C. for 5 min and cooling to 4° C.
[0056] The forward primer 5′-TGCGATAAAGTTTTATTTTTAT-3′ (SEQ ID No 1) and reverse primer 5′-GTTGTGTTTCGTTTTGTTTTTTTTTT-3′ (SEQ ID No 2) used for the first reaction were designed using MethPrimer web software (40) (http://www.urogene.org/methprimer/). A second, nested, PCR was then performed on 1 ul of the amplificate using the upstream and downstream Avy primers (372-bp PCR product) or the upstream and internal Avy primers (307-bp PCR product) of Rakyan et al. (39) with the following cycling conditions: 1 cycle at 80° C. for 1 minute, 1 cycle at 94° C. for 1 min; 2 cycles at (95° C. for 1 min, 63° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 62° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 61° C. for 1 min, 72° C. for 1 min); 2 cycles at (95° C. for 1 min, 60° C. for 1 min, 72° C. for 1 min); 40 cycles at (95° C. for 1 min, 59° C. for 1 min, 72° C. for 1 min); 72° C. for 5 min and cooling to 4° C. The PCR products were electrophoresed through a 2% agarose gel, stained with ethidium bromide, and digitally imaged under UV light using a transilluminator, video camera and LabWorks image acquisition and analysis software (Ultra-Violet Products, Upland Calif.).
[0057] Bisulfite Genomic Sequencing (BGS)
[0058] To eliminate primers and dNTPs, Inventor treated PCR products with exonuclease I (Epicentre, Madison Wis.) and shrimp alkaline phosphatase (Roche, Nutley, N.J.) (41) at 37° C. for 60 min followed by 85° C. for 15 min. Inventor then concentrated and washed these using Montage centrifugal filters (Millipore, Bedford, Mass.) according to the manufacturer's recommendations. The PCR products were sequenced using the nested upstream primer (Avy forward primer) (39) at the UAMS DNA Sequencing Core Facility using a Model 3100 Genetic Analyzer (Applied Biosystems, Foster City, Calif.) and a Big Dye terminator sequencing kit.
[0059] Combined Bisulfite Restriction Assay (COBRA)
[0060] For COBRA analysis (32, 33) PCR products were digested with 20 units of restriction enzyme Taqalphal (TCGA), HpyCH4IV (ACGT), or Acil (GGCG) (New England Biolabs, Ipswich, Mass.). Each of these enzymes has just one site in the bisulfite-converted sequence when the original genomic sequence was methylated, and no site in the bisulfite-converted sequence when the original genomic sequence was unmethylated. For digestion, a 10-to-20 fold excess of enzyme was used for two hours, but digestion was otherwise according to the manufacturer's instructions. The digested PCR products were separated by gel electrophoresis using 3% GenePure high resolution agarose (ISC BioExpress, Kaysville, Utah) and stained with ethidium bromide. Gels were imaged as described earlier and the images saved as TIFF files.
[0061] For COBRA electrophoresis, the amount of digest analyzed was kept low so that the bands were in a gray level (in an approximately linear range) but high enough that they gave a substantial signal. The undigested band and the largest-size digested band were used to quantify methylation because the smaller-size digest bands sometimes did not give a substantial signal. Even at extremes of methylation (near 0 or 100%), at least one band, the undigested or the largest digested band, gave a substantial signal.
[0062] Digital images were scanned with Scion Image software (Scion Corporation, Frederick, Md., http://www.scioncorp.com/pages/scion_image_windows.htm) to measure density. Density ratios of a major digested band to the undigested band were used to calculate the relative copy numbers of fragments and subsequently the percent methylation (21, 33).
[0063] Peak Area Determination from Sequencing Electropherograms
[0064] The ab1 files from sequencing were processed using Phred (42, 43) (http://www.phrap.org/) or BioEdit (http://www.mbio.ncsu.edu/BioEdit/bioedit.html). Sequences were not used if they had substantial artifacts e.g. if more than one T (that had not been a C of a CpG prior to bisulfite) in the region used to quantify methylation showed more than 10% C. The Phred output or BioEdit trace value output were used to read and quantify primary and secondary peaks in the electropherograms. Calculations were performed in Excel (Microsoft, Redmond, Wash.). Peak areas were determined by summing peak trace values. Phred automatically sums the trace values of peaks from baseline (42) and Inventor did the same with trace values from Bioedit after pasting them into Excel spreadsheets. Virtually all baselines between peaks had one or more trace values of zero which allows peak area determination by simple summing of peak trace values.
[0065] Algorithm for Quantification of DNA Methylation
[0066] DNA methylation levels were quantified from sequencing electropherogram trace values using the following algorithm that Inventor calls “Mquant.”
[0067] First, the target CpG site was chosen.
[0068] Second, the mean T area (T bar) from 10 Ts surrounding the target CpG site was determined. Is used to calculate T bar were at least 10 times the area of their secondary base (C, G or A). In Inventor's electropherograms, secondary bases were mainly sequencing noise. Thus, the Ts used to calculate T bar had a T signal-to-noise ratio of 10 or better with respect to their secondary peak. An equal number of T's from each side of the target CpG (i.e. 5 on each side) were used.
[0069] Third, the area of the T at the target CpG site was subtracted from T bar to yield delta T (i.e. T bar−CpG T=delta T).
[0070] Fourth, the level of methylation on the site was calculated as the proportion, (delta T)/(T bar), or the percentage, 100×(delta T)/(T bar).
[0071] This algorithm can be generalized such that: in place of the target CpG site, a target polymorphic site is chosen; in place of cytosine, cytidine or deoxycytidine, nucleotide 1 (N1) is used; and in place of thymine, thymidine or deoxythymidine, nucleotide 2 (N2) is used. In place of secondary base (C, G or A), any secondary base (C, G, A, T, U or other) is used. In place of the level or percentage of methylation, the level or percentage of nucleotide 1 (N1) is used.
[0072] Data Analysis
[0073] Percents methylation by the Mquant and COBRA methods were compared via regression plots using Origin (OriginLab, Northhampton, Mass.) and via Bland-Altman plots using Excel (Microsoft, Redmond, Wash.). Regression was used to calculate slopes, intercepts, and coefficients of correlation between methods, whereas Bland-Altman plots (44, 45) were used to determine means and standard deviations (SDs) of the difference in percents methylation by each method. Bland-Altman 95% Limits of Agreement (95% LoA's) were calculated as the mean±2SDs of the difference in percents methylation by each method, and indicate the limits between which ˜95% of the difference in percents methylation would be expected to fall under a Normal distribution. In some cases Inventor did multiple analyses of single amplificates for which Inventor determined SD, the root mean square error (RMSE) and the coefficient of variation (CV) as measures of run-to-run variation within each experiment.
Results
[0074] The examples as described herein are intended to further illustrate the present invention and are not intended to limit the invention in any way.
[0075] Inventor has developed a method to quantify DNA methylation from BGS electropherograms. This method uses and extends previously published methods of sequence analysis (22, 42, 43, 46) so that Inventor can readily quantify the methylation at a particular site using the data from four-dye-trace electropherograms from fluorescent dye terminator sequencing. This allows Inventor to quantify the percent methylation of numerous CpG sites in an electrophoretogram and to validate these levels at specific sites using COBRA assays (33). This method can greatly speed determinations of DNA methylation.
[0076] COBRA distinguishes between C and T bases using sequence specific restriction enzymes as measured by the intensities of bands on a gel after DNA fragments are separated by electrophoresis (32, 33). BGS, as used here, distinguishes between C and T bases by different fluorescent dyes on each base at specific positions after separation by capillary electrophoresis. At a target CpG site, T is measured directly and C is measured indirectly as the mean intensity of surrounding Ts minus the intensity of T at the target site (which is shared by C and T).
[0077] Inventor used bisulfite PCR amplificates from 45 independent DNA samples containing sites with DNA methylation levels that varied between 0 and 100%. With these, Inventor compared the bisulfite-based techniques of COBRA with a quantitative version of BGS that Inventor calls Mquant. The agouti allele region Inventor used contains 9 CpGs that can be sequenced reliably with the primer sets used. Three of these CpGs are in restriction sites, and were analyzed by both COBRA and Mquant.
[0078] A total of 61 COBRA and 61 Mquant determinations were made (from 45 PCR amplificates) to test for agreement between COBRA and Mquant. Each COBRA and corresponding Mquant was performed on the same bisulfite PCR amplificate.
Example 1
[0079] FIG. 1 shows a COBRA gel for measuring methylation of an HpyCH4IV site (ACGT) and the corresponding site in the sequencing electropherogram. In this and other COBRA gels, the amounts of digest loaded were in a moderate range so that the bands were at a gray level (in an approximately linear range) and still gave a substantial signal. FIG. 2A is a regression plot of COBRA values versus electropherogram values at the ACGT site, and shows a high correlation (0.95) between values measured by the two methods. FIG. 2B is a Bland-Altman plot for this same data. The mean (SD) difference between COBRA and Mquant values for the HpyCH4IV site was +0.72% (7.6%), indicating little evidence for bias (P=0.68) between methods. The outside horizontal lines of FIG. 2B show the Bland-Altman 95% LoA's, which are (−14.4%, +15.9%) for the ACGT site. The mean values of percent methylation for COBRA and Mquant were 31.6% and 32.4% respectively. Overall, these results show that the two methods tend to agree well at the HpyCH4IV site.
Example 2
[0080] FIGS. 3 through 4B show analogous results for the Taqalphal site (TCGA). The correlation between methylation levels measured by the two methods was somewhat lower (0.91). The mean (SD) difference between values measured by COBRA versus Mquant was −8.9% (10.3%), indicating statistically significant evidence (P<0.0001) of a bias toward lower values as measured by Mquant compared to COBRA. The 95% LoA's were (−29.5%, +11.7%) for the TCGA site. The mean values of percent methylation for COBRA and Mquant were 61% and 52% respectively. Although the bias was statistically significant at the Taqalphal site, it was nevertheless under 10% methylation.
Example 3
[0081] FIGS. 5 through 6B show analogous results for the Acil sites (GCGG). The correlation between methylation levels measured by the two methods was high (0.98). The mean (SD) difference between values measured by COBRA versus Mquant was 1.6% (8.1%), indicating little evidence for bias (P=0.48) between methods. The 95% LoA's were (−14.6%, +17.8%) for the GCGG site. The mean values of percent methylation for COBRA and Mquant were 61% and 63% respectively. Overall, these results show that the two methods tend to agree well at the Acil site.
[0082] Inventor made estimates of C to T conversion levels and general noise levels in the electropherograms. First, Inventor measured the C level under Ts from nonCpG Cs. These levels were small and indicated a conversion rate of >93% to 97%. Next, Inventor measured the levels of other bases (G and A) under Ts from nonCpG Cs. Levels of G and A were similar to those of C indicating that a substantial amount of C level may come from sequencing noise and not from incomplete C to T conversion. In any case, C to T conversion levels appear to be between 93 and 100%.
[0083] Inventor tested the number of Ts used to calculate T bar on the calculated DNA methylation level (data not shown) and on correlations with COBRA (Table 1). Inventor tested the use of 2 Ts (one on each side), 4 Ts (two on each side) and so on, up to 20 Ts (10 on each side). In all cases R was >0.90 and all correlations were highly significant (10-12<P<10-7). For Acil and Taqalphal sites the number of Ts between 2 and 20 had little effect on R (0.97 to 0.98 and 0.90 to 0.92 respectively). For HpyCH4IV sites R was 0.91 using 2 or 4 Ts and 0.93 to 0.95 using 8 to 20 Ts.
[0084] The data shown in FIGS. 2A , 4 A and 6 A is a large collection of single COBRA and Mquant determinations from a large number of amplificates. Additionally, to assess run-to-run reproducibility, ten amplificates were subsampled 3 to 5 times and assayed by both methods. The resulting data was analyzed statistically via one-way ANOVA on the parent amplificates in order to obtain the ANOVA root mean-square error (RMSE), which estimates the common standard deviation (SD) of the amplificate replications about their respective mean values. For COBRA, RMSEs were 4.3%, 1.5% and 1.0% for Hpy, Taq and Aci, respectively. For Mquant, RMSEs were 4.5%, 1.8% and 1.6% for Hpy, Taq and Aci, respectively. For the three sites combined, COBRA RMSE was 2.7% and Mquant RMSE was 3.0%. These estimates of SD are low for most methylation levels. For example, an SD of 3.0% is reasonable for a measured methylation level of 90%, 50% or even 20%. Only when methylation levels were very low (e.g. less than 10%) was the SD a substantial proportion of the measured methylation level. Overall, SDs were low, indicating that each method is highly reproducible.
[0085] Both methods measured the midrange as well as extremes of methylation. On the three sites studied by both COBRA and Mquant, in vitro methylated DNA gave 90 to 100% methylation by both methods. Mquant measures of methylation in 9 CpGs in the Avy allele of in vitro methylated DNA gave values from 90 to 98% with an average of 95%+/−2%. On the other extreme, Inventor observed nine instances of CpG sites with less than 10% methylation by both COBRA and Mquant.
[0000]
TABLE 1
The Effects of T Numbers on Correlations and
P values when Mquant is Compared with COBRA.
2T
4T
6T
8 to 20T
HpyCH4IV
R
0.91
0.91
0.92
0.93 to 0.95
P
2.6 × 10−8
2.9 × 10−8
1.0 × 10−8
<2 × 10−9
Taqalpha1
R
0.90
0.91
0.92
0.91 to 0.92
P
1.6 × 10−11
1.0 × 10−11
2.2 × 10−12
<8 × 10−12
Acil
R
0.97
0.97
0.97
0.98
P
2.2 × 10−8
5.2 × 10−8
1.6 × 10−8
<6 × 10−9
Example 4
[0086] Mquant also works if an odd number of Ts are used and/or if the number of Ts used are based on which are closest rather than an equal number on each side. For example, in a case where 10 Ts arranged 5 on each side give a percent methylation of 92.5 using instead the first (closest) 5 Ts gave 92.7%, the first (closest) 6 Ts gave 92.7%, and the first (closest) 10 Ts gave 92.5%. In these, 5 Ts were 3 upstream and 2 downstream, 6 Ts were 4 upstream and 2 downstream, and 10 Ts were 6 upstream and 4 downstream.
[0087] In another example, where 10 Ts arranged 5 on each side give a percent methylation of −1.3% using instead the first (closest) 5 Ts gave −3.2%, the first (closest) 6 Ts gave −0.8%, the first (closest) 9 Ts gave −0.1%, the first (closest) 10 Ts gave −3.0%, the first (closest) 15 Ts gave −6.5%, and the first (closest) 16 Ts gave −5.8%. In these, the arrangements of Ts upstream and downstream were asymmetrical.
[0088] In another example, where 10 Ts arranged 5 on each side give a percent methylation of 33.0% using instead the first (closest) 5 Ts gave 36.3%, the first (closest) 6 Ts gave −38.0%, the first (closest) 9 Ts gave 32.3%, and the first (closest) 10 Ts gave 31.4%. In these, the arrangements of Ts upstream and downstream were asymmetrical.
Example 5
[0089] This method was applied to several mouse sequences and several human sequences. One example of each and their quantification are shown in FIGS. 7 and 8 and Tables 2 and 3. FIG. 7 deals with mouse PEG 10 gene sequence (SEQ ID No 10). FIG. 8 shows human TERT gene sequence (SEQ ID No 17).
[0090] An electropherogram of bisulfite treated and PCR amplified mouse Peg 10 gene (47) is shown in FIG. 7 . This gene is imprinted and has intermediate levels of methylation on many CpG sites. Peg 10 primers were forward: 5′-GTAAAGTGATTGGTTTTGTATTTTTAAGTG-3′ (SEQ ID No 3) and reverse: 5′-TTAATTACTCTCCTACAACTTTCCAAATT-3′ (SEQ ID No 4).
[0000]
TABLE 2
Proportion of DNA methylation (MethylC) on Peg10
sites in FIG. 7
Proportion
No. Position
Sequence
MethylC
(1) 122
TATAGG CG TTTT
0.21
(SEQ ID No. 5)
(2) 131
TTTATG CG TTAT
0.33
(SEQ ID No 6)
(3) 151
TATAGG CG TTTT
0.22
(SEQ ID No 7)
(4) 160
TTTATG CG TTAT
0.35
(SEQ ID No 8)
(5) 180
TATAGG CG TTTT
0.36
(SEQ ID No 9)
[0091] Table 2 shows data related to the quantification of methylation on the Peg10 gene as shown in FIG. 7 . In particular the column labeled Proportion MethylC shows the proportion of methylation on sites and the column labeled Sequence gives the sequence context in FIG. 7 used to locate the methylated CpG site.
[0092] An electropherogram of bisulfite treated and PCR amplified human telomerase reverse transcriptase gene (TERT) (48) is shown in FIG. 8 . In some cell types the gene has high levels of methylation on multiple CpG sites. TERT primers used were: forward, 5′-GTTTTTGTATTTTGGGAG-3′ (SEQ ID No 11) and reverse, 5′-AATCCACTAAAAACCC-3′ (SEQ ID No 12).
[0000]
TABLE 3
Proportion of DNA methylation (MethylC) on four
TERT CpG sites in FIG. 8
Proportion
No. Position
Sequence
MethylC
(1) 37
TGGGTT CG TTCG
0.82
(SEQ ID No 13)
(2) 41
TTCGTT CG GAGT
0.91
(SEQ ID No 14)
(3) 58
CGTTGT CG GGGT
0.85
(SEQ ID No 15)
(4) 69
TTAGGT CG GGTT
0.73
(SEQ ID No 16)
[0093] Table 3 shows data related to the quantification of four sites of methylation on the human TERT gene as shown in FIG. 8 . In particular, the column labeled Proportion MethylC shows the proportion of methylation on sites and the column labeled Sequence gives the sequence context in FIG. 8 used to locate each methylated CpG site.
Discussion
[0094] The above mentioned examples define a new method to quantify DNA methylation from BGS four-dye-trace electropherograms. This method uses data from the thymine trace almost exclusively and thus avoids any complications due to independent normalization of A, G, C and T peaks in four-dye-trace electropherograms (26). This method uses available, established software to read electropherograms (Phred and Bioedit).
[0095] Inventor's method analyzes sites independently and uses the same number of non-CpG Ts on either side of the analyzed site. Inventor first attempted a similar quantification using a mean of most or all non-CpG Ts in electropherograms, but this gave poor results, and simple inspection of the numbers in the Phred output revealed that the mean was less than most of the non-CpG Ts early in the electropherogram and that the mean was greater than nearly all of the non-CpG T's late in the electropherogram (data not shown). The areas (and heights) of thymine peaks gradually decline over most electropherograms and this is likely responsible for this effect. By taking the same number of Ts on either side of the analyzed CpG an effect of this gradual peak area decline over the electropherogram is obviated. The peak areas (and heights) also vary locally so that it is important to average two or more to get a value for 100% T. Fitting methods such as linear regression on neighboring T peaks could probably be used with similar effect.
[0096] Any CpG site can have between 0 and 100% methylation. In the TCGA (Taqalphal) site COBRA and Mquant differences are statistically significant yet the mean values are still within 10% methylation of each other. One possible explanation involves consistent differences readily observed in T peak areas and heights in electropherograms. Certain patterns, such as three successive Ts in a particular part of a sequence showing a gradual decline in height, are reproducible in multiple sequencings. This indicates that if a particular T derived from the C of a CpG is consistently above average height (and area) in its region of the sequence, the average methylation level measured by Mquant will be low. Similarly, if the particular T were consistently below average height (and area) in its region the average methylation level measured by Mquant would be high. Fortunately, differences that may be attributable to this effect at the Taqalphal site are small. The ACGT (HpyCH4IV) site gave nearly identical mean methylation values by COBRA and Mquant as did the GCGG (Acil) site. These mean values were within 2% methylation of each other.
[0097] Inventor agrees with other groups (22, 26) that BGS probably has limitations to quantification due to incomplete C-to-U conversion and imperfect specificity for only unmethylated C's. However, Inventor finds good agreement with the established COBRA method when Inventor quantifies methylation in bisulfite electropherograms by averaging T's on both sides of the target CpG and subtracting the T signal at the CpG site from this average T. To measure very high levels of methylation, e.g. 90% to 100%, it is necessary that the signal-to-noise ratio be very high, so that the average nonCpG T value is high and the noise at the CpG site is very low. For example, a noise level of 10% in the T trace at a CpG site leaves the maximum methylation detectable at 90% even if the DNA is actually 100% methylated. Inventor made estimates of likely conversion levels and finds them to be high (93 to 100%). Noise levels in sequencing and PCR may be higher than C signals due to incomplete C to T conversion.
[0098] Because it relies on nearby Ts to calculate methylation levels at CpGs, the Mquant method may not work as well in parts of some dense CpG islands, such as those of tumor suppressor genes, where there are few (or no) nearby Ts. In contrast, COBRA and some other methods would not be expected to show effects of nearby T density and thus COBRA may be a method of choice for such sequences. Mquant also relies on a high bisulfite conversion level and high quality sequencing traces which may not always be available. For example, the algorithm of Lewin et al. (26) corrects for bisulfite conversion levels and aligns sequences and thus can work with sequencing traces that may not be useful with Mquant.
[0099] Mquant has several advantages over COBRA. Mquant quantifies methylation on multiple independent CpG sites from analysis of a single sequencing run In contrast, COBRA usually analyzes the methylation of just one CpG site at a time. In most sequences only a minority of CpG sites are part of a restriction site as required for COBRA analysis. Mquant is amenable to robotic or manual high throughput methods. For example, most or all of the steps could be done in a 96 well format up until the sequencing capillary electrophoresis which is also available in a 96 capillary format. In contrast, COBRA is generally done by gel electrophoresis with manual imaging and analysis of gels. These COBRA methods are laborious and, on average, probably less reliable than automated sequencing by capillary electrophoresis and fluorescent dye detection. Mquant also uses less than half of the DNA needed for one COBRA analysis.
[0100] Mquant works well over the entire range of methylation levels making it suitable for analyse associated with imprinting. Inventor obtained good overall correlations between Mquant and COBRA including levels near 0% and 100% methylation. Mquant and COBRA both gave high methylation levels (90 to 98%) with in vitro methylated DNA. There are always trace values for all four bases (including T) in electropherograms and there is always background noise in COBRA gel scans. Thus no measures gave a value of 100%.
[0101] Inventor's use of the thymine trace data to quantify methylation has similarities to the method of Dikow et al. (22), but also differs in several ways. Like Mquant the Dikow algorithm can quantify from just the T trace values. However, the Dikow algorithm uses all Ts in a region without a way of choosing those well suited to quantify at a particular CpG site. In other words, they choose one set of Ts for quantification at multiple CpG sites whereas Mquant uses sets of Ts tailored to each CpG site. In Mquant each CpG uses a different set of Ts from every other CpG (unless two or more CpGs happen to have no Ts between them). Dikow et al. read electropherograms with Applied Biosystems Genescan software, whereas Inventor used Phred and Bioedit. Dikow et al. report their maximum mean signal to be just over 80% methylation in DNA where they measured nearly 100% methylation by their established methylation-specific multiplex ligation-dependent probe amplification (MS-MLPA) method. As discussed above, inventor is able to read methylation levels of 90 to 98% from in vitro methylated DNA.
[0102] Lewin et al. (26) use both the C and T trace values in a sophisticated but complex algorithm that ultimately normalizes the C and T traces to each other. They then use both the C and T trace data to calculate the level of methylation at each CpG. The Lewin algorithm also corrects for bisulfite conversion levels and aligns sequences. In contrast, Mquant quantifies methylation levels using only the T trace and thus does not require normalization or alignment. However, Inventor mainly uses sequences that are well aligned and that have high bisulfite conversion levels. The Lewin algorithm correction and alignment features allow it to use sequences that Inventor might reject for Mquant.
[0103] Inventor tested the Mquant method using different numbers of surrounding nontarget Ts (2 to 20) on either side of the target T/CpG. Inventor found few differences, although correlations with COBRA were slightly higher when using a larger number of Ts (6 to 20).
[0104] Most methods to quantify methylation target only a few sites, require laborious, specialized laboratory techniques, or require highly specialized instrumentation. Inventor used a specialized laboratory technique, COBRA, on three short sequences to show a very high correlation with the Mquant method. This method uses widely available techniques and instrumentation and should be useful in many laboratories to quantify DNA methylation levels.
[0105] While the present invention has now been described in terms of certain preferred embodiments, and exemplified with respect thereto, one skilled in the art will readily appreciate that various modifications, changes, omissions and substitutions may be made without departing from the spirit thereof. It is intended, therefore, that the present invention be limited solely by the scope of the following claims.
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48. Clement G, Braunschweig R, Pasquier N, Bosman F T, Benhattar J. Methylation of APC, TIMP3, and TERT: a new predictive marker to distinguish Barrett's oesophagus patients at risk for malignant transformation. J Pathol. 2006 January; 208(1):100-7. | A method for quantifying cytosine methylation at a particular target CpG site in DNA of a cell or organism, by performing bisulfite genomic sequencing, wherein a DNA sample extracted from a cell or organism is treated with sodium bisulfite to convert cytosine to uracil and a selected fragment of this treated DNA is amplified, performing a sequence analysis of the amplificate from an electropherogram wherein the area under a peak is measured in a plurality of peaks at either side of the target CpG site to determine the mean T area (T bar) surrounding the site, subtracting the area of the T at the target CpG site from the mean T area wherein the difference is termed delta T, and calculating the proportional level of methylation as a quotient of delta T/T bar, or as a percent value, is presented. | 2 |
FIELD OF THE INVENTION
The present invention is directed toward a substantially impermeable phone case. More specifically, the present invention is able to accommodate either a non-flip phone or a flip phone that has a hinge, and which allows use in inclement weather on or during boating or outdoor activities.
BACKGROUND OF THE INVENTION
Cellular phones have been experiencing increasing demand over the past decade. As the use of cellular phones has increased dramatically, so has the desire to use them in any location without restriction. It is well known that water, sand or other foreign debris does not mix well with electronics, including the electronics of a cellular phone. Current products exist that protect phones from water by having an enclosed plastic case that is sealable, and therefore, waterproof. This enables the user to have their phone with them when they are enjoying water sports or in any other environment where water might be present without jeopardizing the phone.
Previous products have addressed these basic problems. Specifically, Dry Paks and Gunzi Aqua Pacs by Kwik Tek are both products that provide a waterproof case for traditional non-flip phones. These products generally include a sealing member, locking mechanisms and an enclosure member. The drawback of these present products, however, is that they are only applicable with a traditional non-flip phone. Non-flip phones are phones that do not have any folding mechanism, any hinging mechanisms, or any variation thereof. Although existing products provide a reasonable solution for this certain type of phone, they do no provide a good waterproof solution for a phone with any moving parts, especially a flip phone.
A problem with these known devices is that they do not provide adequate means to operate a flip phone. A flip phone is not able to open once it is inserted in these known devices. Another option is to have the phone opened and then insert it into these devices. However, doing so subjects the flip phone to undue stresses that could potentially damage the flip phone. Doing this could also lead to an unwanted call being sent or overusing the phone battery because the flip phone must always be in the open position
A second drawback to the existing designs of these devices is that they do not provide a means for housing the antenna of phones. Antennae are a very fragile part of the phone. Especially in flip phones the antennae do not perform well under high stresses. Known devices constrain the antenna of the phone and therefore have been known to damage the antennas as well as other parts of the flip phones.
A further drawback of the existing devices is that they are not operable with any style of phone. Rather, they are designed for a single phone and thus if someone wants to upgrade their phone, they must buy a new waterproof case for that phone. This is an unnecessary burden on consumers who may want to switch their phone without switching all accessories that they owned for their previous phone.
It is therefore an aspect of the present invention to provide a waterproof flip phone case that is operable to use with any type of phone, either flip or non-flip. It is a further aspect of the invention to provide use of a phone without damaging any components of the phone while it is inside the case, and thus provide a sealable, substantially impermeable, flexible case with a transparent material that allows use of the phone while it is secured within the enclosure.
SUMMARY OF THE INVENTION
The present invention relates to a substantially waterproof flip phone device and methods of providing a waterproof enclosure for a flip phone. The selectively waterproof flip phone case generally includes a sealing member, locking mechanisms to engage and disengage the sealing member, a top enclosure, a bottom enclosure, and a hinge member. The sealing member provides access to the enclosures by disengaging and opening. The locking mechanisms can be a thumbnut, screws, clamps, or any other selective locking mechanism known in the art. Also the sealing member in one embodiment is a pair of gaskets that can be pressed together to create a fluid tight seal. However, the sealing member can also be a tooth locking arrangement, a hook and loop substantially waterproof seal or any form of watertight seal.
Once the sealing member is opened a flip phone may be placed inside the enclosure. The phone can be either a conventional non-flip phone or a flip phone that incorporates a hinge and multiple parts. When the phone is inside the case, the sealing member may be engaged by the locking mechanisms. Once engaged, the phone is inside a waterproof container and is thus safe to use underneath, or in the presence of water, or any other adverse environmental condition, which would otherwise pose a serious threat to the electronics of the phone.
In one instance of the invention, the hinge member connects the top enclosure and bottom enclosure providing a continuous waterproof case from the closed end of the top enclosure to the engaged sealing member. The hinge member allows a flip phone to be operated in both the open and closed position without damaging any part of the phone. For example, the user inserts a flip phone into the enclosures wherein a back portion of the phone goes inside one of the enclosures and the face of the phone goes inside the other enclosure. The hinge member that connects the front and back enclosures thus allows for the opening and closing motion of the flip phone while the phone is inside the waterproof case. The hinging member can be any one of a rigid hinge, a flexible hinge, a flexible material, a flexible continuation of the top and bottom enclosures or any variation thereof known in the art.
In one embodiment, the phone also includes an antenna pocket which facilitates the use of the phone without damaging the antenna. The antenna pocket can be placed anywhere on the case where an antenna of a phone might exist. For instance, with flip phones where the antenna is near the hinge of the phone, the antenna pocket would be placed near the hinge member of the case. The antenna pocket provides a space where the antenna of a phone can be extended while the phone is positioned within the case.
A further embodiment of the invention includes an interlocking member. The interlocking member is operable to connect the top enclosure and bottom enclosure when the case is in a closed state. The interlocking member can be a hook and loop material, magnets, snaps, a button, clasps, hooks or any other interconnecting means known in the art. The interlocking member ensures that while the phone is inside the case it does not open until it is desired. This helps ensure that the flip phone remains in the closed position and no undesired calls are made and the phone battery is not overused.
These and other benefits and advantages of the invention will be made apparent from the accompanying drawings and description of the drawings, as well as a detailed description of those drawings and the inventions disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
FIG. 1 is a front view of one embodiment of the closed waterproof flip phone case;
FIG. 2 is a perspective view of one embodiment of the flipped-open waterproof flip phone case;
FIG. 3 is a rear view of one embodiment of the waterproof flip phone case with flip phone inside; and
FIG. 4 is a front view of one embodiment of the flipped-open waterproof flip phone case and flip phone inside.
The following components and numbers associated thereto are shown in the drawings and provided here for ease of reference:
#
Component
10
Waterproof flip phone case
12
Sealing member
14
Locking mechanism
16
Top enclosure
18
Bottom enclosure
20
Interconnection means
22
Hinging mechanism
24
Antenna pocket
26
Hole in the sealing member
30
Flip phone
32
Antenna
34
Flip phone back
36
Flip phone face
It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the 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
While the present invention has been illustrated by description of preferred embodiments, and while the illustrated versions have been described in considerable detail, it is not the intention of the inventors to restrict or in any way limit the scope of the pending claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art upon reading this detailed description. Therefore, the invention, in its broader aspects, is not limited to these specific details, respective apparatus and methods, and illustrated samples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the inventor's general inventive concepts.
Referring initially to FIG. 1 , there is shown a waterproof flip phone case 10 . In one embodiment, the flip phone case 10 includes a sealing member 12 and a locking mechanism or locking mechanisms 14 . The locking mechanisms 14 operate to engage and disengage the sealing member 12 so that water, sand, or other foreign objects are not allowed to enter the waterproof flip phone case 10 when the sealing member 12 is engaged. The locking mechanisms 14 can be a thumbnut, screws, clamps or any other locking mechanism known in the art. Although locking mechanisms are shown, it may not be necessary to utilize them if a self-locking sealing member 12 is used. In one embodiment, the sealing member 12 is a pair of gaskets on oppositely facing clips. The clips are brought together and pressed to form a watertight seal on the open end of the case 10 . The locking mechanisms 14 act to secure the seal, but there exist other sealing mechanisms that could easily substitute for the sealing member 12 depicted that do not require a locking mechanism.
There is also provided a top enclosure 16 , and a bottom enclosure 18 . The bottom enclosure 18 is generally connected to the top enclosure 16 by a hinging mechanism 22 . The top enclosure 16 and bottom enclosure 18 are made of a flexible, substantially waterproof material in a preferred embodiment. Also, the hinging mechanism 22 can be a continuation of the top enclosure 16 and bottom enclosure 18 with a minimal surface relief on one side of the hinging mechanism 22 . The surface relief accommodates the folding of the top enclosure 16 over the bottom enclosure 18 . In another embodiment, the hinging mechanism 22 could be a set of rigid hinges connecting the top enclosure 16 and the bottom enclosure 18 . Another embodiment would have the hinging mechanism 22 simply be a continuation of the top and bottom enclosures 16 and 18 respectively but made of a slightly more flexible material that would allow for the folding motion of the flip phone. These and other arrangements of the hinge will become readily apparent to those skilled in the art after reading this description. The hinging mechanism 22 provides a means of folding the top enclosure 16 over the bottom enclosure 18 to facilitate the folding of a flip phone 30 . The hinging mechanism 22 is also able to provide a continuous opening between the top and bottom enclosures, while allowing a flip phone to open and close as it is designed to. The top enclosure 16 and bottom enclosure 18 , along with the hinging mechanism 22 , provide an enclosed environment for any phone that is placed inside the case 10 when the sealing member 12 is engaged.
In a particular embodiment, there is also provided an interconnection means 20 which may be a hook and loop material, magnets, snaps, clasps, hooks, a button, or any other interconnection means known in the art. This interconnection means 20 prevents the phone case 10 from being opened unless the user desires the phone 30 to be open. Basically, the interconnection means 20 maintains the closed state of the flip phone 30 and case 10 automatically, until it is desired to open the phone 30 .
In one embodiment, an antenna pocket 24 is provided. The antenna pocket 24 is operably connected to the top enclosure 16 and/or the bottom enclosure 18 near the hinging mechanism 22 . The antenna pocket is situated to receive an antenna of either a flip phone or a non-flip phone. The antenna pocket 24 provides a means of enclosing the entire phone 30 and its antenna 32 within the waterproof enclosure 10 . The antenna pocket 24 also allows the user to pull out the antenna of any phone and have it in the antenna pocket 24 so that it is not subjected to unnecessary stresses that could lead to breakage or damage of the antenna of a phone.
Referring now to FIG. 2 , a waterproof phone case 10 is depicted in its open state. As shown, the top enclosure 16 and the bottom enclosure 18 are connected by the hinging mechanism 22 . The antenna pocket 24 is also depicted that provides for use of the antenna 32 within the phone enclosure. There is also shown both portions of the locking mechanisms 14 . Additionally, the interconnection means 20 are shown to be disconnected so the case 10 is positioned in the flipped-open state.
As can be viewed in FIG. 3 , a phone 30 can be inserted into the top 16 and bottom 18 enclosures. The antenna pocket 24 provides adequate space for the antenna of a flip phone 32 . In one embodiment, a flip phone 30 may be provided and the front flip phone face 36 can be inserted into the top enclosure 16 and the flip phone back 34 can be inserted into the bottom enclosure 18 . There is also shown in FIG. 3 a hole in the sealing member 26 that can be used to either hold or carry the flip phone case 10 . A lanyard, belt hook, rope, string, or any other fastener may be used to run through or used with this hole in the sealing member 26 to enable the user of the flip phone case 10 to carry their phone 30 and flip phone case 10 without use of their hands.
With respect to FIG. 4 , a flip phone 30 is shown in the flip phone case 10 in an opened position. The phone front base 36 is inside the top enclosure 16 and the phone's back 34 is shown in the bottom enclosure 18 . However, the flip phone back and flip phone face could be inserted in the opposite enclosures. Mainly, the flip phone face 36 can be used in the bottom enclosure 18 and the flip phone back 34 could be placed in the top enclosure 16 . It is not necessary to have the phone 30 oriented in any one direction within the case 10 , even though there exist preferred orientations of the phone 30 .
It is not necessary to use a flip phone case in the waterproof flip phone case 10 . Rather, one aspect of the invention provides that the enclosure accommodates flip phones, non-flip phones or any other object that is desired to be kept away from water, sand, or other adverse materials.
A further embodiment of the invention uses a material for the enclosures 16 and 18 , hinging mechanism 22 , and antenna pocket 24 that is substantially impermeable to water but still allows the transmission of sound and light. The material is generally transparent so that a user can view the phone 30 while it is in the case 10 . Additionally, the user can use the phone to make a call while the phone is within the case and any sound from the speaker can be heard. Further, the receiver can pick up any sound that is made by the user.
The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing description, for example, various features of the invention are grouped together in one or more embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all the features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this detailed description, with each claim standing on its own as a separate preferred embodiment of the invention.
Moreover, the description of the invention has included descriptions of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claims, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed, and without intending to publicly dedicate any patentable subject matter. | The present invention relates to a waterproof flip phone case having a sealing member, at least two waterproof enclosures, and a hinging member that provide a waterproof environment for a phone, specifically a flip phone. In one embodiment of the invention, the sealing member includes at least one locking mechanism that is operable to engage and disengage the sealing member to allow insertion of a flip phone into the case when the member is not engaged and prevents water from entering the enclosures when the member is engaged. | 0 |
RELATED APPLICATION
This a continuation-in-part of Ser. No. 08/053,188 filed Apr. 27, 1993 for "IMPROVED FABRIC, ITS MANUFACTURE AND USES THEREOF" now U.S. Pat. No. 5,437,239.
In the above-application, a fabric, manufacture and uses thereof, are described. As a result of the manufacturing process, the completed fabric comprising three separate layers, one of which being stretchable during formation and then relaxable thereafter, to provide a natural state wherein a series of puffs are formed in rows across the layers normal to the axial stretch direction of the stretchable layer, and columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows a constant amount thereby creating an aesthetically pleasing finished fabric. It has now been discovered that if the top layer has natural resiliency such as found in velvet, silk and denim, there is sufficient volume to permit formation of puffs without the need of an interior layer.
SCOPE OF THE INVENTION
This invention relates to an improved puffed, quilt-like, smocked fabric consisting only of first and second layers stitched together in automated manner. In one aspect of the invention, the second, interior layer is fed from a roller via a positive roller driver, such second layer being biaxially stretchable such that the same undergoes elongation in the longitudinal direction between 50 to 100 percent of its normal relaxed state as a section (along with the first layer) pass a multiple stitching head of pre-selected lateral extent. The first exterior layer is not stretched but has a natural resiliency to permit formation of puffs after feeding in a position atop the second layer.
The stitching head undergoes cam controlled lateral movement as a function of longitudinal tandem movement of the first and second layers comprising the fabric of the invention to define a saw-toothed stitch pattern when viewed from the interior second layer but creating worm-like folds when viewed from the outer first layer wherein the length of each fold is a function of the normalized two values from which the arcuate amplitudes of neighboring stitch patterns vary over one-half of the section (i.e., the fabric section is equal to a cycle of the sawtoothed stitching pattern.).
DEFINITIONS
These terms are used in the specification and are defined as follows.
SMOCKING--A decorative stitching used in gathering cloth to make it hang in folds.
QUILT--To stitch together as two pieces of cloth with a soft innerlayer in lines or patterns of square, longitudinal or lateral extending lines.
FABRIC--Cloth formed by fibers by the processes of weaving, knitting, pressing etc., wherein the fibers can be formed from naturally occurring products such as wool, hair, cotton, flax, hemp or can be formed of synthetic fibers.
FIBER--The fundamental unit used in the fabrication of textile yarns and fabrics. A unit used in the fabrication of textile yarns and fabrics. A unit of matter characterized by having a length at least 100 times its diameter or width, and having definitely preferred orientation of its crystal unit cells with respect to a specific axis.
SYNTHETIC TEXTILES--A group of man-made fibers made by chemical synthesis or by chemical compounds through interaction.
STRETCH FABRICS--Cloths that have properties of elongation and recovery from using Spandex and like yarns.
STRETCH YARNS--Specially treated, synthetic continuous filament yarn. Examples: giving torque or false twist; by deforming them. Merits are rapid and near completed recovery and improved holding power.
TRIAXIAL STRETCH FABRIC--Cloths that have the ability to stretch and recover along x, y and bias axes in equalized segments, i.e., segment measurements per common length per common tensile force per x, y or bias directions are equalized.
BIAXIAL STRETCH FABRIC--Cloths that have the ability to stretch and recover along both the bias axis and one of the x or y axis is minimum.
YARN--A continuous string of textile fibers such as spun or continuous filament yarns. Spun yarn is short fibers while the latter is a grouping of endless parallel continuous filaments, its the basic material made into fabric, thread, twine or cable. It can be woven, knotted, crocheted, tatted, netted or braided depending on the result desired and the character of the yarn. Continuous filament yarns are formed of rayon, nylon and other synthetic textiles.
YARN NUMBER--A conventional measure of fineness of yarn. In spun yarns, a lower number means the heavier the yarn while a higher number refers to finer-sized yarns. Man-made fibers are measured in deniers and is the reverse of the above, viz., lower number means finer-sized yarns and vice versa.
BACKGROUND OF THE INVENTION
While various techniques are available for forming puffed fabrics, these are manufactured by batch processes using individual sewing heads wherein the layers of material pass in multiple pass fashion across the sewing heads. As a result, the final fabric is expensive and labor intensive.
In my above-identified application, I set forth a method of making a puffed fabric comprising three separate layers, one of which being stretchable during formation after which the same is permitted to relax to its natural state wherein a series of puffs are formed in rows across the layers normal to the axial stretch direction the stretchable layer, and columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows a constant amount. As a result, there is created an aesthetically pleasing finished fabric. It has now been discovered that if the top layer has a natural resiliency but still is non-stretchable such as found in velvet, silk, denim and like materials, there is sufficient volume to permit formation of folds without the need of an intermediate layer between the exterior non-stretchable layer and the interior stretchable layer. As a consequence, a lower cost yet aesthetically pleasing fabric is created.
SUMMARY OF THE INVENTION
The present invention relates to an improved puffed, smocklike quilted fabric consisting of a natural resilient first layer such as velvet, silk or denim overlaying a stretchable interior second layer. The layers are stitched together in automated manner. The second layer is a synthetic long chain polymer comprising at least 85% of a segmented polyurethane commonly called Spandex having biaxial stretching capability and is fed from a roller via positive roller driver such the second layer undergoes biaxial elongation in the longitudinal direction between 25 percent to 300 percent of its normal relaxed state with a range of 100 percent to 250 percent being preferred as a section passes through a multiple stitching head. The stitching head undergoes cam controlled lateral movement as a function of longitudinal movement of the fabric to provide a puffed, smock-like quilted fabric. The fabric is particularly well adapted for use in making garments such as coats and the like as well as a covering for burial caskets.
The biaxial stretch capacity of the second layer is normally between 600 to 700% of its relaxed state. Hence an uniform stretching force applied along the width of the layers to provide 25 to 300% is easily achieved. The second layer is preferably called by the generic name "Spandex". Spandex itself is defined as a manufactured fiber in which the fiber-forming substance is a long chin synthetic polymer comprising at least 85% of a segmented polyurethane (Source: FTC). Examples are Lycra, Glospan and Numa, all trademarked fabrics, In the manufacturing process of Lycra, a trademark of DuPont Company, the segmented polyurethane structure is achieved by reacting diisocyanates with long chain glycols which are usually polyester or polyethers of 1000 to 2000 molecular weight range. The reaction product is then chain extended through the use of glycol, diamine or water. This gives the final polymer which is converted into fibers by dry spinning. In the finished fiber the chains are randomly oriented and when stretched, the chains become oriented but exhibit spontaneous recovery to the disordered state upon release of the force acting on the fiber.
During manufacture of the fabric of the invention, the second layer formed of Spandex is wound on a roller. The roller is controlled by a driver to provide positive unrolling of the second layer to provide a substantially constant velocity relative to the driver. Such driver also provides the second layer with an uniform elongation or stretch across the width of the second layer, such elongation being between 11/4 to 3 times normal. The driver also provides uniform movement of the first (upper) layer wherein its roller is unrolled without positive braking second pressure being applied. The rollers containing the first and layers are pulled toward the multiple sewing head by the driver that contacts the first and second layers and provides inwardly directed pressure relative therebetween. The drive pressure applied to the first layer is well below its tensile strength however.
The multiple sewing head is provided with a cam assembly the provides of lateral movement of the plurality of threaded needles to provide side-by-side sinusoidal line patterns. The plurality of threaded needles are divided into a first set provided with common lateral movement through a first cam and cam follower subassembly. Between neighboring needles of the first set, there is provided a needles of the second set. Such needles is provided with opposite movement through a second cam and cam follower subassembly. As a result, its sinusoidal line pattern is complementary to line pattern of the first set. After the quilted fabric passes downstream of the driver, the second layer of Spandex is permitted to return to it relaxed state and the finished fabric is wound about a final roller. The finished fabric as viewed from the first layer in its relaxed state comprises rows of elongated puffs extending above a base line and of uniform length normal to the precursor initial stretch direction of the second layer defined during sewing. The ends of adjacent puffs of any row are crimped by stitching so that any one row of puffs resembles a string of attached wieners. Between successive rows, the crimped ends of the puffs of one row are offset relative to he crimped ends of its next adjacent neighboring row of puffs. Thus, the columns of puffs of every other row are aligned but successive columns are offset. As a result, an aesthetically pleasing fabric is formed that has be useful in making coats (the rows of puffs running in vertical manner from the neck toward the belt and sleeves) and in padding the inner walls of a casket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view illustrating the process by which present invention is performed including a series of rollers carrying thereon first and second layers in a longitudinal direction to and through a sewing head assembly, the layers being pulled in a positive sense by a positive driver positioned between a multiple sewing head and a take-up roller upon which the puffed fabric of the invention is wound;
FIG. 2 is an end view, partially cut-away, of the roller about which the second layer is wound, having a brake assembly;
FIG. 3 is a detail side view, partially schematic, of the cam assembly for providing bilateral, independent movement of the two sets of needles comprising the multiple needle head wherein sinusoidal stitching pattern is provided the layers passing adjacent to the needles head;
FIG. 4 is a plan view of the puffed fabric wound of he take up roller of FIG. 1 in which the second layer is in relaxed state:
FIGS. 5 and 6 are vertical sections taken along line 5--5 and 6--6, respectively, of FIG. 4;
FIG. 7 is bottom view of the puffed fabric of FIG. 4;
FIG. 8 is a plan view of the puffed fabric of FIG. 4 in which uniform force has been applied to provide biaxial stretch the fabric to illustrate the elongated shape of the puffs under such condition similar to that occurring at the sewing head of FIG. 1;
FIG. 9 is a bottom view of the puffed fabric of FIG. 4 in similar to that occurring in FIG. 8;
FIG. 10 is a front view of a buttoned coat constructed with the puffed fabric of the invention in which the aesthetically pleasing rows of puffs run in a vertical manner from the neck toward the belt and sleeves of the coat;
FIG. 11 is a front view of the coat of FIG. 10 unbuttoned to illustrate its lining and construction thereof;
FIG. 12 is a top view of a pillow in which the pillow covering is formed of the fabric of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates in schmatic fashion, an assembly 9 by which the process of the present invention is performed. As shown, a series of rollers 11, 12 and 13 are depicted upstream of a multiple sewing head assembly 14. Downstream from the sewing head assembly 14 are a driver roller assembly 15 and a take-up roller 16. A non-stretch layer 20 such as velvet, silk and/or denim is wound about roller 11. A biaxial stretch layer 22 is wound about roller 12. The height and position of the rollers 11 and 12 so that the layers 20 and 22 pass over the feed roller 13 in planar face-to-face relationship wherein the non-stetch layer 20 is above the biaxial stretch layer 22.
The layers 20, 22 pass between sewing head assembly 14 under positive pressure via positive drive rollers 15a, 15b of the driver roller assembly 15.
The rollers 11 and 12 are unwound via the force applied by the driver roller assembly 15 at the downstream side of the sewing head assembly 14. The roller 11 is provided with conventional tension controls for holding proper tension on the layer 20. In accordance with the present invention, the same tension must be applied to positive drive rollers 15a, 15b of the driver roller assembly 15 on take-up as is applied to the layer 20. feeding into sewing head assembly 14. Once in rotation, the roller 11 tends to rotate with a constant velocity. In this regard, the rollers 11 and 12 include a braking assembly 30 as shown in FIG. 2. The purpose of the braking assembly 30: to cause biaxial stretching of the lower layer 22 wound about roller 12 (see FIG. 1) in an amount 25 to 300% of the relaxed state of the layer 22, as previously mentioned, as well as to cause 0% elongation of the top and interior layers 20, 21. After the lower layer 22 is permitted to relax, the finished fabric 17 of the invention is wound about take-up roller 16.
FIG. 2 shows the braking assembly 30 in more detail. As shown, FIG. 2 relates to roller 12 but the description which follows is also germane to similar braking assemblies associated with the roller 11. As shown, end 31 of the roller 12 rotates within a stationary drum 32 attached to upright standard 33. The drum 32 has an end wall 34 and side wall 35 that extend adjacent to the end 31 of the roller 12. The end wall 34 includes a hub 38 that attaches to the upright standard 33. Note that the circumferencial side wall 34 extends over a portion of the circuferential surface 37 of the roller 12. An arcuate brake pad 38 is placed in contact with outer surface 37 of the roller 12 and is capable of radial movement in the direction of arrow 39 via bolts 40 having interior ends that butt against the pad 38. As shown, the bolts 40 attach to and through threaded openings (not shown) in the side wall 35 of the drum 32. Note that the tension applied by the separate brake assemblies 30 to the rollers 11 and 12 of FIG. 1 is separately adjustable. The purpose of the adjustments: to cause biaxial stretching of the lower layer 22 in an amount 25 to 300% of the relaxed state of the layer 22, as previously mentioned, as well as to cause 0% elongation of the top layer 20. Since the amount of tension at the drive roller assembly 15 for the rollers 11 and 12 is constant, the maximum braking or friction force (F) for the rollers 11 and 12 is a function of the elongation strength of the layers 20 and 22 such that such tension force (T) of the drive assembly 15 is below the ultimate strength of the layer 20 but is sufficent to provide between 25 to 300% elongation of the layer 22.
Returning to FIG. 1, while the sewing head assembly 14 is typical for the purpose of stitching the layers 20-22 together using side-by-side needle bars 49a, 49b having separate side walls 46 into which needles 47 are attached. The needle bars 49a, 49b are also controlled to undergo separate, lateral movement, however. The direction of such lateral movement is depicted by arrow 50 in FIG. 3. In addition, the needles 47 of the needle bars 49a, 49b also undergo typical vertical movement in the direction of arrow 51. As a result, thread releasably attached to the needles 47 is caused to enter the layers 20, 22 to provide typical stitching patterns 53, 54 of FIGS. 8 and 9 as viewed from the top layer 20 and bottom layer 22, respectively.
Lateral movement of the needle bars 49a, 49b is depicted in detail in FIG. 3.
As shown, the needle bar 49a has an end 55 forming a cam follower surface in contact with surface 57 of cam subassembly 58. The end 55 is provided positive surface tension via spring 60 so that the interaction of the shape of the surface 57 of the rotating cam 58a of the cam subassembly 58 provides for left-hand stitchings 53a, 54a of the patterns 53, 54 respectively shown in FIGS. 8 and 9. Returning to FIG. 3, note that needle bar 49a is open along its bottom edge 59. As a consequence the needles 47 associated with the needle bar 49a form a first set, while the needles 47 associated with the needle bar 49b forms a second set. Between neighboring needles 47 of the first set, there is a needle 47 of the second set controlled by needle bar 49b.
That is to say, the needle bar 49b has an end 64 forming a cam follower surface in contact with surface 67 of cam 68a of cam subassembly 68. The end 64 is provided positive surface tension via spring 69 so that the interaction of the shape of the surface 67 of the rotating cam 68a of the cam subassembly 68 provides for the right-hand stitchings 53b, 54b of the patterns 53, 54, respectively shown in FIGS. 8 and 9. Note in FIGS. 8 and 9 that uniform tension has been applied to the finshed fabric 17 in the direction of arrow 60 to provide biaxial stretch as the needle bars 49a, 49b move laterally to the direction of application of the tensil force (T), see FIG. 1. In addition, the seam patterns 53, 54 are seen each to be sinusoidal-like in plan view, oscillating about axes of formation 62 wherein peaks 53b, 54b and troughs 53c, 54c of side-by-side seams laterally coincide in a direction normal to arrow 60.
As a result of the relative stetching of the layer 22 as the complementary sinudoidal stitch patterns 53, 54 of FIGS. 8 and 9 are laid down, there is provided a series of improved puffs 70 of the surface of layer 20 and in layer 22 as shown in FIGS. 4 and 7, respectively. Note that in FIG. 4, the puffs 70 are shaped as shown as soon as the the pre-tensioning force in the direction of arrows 60 in FIGS. 8 and 9 are released and the layer 22 of FIG. 7 is permitted to relax as the finished fabric 17 of FIG. 1 is wound about take-up roller 17. Note that the puffs 73 appear on the surface of the layer 20 and layer 22 as shown in FIGS. 4 and 7, respectively.
FIGS. 5 and 6 are sections that illustrate the shape of the puffs 70 in more detail as viewed along columnar lines 5--5 and 6--6 of FIGS. 5 and 6, respectively.
Note in FIG. 5 that the section is taken through rows R1, R2 . . . Rx of the puffs 70 of FIG. 4 such that the section line of the odd rows R1, R3, R5 . . . passes through arcuate ends 71 of the puffs 70 of such odd rows. Thus the puffs 70 of the odd numbered rows R1, R3, . . . in FIG. 4 are columnarly aligned. Also the puffs of the even numbered rows R2, R4 . . . are columarly aligned but offset from puffs 70 of the odd numbered rows R1, R3 . . . But the section line is seen to also bisect the puffs 70 of the even rows R2, R4 . . . at maximum height h of each puff 70. As a result, the puffs 70 of the even rows R2, R4 . . . define cavities 72 between top and bottom layers 20, 22.
While the layers 20 22 forming the puffs 70 of the odd rows R1, R3 . . . follow the same contour so that the cavities 73 are of minimum volume.
Note in FIG. 6 that the section is taken through rows R1, R2 . . . Rx of the puffs 70 at a columnar location in which the height h of the puffs 70 is seen to be essentially constant from row-to-row. Moreover, the cavities 72, 73 of the rows R1, R3 . . . are of the same shape and volume. The cavities 72, 73 are formed between top and bottom layers 20, 22.
But referring again to FIG. 4, the puffs 70 of odd numbered rows R1, R3, R5 . . . are seen to be columnarly aligned. Also the puffs 70 of the even numbered rows R2, R4, R6 . . . are likewise columnarly aligned but are offset from puffs 70 of the odd numbered rows R1, R3 . . . by a constant amount, say equal to L/2 where L is the length of each puff 70.
FIGS. 10 and 11 illustrate a garment 80 in the form of a jacket comprising an outer shell 81 formed of the finished fabric 17 associated with take-up roller 16, see FIG. 1. The outer shell 81 has a pair of front panels 82, 83 attached to a waistband 79 and a rear panel 85. The rear panel 85 is attached to the front panels via shoulder seams 84. Sleeves 86 are also a component of the outer shell 81 and are attached via an arcuate set of seams 87 to the front and rear panels 82, 83 and 85. An attached collar 86, front button bands 87, 88 and inner liner 89, complete the garment 80. The collar 86 attaches to the upper edges of the front and rear panels 82, 83 and 85. The button bands 87, 88 attach vertically between the collar 86 and the waistband 79 and laterally via side edges 90 of front panels 82, 83. Note that the puffs 70 of the outer shell 81 has rows R1, R2, R3 . . . that run generally in a vertical pattern between the waistband 79 and the collar 86. As a result, the vertical line of the puffs 70 is generally slimming to the user and pleasing to the eye of the on-looker.
FIG. 12 is a top view of a pillow 92 that includes a pair of front and rear panels 93, 94 of rectangular cross section internalizing an interior filler material 95 of a conventional type such as feathers, plastic (polyethylene, polypropylene etc.). Each front and rear panel 93, 94 includes top and bottom edges 96, 97 and a pair of side edges 98. Top and bottom seams 99 and side seams 100 attach together the front and rear panels 93, 94. Note that the puffs 70 of the pillow 92 run generally parallel to the top and bottom seams 99 so as to be pleasing to the eye of the on-looker.
While preferred embodiments have been shown and described in the foregoing, it will be understood that the invention is capable of numerous modifications, rearrangements and substitutions without departing from the spirit of the invention as set forth in the appended claims. For example, the invention is capable of being carried out using a quilting machine manufactured by Edgewater Machine Company, 13-20 131st St., College Park, N.Y. wherein such machine is modified to provide correct braking of the layers of material prior to sewing and to provide correct movement of the sewing head relative to such layers as sewing occurs. | In the process of defining quilted fabric, non-stretchable, stretchable and interior layers of materials are wound on separate rollers. Then the layers are positively fed from the rollers to a bi-directional acting sewing assembly wherein the non-stretchable layer is provided with zero elongation and the stretchable layer is provided with 25 to 300 percent stretch. Next, the arranged layers are sewn in sets of sinusoidal-like seam patterns. Finally the stretched layer is permitted to relax to a natural state wherein a series of puffs are formed in rows across the layer normal to stretch direction of the stretchable layer. Result: columns of puffs of even numbered rows are aligned with each other but are laterally offset with respect to puffs of odd numbered rows by a constant amount. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a national phase entry under 35 U.S.C. §371 of International Application No. PCT/SE2010/050266 filed Mar. 9, 2010, published in English, which claims priority from Swedish Application No. 0900351-8, filed Mar. 19, 2009, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to treatment of cellulose pulp and in particular to a screening arrangement for cellulose pulp and a system and a method for screening of cellulose pulp.
BACKGROUND OF THE INVENTION
In the course of preparing a cellulose pulp to be used for further processing, such as for example in papermaking or the like, a number of “standard” operations are often performed. For chemical pulp, lignin from wood chips is dissolved in a digester in order to separate the fibers within the wood chips from each other. The cooked pulp is then transported to washing and screening devices. During cooking, not all of the wood chips are equally well digested, and the resulting pulp thus contains not only individually separated fibers, but also pieces of uncooked wood chips, knots and fiber bundles known as shives. The shives, knots and other impurities (e.g. sand, bark, etc.) still remaining in the pulp may cause problems in later stages of the pulp processing, and thus need to be removed. There are a number of well-known operations used, separately or in combination, to separate impurities from the pulp, including sedimentation, screening and vortex cleaning operations.
Screening refers to an operation in which fibers in a pulp suspension pass through a perforated plate with holes or slots, while the impurities are retained. The fraction of pulp passing the plate is referred to as the accept fraction or simply the accept. The fraction of pulp not passing through the openings of the plate is referred to as the reject fraction or simply the reject. The pulp fraction fed to the perforated plate is referred to as the inject fraction or simply the inject. An inject can thus be said to be a pulp flow about to be divided into an accept and a reject. Instead of a perforated plate, slots for separation may be created in other ways, e.g. through forming a screen basket of longitudinal bars.
In a pulp mill, there are often several screening operations at different locations throughout the process. For example, there is often a primary screening operation, in connection with the pulp being washed and dewatered, and an after-screening operation after bleaching of the pulp. Each screening operation can, and often will be, performed in several stages. One single screening apparatus is often not sufficient to separate all impurities in one stage. In order to achieve good screening efficiency, the reject flow has to be sufficiently large to make sure that the impurities not passing through the screen are removed from the screening apparatus. In case the reject flow is too small, impurities may be retained in the screening chamber where they can cause unnecessary wear to the screen. Since the reject flow must therefore be of a certain magnitude, this implies that a large number of “good” fibers (i.e. fibers that would belong to the accept) is not given enough time to pass the perforated plate or through slots between longitudinal bars, but instead becomes a part of the reject. The accept portion from the screening stage is passed to the next processing step, while the reject portion is passed to a subsequent screening stage, in order to be screened again. In order to minimize fiber losses, the accept from the subsequent screening stage is then returned to the inject of the preceding screening stage. In that way, most of the “good” fibers are recovered.
There are several different kinds of screening apparatuses. One commonly used screening apparatus is a so-called combi-screen, meaning that two or more screening stages are combined within the same screen housing. An example of such an apparatus is disclosed in European Patent No. 1,165,882, where a first screening means is located at least partly within a second screening means. Combi-screens have been developed in order to provide a cheaper process in which two different screening apparatuses are combined into one apparatus, eliminating the need for e.g. a separate knotter. There are also other kinds of multistage screens in which several screening stages are combined within the same apparatus. For example, the separate screening stages may be arranged by means of screens on top of each other, or by one high screening basket being divided into separate screening sections
While using a combi-screen, it is not possible to return the accept from a subsequent screening stage after the combi-screen to its directly preceding screening stage, such as e.g. a fine screen contained within the combi-screen. The accept portion from the subsequent screening stage (at this stage not containing any larger particles), when returned to a combi-screen, will have to pass both screening stages within the combi-screen again, which implies an unnecessary load on the coarse screen. Part of the pulp entering the coarse screen has then already been screened for larger impurities, and does not require the coarse screening stage. The return flow from the subsequent screening stage can submit to about 15-20% of the main flow into the combi-screen. This implies that the pump before the combi-screen must be dimensioned to handle a larger flow, in case the return flow is to be added before the pump. Even if the flow is added after the pump, the coarse screen still has to be dimensioned to be able to handle the larger flow. All of these measures render a more expensive process.
One object of the present invention is thus to provide an improved system and arrangement for the screening of cellulose pulp. Another object of the present invention is to achieve a more efficient way of screening while minimizing fiber losses, and at the same time keeping the number of individual screening apparatuses as low as possible, in order to minimize the total investment cost. Another object of the present invention is to provide a screening system and an arrangement where the screening means and associated equipment does not have to be overdimensioned, also in order to minimize the investment cost.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the discovery of apparatus for screening a cellulose pulp stream comprising a housing, a first screen member contained within the housing including screen openings for permitting a first predetermined accept portion to pass therethrough and for creating a first reject portion, a second screen member contained within the housing including screen openings for permitting a second predetermined accept portion to pass therethrough and for creating a second reject portion, a primary inlet for directing the cellulose pulp stream into the housing, an accept outlet for withdrawing the second predetermined accept portion from the housing, a reject outlet for withdrawing at least one of the first and second reject portions from the housing, a first screening chamber for receiving the cellulose pulp stream from the primary inlet for transfer to the first screen member, a first accept chamber for receiving the first predetermined accept portion of the cellulose pulp stream which has passed through the first screen member, a second screen chamber for directing the first predetermined accept portion of the cellulose pulp stream from the first accept chamber to the second screen member, a secondary pulp inlet for receiving a second cellulosic pulp feed stream comprising a screened cellulose pulp accept fraction and directing the second cellulose pulp feed stream to the second screen member, whereby the second predetermined accept fraction is delivered to the accept outlet. In a preferred embodiment, the screen openings in the first screen member and the second screen member have different sizes.
In accordance with one embodiment of the apparatus of the present invention, the first and second screen members are coaxially disposed within each other within the housing, and the first screen member is rotatably mounted within the second screen member.
In accordance with another embodiment of the apparatus of the present invention, the screen openings in the first screen member comprise coarse screen openings and the screen openings in the second screen member comprise fine screen openings smaller than the coarse screen openings.
In accordance with another embodiment of the apparatus of the present invention, the second cellulose pulp feed stream merges with the first predetermined accept fraction before entering the second screen member.
In accordance with another embodiment of the apparatus of the present invention, the secondary pulp inlet is disposed in the lower portion of the housing.
In accordance with another embodiment of the apparatus of the present invention, the apparatus includes a secondary pulp inlet chamber for directing the secondary cellulose pulp feed stream from the secondary pulp inlet to the second screen member. In a preferred embodiment, the secondary pulp inlet is disposed in the lower portion of the housing below the first screen member, whereby the secondary cellulose pulp feed stream flows from the secondary pulp inlet into the secondary pulp inlet chamber from below. In another embodiment, the apparatus includes a bearing unit centrally disposed within the first screen member and a stator disposed between the first screen member and the bearing unit, the secondary pulp inlet chamber being disposed between the bearing unit and the stator. In a preferred embodiment, the secondary inlet chamber and the first accept chamber are connected to each other. In yet another embodiment, the secondary inlet is disposed in the largest diameter portion of the housing.
In accordance with another embodiment of the apparatus of the present invention, the secondary pulp inlet is disposed in the upper portion of the housing. In a preferred embodiment, the housing includes a cover, and the secondary pulp inlet is disposed in the cover.
In accordance with the present invention, a system has also provided including the apparatus set forth above, as well as a separate housing including a third screen member for screening a separate cellulose pulp stream and producing a third accept portion thereby, and conduit means for passing the third accept portion to the secondary pulp inlet. In a preferred embodiment, the secondary pulp inlet includes mixing means for mixing the third accept portion with the first predetermined accept portion for feeding into the second screen member.
In accordance with the present invention, a method has also been devised for screening a cellulose pulp stream in a housing including an inlet, a first screen member including screen openings for permitting a first predetermined accept portion to pass therethrough, and a second screen member including screen openings for admitting a second predetermined accept portion to pass therethrough, the method including directing the cellulose pulp stream into the inlet in the housing, directing the cellulose pulp stream from the inlet to the first screen member, screening the cellulose pulp stream in the first screen member to produce a first accept portion of the cellulose pulp stream and a first reject portion thereof, receiving the first accept portion of the cellulose pulp stream which has passed through the first screen member, screening the first accept portion of the cellulose pulp stream in the second stream member to produce a second accept portion of the cellulose pulp stream and a second reject portion thereof, withdrawing the second accept portion from the housing, withdrawing at least one of the first and second reject portions from the housing, providing a second cellulose pulp stream comprising a screened cellulose pulp stream, and directing the second cellulose pulp stream to the second screen member. In a preferred embodiment, the method includes mixing the second cellulose pulp feed stream with the first accept portion before screening in the second screen member.
In accordance with the present invention a screening arrangement, a system and a method for screening are proposed in which a fiber fraction can be returned from at least one subsequent screening arrangement to a first screening arrangement, the first screening arrangement being an arrangement in which at least two screening stages, e.g. a coarse screen and a fine screen, are combined in one apparatus in such a way that the returned fiber fraction or fiber fractions from the at least one subsequent screening arrangement enters as inject to a second screening means (e.g. a fine screen) of the first screening arrangement and is screened only through the second screening means of the first screening arrangement.
In accordance with the present invention an arrangement for screening of cellulose pulp in several stages is proposed comprising at least two screening means within the same apparatus, where the screening means have openings for allowing certain fractions of cellulose pulp to pass through the screens. The screening means are enclosed in a housing, and the arrangement further comprises a main inlet for input of pulp to the screening arrangement, at least one outlet for output of an accept fraction of pulp from the screening arrangement, and at least one outlet for output of a reject fraction. The arrangement further comprises a first screening chamber being arranged to receive pulp from the main inlet for input of pulp, a first accept chamber arranged to receive pulp passing through a first screening means and a second screening chamber arranged to receive pulp at least from the first accept chamber before screening through a second screening means, and the screening arrangement further comprises a secondary pulp inlet for input of pulp from a subsequent screening arrangement to be screened through the second screening means.
More specifically, in accordance with the present invention a screening arrangement, a system and a method for screening are provided in which the first screening arrangement is provided with a secondary pulp inlet separated from a main pulp inlet, and the secondary pulp inlet is arranged so that pulp entering the mentioned inlet is merged with the accept fraction of the first screening means in order to form an inject to be fed to the second screening means.
According to one embodiment of the present invention, the screening means are arranged co-axially and the first screening means is rotatably arranged at least partly within the second screening means. According to another embodiment, the size of the openings of the first and second screening means are different for the respective screening means.
According to another embodiment of the present invention, the first screening means is a coarse screen and the second screening means is a fine screen with openings smaller than the first screening means, and the main inlet for input of pulp is arranged so that the pulp from the main inlet is fed to the coarse screen.
The secondary pulp inlet may be arranged in the lower part of the screen, e.g. through a gable of the screen housing. Alternatively, the secondary pulp inlet may be arranged in the upper part of the screening arrangement, e.g. arranged to go through a cover of the housing enclosing the screening means.
According to another embodiment of the present invention, a secondary pulp inlet chamber is arranged to receive the pulp entering the secondary pulp inlet. The secondary pulp inlet can be arranged below the first screening means so that, in operation, a secondary pulp flow will enter the secondary inlet chamber from below. The secondary inlet chamber may be arranged, as seen in a circumferential direction, between a bearing unit centrally placed in the screening arrangement and a stator enclosed within the first screening means.
According to another embodiment of the present invention, the secondary inlet chamber and the first accept chamber are in connection with each other.
The secondary pulp inlet may consist of a connection piece arranged to fit within the largest diameter of the screening arrangement. In that way, any extra piping or the like sticking out of the screening arrangement is avoided. The screening arrangement thus maintains a compact design.
The present invention further relates to a system comprising a first screening arrangement as described above and further at least one subsequent screening arrangement, the respective screening arrangements being arranged, during operation, to allow an accept fraction/accept fractions of at least one subsequent screening arrangement to be returned to the first screening arrangement by means of the secondary pulp inlet. Several accept fractions from different subsequent screening arrangements could thus be returned to the first screening arrangement. According to a further embodiment of the system of the present invention, the secondary pulp inlet is arranged so as to enable mixing of the accept fraction from at least one subsequent screening arrangement with the accept fraction of the first screening means of the first screening arrangement to form an inject fraction to the second screening means of the first screening arrangement.
The present invention also relates to a method for screening a cellulose pulp suspension, using the system described above, in which an accept fraction from at least one subsequent screening arrangement is returned to an inject fraction to a second screening means of a first screening arrangement by means of a secondary pulp inlet, the accept fraction from the subsequent screening arrangement being screened only through the second screening means. It is to be understood that several accept fractions from different subsequent screening arrangements could be returned, as well as only the accept fraction of a particular subsequent screening arrangement. According to an embodiment of the method of the present invention, the accept portions of at least one of the subsequent screening arrangements and the first screening stage of the first screening arrangement are mixed before entering the second screening means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention, together with further objects and advantages thereof, may best be understood by reference to the following detailed description which, in turn, refers to the appended drawings, in which:
FIG. 1 is a side, elevational, schematic cross-sectional view of a screening arrangement according to a preferred embodiment of the present invention;
FIG. 2 is a top, elevational, transverse, cross-sectional view of the screening arrangement illustrated in FIG. 1 , taken along cross-section A-A of FIG. 1 ;
FIG. 3 is a side, elevational, schematic, cross-sectional view of an alternative embodiment of the screening arrangement of the present invention;
FIG. 4 is a diagrammatic block diagram of a screening system comprising a screening arrangement as illustrated in FIGS. 1-3 ; and
FIG. 5 is a diagrammatic block diagram of another screening system comprising a screening arrangement as illustrated in FIGS. 1-3 .
DETAILED DESCRIPTION
Referring to the drawings, similar or corresponding elements will be denoted by the same reference numbers. It should be noted that, although the following description primarily refers to a combined screening arrangement in which a fine screen is located outwardly of a coarse screen, seen from the center of the screening arrangement, the teachings are also applicable to “inside-out” arrangement, i.e. where the fine screen is located on the inside of the coarse screen. Inside-out arrangements with the coarse screen located on the outside of the fine screen hence lie within the scope of the present invention. It is also to be noted that the teachings are applicable to all kinds of such combi-screens combining a coarse screen and a fine screen within the same apparatus, as well as other multi-stage screens where several screening stages are performed in the same arrangement. The teachings hereof are thus applicable irrespective of whether the multi-stage screening apparatus contains a coarse screen or not. The screening means in the different stages may, for example, be of the same kind with openings of the same size. The screening means could also be located on the same diameter, i.e. on top of each other.
The screening apparatus 100 shown in FIG. 1 comprises a screen housing 1 with an upper portion 2 and a lower portion 3 . The housing can preferably be pressurized. The lower portion 3 ends in a gable 29 which is placed on a frame 30 . In the screen housing, a first screening means 4 is arranged on a rotor means 5 which is rotatable about a rotor shaft 6 contained in a bearing unit 7 . The first screening means has a cylindrical shape and is located partially in the lower portion 3 of the screening arrangement. The first screening means 4 is arranged to rotate with the rotor means 5 . A second screening means 8 is located in the upper portion 2 of the screening arrangement 100 . The second screening means 8 is arranged coaxially with the first screening means 4 and has a greater diameter than the first screening means 4 . At least a part of the first screening means 4 is arranged within at least a part of the second screening means 8 . The first and second screening means may also be located vice versa. They may further be arranged on the same diameter, in that case none within the other but instead on top of each other.
A first screening chamber 9 is formed with a guide surface 10 being one limiting surface, outwardly in the circumferential direction, and the screening means 4 being the other, in the inward direction. The guide surface 10 is a cylindrical tubular means arranged coaxially with the first screening means 4 , having a diameter larger than the first screening means 4 so that a space is formed between the screening means and the guide surface. The guide surface 10 is arranged to extend in an upward direction so that a substantial part of the first screening means 4 is surrounded by the guiding surface. This arrangement forces the pulp flow from a main pulp inlet 11 to enter the first screening chamber mainly in the vicinity of the upper part of the first screening means 4 . In this way, a downward flow is created, which aids the reject flow since a reject from the first screening means 4 is to be taken out from the lower part of the screening arrangement through a first reject outlet 15 .
In operation, a pulp flow to be screened enters the first screening chamber 9 through the main pulp inlet 11 and the pulp is then fed towards the first screening means 4 . The pulp inlet in the illustrated embodiment is placed in the lower portion 3 of the screening arrangement, although near the middle of the screening arrangement. As previously described, the pulp is forced to flow upwardly due to the guide surface 10 in order for the pulp to enter the first screening means 4 at its uppermost location. Fibers of a size smaller than the size of the openings in the perforated screen plate pass through the screening means 4 and enter a first accept chamber 12 . The accept chamber 12 is limited by the screening means 4 and by a stator 13 located inside the screening means 4 . The stator is a stationary part, preferably cylindrical and provided with at least one pulse means 14 . The pulse means 14 are arranged upon rotation of the rotary screening means 4 to create pressure pulses for clearing the first screening means 4 . The screening is performed from the outside-in, which is preferable due to the centrifugal force preventing large and heavy particles from being in close contact with the screening means. This first screening stage can preferably perform the task of separating mainly larger impurities (e.g. knots), such a screening stage being commonly known as a knotter.
The reject portion, i.e. the particles not passing through the screen, is taken out through a reject outlet 15 . This reject portion is also denoted the coarse reject in case the first screening means is a coarse screen. The accept fraction is further fed to a second screening chamber 16 to form an inject to the second screening means 8 . The pulp passing the second screening means 8 is taken out through an accept outlet 26 while the reject portion is taken out through at least one reject outlet 27 .
A secondary pulp inlet 17 is arranged so that pulp flowing through the secondary inlet is mixed with the accept portion from the first screening means 4 before entering the second screening means 8 . The pulp entering the secondary inlet 17 consists of an accept fraction from a subsequent screening arrangement (not illustrated in this figure) in which the reject from the second screening means 8 has been screened again. The accept portion of the subsequent screening arrangement, together with the accept portion from the first screening means 4 in the screening arrangement 100 , forms the inject to the second screening means 8 . In this way, the “good fibers” contained in the reject portion from the second screening means 8 is brought back to the pulp flow moving along in the process and fiber losses are minimized.
Pulp from the secondary inlet 17 enters a secondary pulp inlet chamber 18 . The secondary pulp inlet chamber 18 is limited inwardly, as seen in the circumferential direction, by the bearing unit 7 and outwardly by the stator 13 . The secondary pulp inlet chamber 18 could also be arranged within the bearing unit 7 , with the secondary inlet 17 placed below the bearing unit. In such a case, at least one opening will be provided in the outward wall of the bearing unit for transport of the pulp towards the second screening chamber 16 . In the embodiment shown in FIG. 3 , the secondary inlet chamber 18 at least partly coincides with the second screening chamber 16 .
In a preferred embodiment of the present invention, the first screening means is a coarse screen and the second screening means is a fine screen. By the term coarse screen is meant a screen designed primarily to separate larger impurities such as knots. Typically the openings may be about 6-10 mm, normally about 8-10 mm in diameter. By the term fine screen is meant a screen designed to primarily separate skives from fibers. For a slotted fine screen, the slots may be in the range of about 0.15-0.60 mm, typically about 0.15-0.40 mm. Slots or holes may be used dependent on which process parameters are to be optimized.
In FIGS. 1 and 2 the secondary pulp inlet 17 is located in the lower portion of the screening apparatus 100 , e.g. below the gable 29 of the screen housing 1 . Preferably, the inlet consists of a connection piece adapted to fit within the largest diameter of the screening arrangement. This placement gives the advantage of eliminating any extra piping protruding from the screening arrangement. The secondary pulp inlet 17 is located in such a way that pulp flowing through the inlet is fed into the secondary inlet chamber 18 . For example, the secondary pulp inlet 17 may be arranged to have an inlet opening 19 below an opening 28 in the gable 29 of the screen housing 1 . From the secondary inlet chamber 18 the pulp is transported to the second screening chamber 16 to be passed through the second screening means 8 . In one embodiment, the secondary inlet chamber 18 and the first accept chamber 12 are connected to each other at their respective lower portions by means of a connection portion 20 , as well as at their respective upper portions by means of a second connection portion 25 . At least a part of the accept from the first screening stage in the first screening arrangement can thus flow into the secondary inlet chamber 18 from below and merge with the accept from the subsequent screening stage of the second screening arrangement (not shown). A part of the accept from the first accept chamber 12 will enter the second screening chamber 16 directly, flowing upwardly in the screening arrangement. However, due to the connection portion the flow from the first accept chamber 12 going in an upward direction will also be at least partly mixed with the flow from the secondary inlet chamber 18 before entering the second screening chamber 16 . Since the flow entering the secondary pulp inlet 17 and the flow in the first accept chamber 12 may differ in concentration, it is preferable to merge the flows before entering the second screening chamber in order to create a homogeneous flow to the second screening means 8 .
FIG. 2 illustrates a cross-section A-A of a screening arrangement according to the embodiment shown in FIG. 1 . The secondary pulp inlet 17 in this case is arranged as a connection piece comprising an outer connection flange 21 and an inner inlet opening 19 . The inlet opening 19 is in communication with the secondary inlet chamber 18 , and may also be in communication with the first accept chamber 12 . In the figure the inlet opening is placed mainly underneath the first accept chamber 12 . In this case, the first accept chamber 12 and the secondary inlet chamber 18 are in communication by means of the connection portion 20 . The flow through the secondary pulp inlet 17 thus enters the secondary inlet chamber 18 through the connection portion 20 . The inlet opening 19 may, however, be placed such that direct access is made to the secondary inlet chamber 18 .
FIG. 3 shows a screening arrangement where the secondary pulp inlet 17 is located in the cover 22 of the screen housing 1 . The accept from at least one subsequent screening arrangement is fed through the secondary pulp inlet 17 in the cover 22 of the screening housing 1 and enters the screening chamber 16 . According to this illustrated embodiment, a connection piece 23 a is arranged within the cover and pulp fed through the secondary pulp inlet 17 is mixed in the second screening chamber 16 mixed with the accept portion from the first accept chamber 12 flowing up through the rotor means 5 . The rotor means is preferably arranged with rotor pulse means 24 in order to create suction pulses to clean the second screening means 8 . Alternatively, a connection piece 23 b , located in the center of the cover 22 may be used as a secondary pulp inlet 17 . The location of the secondary pulp inlet 17 should be chosen to optimize mixing with the flow from the first accept chamber 12 in order to create a homogeneous flow to the second screening means 8 .
FIG. 4 is a block diagram showing a system comprising two separate screening arrangements in which the first screening arrangement 100 is a combined screening arrangement comprising two screening stages, a first screening stage 101 and a second screening stage 102 . Pulp is fed to the first screening arrangement as a first inject I 1 . In the first screening stage 101 , pulp is separated into a first accept portion A 1 and a first reject portion R 1 . The first reject portion R 1 is taken out of the screening arrangement to be handled separately. The first accept portion A 1 is fed within the first screening arrangement 100 to the second screening stage 102 , where it is separated into a second accept portion A 2 and a second reject portion R 2 . The second accept portion A 2 is fed forward in the processing line to the next processing step. The system further comprises a second screening arrangement 200 , which is arranged to follow subsequently upon the first screening arrangement 100 , meaning that a reject portion R 2 from the second screening stage 102 is fed as an inject 13 to the second screening arrangement 200 . The second screening arrangement 200 is normally a screen with finer slots or holes than the second screening stage 102 , or about the same. The pulp is in the second screening arrangement 200 separated into a third accept portion A 3 and a third reject portion R 3 . According to the invention, the third accept portion A 3 is returned to the first screening arrangement 100 and together with the first accept portion A 1 fed as a second inject 12 (A 1 +A 3 ) to the second screening stage 102 .
FIG. 5 is a block diagram showing a system comprising three separate screening arrangements in which the first screening arrangement 100 is a combined screening arrangement comprising two screening stages. In this embodiment, accept may also be returned from a subsequent third screening arrangement 300 . This screening arrangement is used to screen the reject portion R 1 from the first screening stage 101 of the first screening arrangement 100 . The reject portion R 1 is thus divided into an accept portion A 4 and a reject portion R 4 . The accept portion A 4 may, as illustrated, be returned to the second screening stage 102 of the first screening arrangement 100 . It is possible to return only the accept A 4 from the third screening arrangement 300 , excluding the accept A 3 from the second screening arrangement 200 , but more preferably both accepts A 3 and A 4 are returned to be screened through the second screening stage 102 of the first screening arrangement 100 .
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. | Apparatus for screening cellulose pulp streams is disclosed including first and second screens contained in a housing, and a primary inlet for directing the cellulose pulp stream into the housing, an accept outlet for withdrawing an accept portion from the housing, a reject outlet for withdrawing a reject portion from the housing, a first accept chamber for receiving the accept portion which has passed through the first screen, a second screen chamber for directing the first accept portion to the second screen, and a secondary pulp inlet for receiving a second cellulose pulp feed stream comprising a screened cellulose pulp accept fraction and directing it to the second screen whereby the second accept fraction is delivered to the accept outlet. Methods and systems for screening cellulose pulp systems are also disclosed. | 3 |
TECHNICAL FIELD
The present invention relates to toys or decorative articles, and more particularly relates to an imitation hot-air balloon.
BACKGROUND OF THE INVENTION
Hot-air ballooning has long been known as a means of air transportation and recreation. These balloons usually include a spherically-shaped nylon envelope and an basket-shaped passenger gondola suspended below the envelope. When the envelope is inflated with hot air, it provides enough buoyancy to lift the gondola.
The means for heating air to fill the envelope through a lower opening is normally provided by a natural gas or propane burner, which is positioned outside and below the balloon envelope, but has its heat exhaust port directed upwardly toward an opening provided at the bottom of the envelope. A tubular skirt typically extends downwardly from the envelope opening, and provides a means for guiding the heated air from the burner to within the envelope.
The envelopes of these balloons may display bright colors and have a high degree of aesthetic appeal. It therefore has become desirable to provide a miniature imitation hot-air balloon for toy or display purposes, which likewise has an aesthetic appeal, but does not necessarily have to include a burner, which could be potentially dangerous especially if handled by children.
U.S. Pat. No. 1,427,396 to Keith discloses a toy air ship including an elongated type balloon having various attachments including end cones and a car. United Kingdom Pat. No. 6512 to Waegemann discloses a childrens' balloon in the form of a "zeppelin"-type air ship including a cigar-shaped rubber tube surrounded by thin tissue from which various fins extend. French Pat. No. 402,983 to Mondy discloses an imitation air ship including a spherically-shaped balloon from which a gondola is suspended.
The applicants' U.S. Patent Application No. 06/858,686, hereby incorporated by reference, discloses an imitation lighter-than-air craft including an exterior envelope, a gas bag situated within the exterior envelope, and a gondola suspended below the exterior envelope and the gas bag.
Although the above-mentioned devices do simulate hot-air balloons, it may be seen that some of these devices tend to be relatively complex, and require an investment in materials and assembly time. Therefore it is desirable to provide an imitation hot-air balloon which closely simulates a true hot-air balloon, yet is simple in construction and easily assembled.
SUMMARY OF THE INVENTION
The present invention solves the above described problems in the prior art by providing an improved imitation hot air balloon. An imitation hot air balloon according to the present invention includes a conventional inflatable balloon, and also includes an imitation skirt which is secured to the neck of the balloon, and conceals the neck from normal view.
Generally described, the imitation lighter-than-air craft according to the present invention includes an inflatable balloon having a inlet valve, the inlet valve including an outwardly disposed neck, a locking disc attached to the neck, a tubular skirt having a longitudinal bore, the locking disc positioned within said bore, and means for securing said disc within said bore such that said skirt is secured to said balloon.
Thus, it is an object of the present invention to provide an improved imitation hot air balloon assembly.
It is a further object of the present invention to provide an imitation hot air balloon assembly which is aesthetically pleasing.
It is a further object of the present invention to provide an imitation hot air balloon assembly which is inexpensive and is simple to assemble.
It is a further object of the present invention to provide an imitation hot air balloon assembly with buoyant properties.
Other objects, features and advantages of the present invention will become apparent from reading the following specification when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of an imitation hot air balloon assembly according to a first preferred embodiment of the present invention, showing the skirt of the balloon assembly in partial cutaway.
FIG. 2 is a close-up view of the skirt of the balloon assembly as shown in FIG. 1.
FIG. 3 is a cutaway view of the balloon assembly of FIG. 1 along line 3--3, as viewed from above.
FIG. 4 is a close-up, partially exploded view of the balloon assembly of FIG. 1, with the gondola in partial cutaway and separated from the assembly. The assembled position of the gondola is indicated in phantom.
FIG. 5 is an isolated pictorial view of the skirt of the balloon assembly of FIG. 1, shown in partial cutaway to expose the locking ring.
FIG. 6 is a second embodiment of the present invention, positioned atop a supporting surface.
FIG. 7 is a third embodiment of the present invention, which includes an alternative gondola configuration, the skirt and gondola being shown in partial cutaway for purposes of illustration.
FIG. 8 is a forth embodiment of the present invention, which includes the use of decorative ribbons.
FIG. 9 is a fifth embodiment of the present invention, which includes the use of a tissue-type paper covering the balloon.
FIG. 10 is a sixth embodiment of the present invention, showing the integral nature of the skirt and locking disc.
DETAILED DESCRIPTION
Referring now in more detail to the drawings, in which like numerals indicate like parts throughout these several views, FIG. 1 shows an imitation hot-air balloon assembly noted generally at 10 which includes a balloon 12, a skirt 14, a locking ring 32, a locking disc 16, gondola suspension cords 18, and a gondola 20.
Referring now generally to FIGS. 2-5, the balloon 12 is capable of containing air or gas and includes a mouth 22 through which such air or gas may be introduced or exhausted. The balloon 12 also includes walls 24, and a neck 52 (see FIG. 2).
The skirt 14 is cylindrical in shape, and has an circular outer transverse cross section of diameter X (see FIG. 5) and a circular bore cross section of diameter Y (also see FIG. 5). The skirt 14 includes an outer wall surface 26, an inner wall surface 28, an upper ridge 38, and a wall of thickness t (See FIG. 5).
Within the bore of the skirt 14 is mounted a locking ring 32 rigidly attached to the interior wall 28 of the skirt by gluing or other suitable means. Referring now only to FIG. 5, the locking ring 32 has a circular outer diameter of length Y, and a circular inner diameter of length Z. As will be discussed later in this application, the locking ring 32 provides an annular shoulder within the bore of the skirt 14 which prevents the locking disc 16 from passing through the bore of the skirt 14 when the skirt and the ring are in nondeformed states, and the primary planar surfaces of the disc are normal to the bore axis of the skirt.
The locking disc 16 is planar and defines a center hole 34 (see FIG. 2) and four suspension cord holes (not shown) spaced about the outer perimeter of the disc. The locking disc 16 has a circular outer perimeter, the diameter of which is less than the inner diameter Y of the skirt, but greater than the inner diameter Z of the locking ring.
Gondola suspension cords 18 pass through the suspension cord holes defined by the locking disc 16. The upper end of each of the gondola suspension cords 18 is knotted at 36, such that the upper ends of the gondola suspension cords 18 may not pass through the corresponding holes in locking disc 16. A gondola 20 is suspended beneath the locking disc 16 by the gondola suspension cords 18.
To assemble the device, the gondola suspension cords 18 are passed through the suspension cord holes in locking disc 16, and the upper ends are knotted at 36. The lower ends of the gondola suspension cords 18 are attached to the gondola 20 in a conventional manner in the embodiment shown in FIG. 1. Air or gas, whichever is preferred, is introduced into the mouth 22 of the balloon 12 until the balloon 12 reaches a desired size. The mouth 22 is then passed through the hole 34 in the locking disc 16 and a conventional clip 40 is attached to the neck 52 of the mouth 22. It should be understood that the clip 40 is of sufficient size such that it will not pass through the center hole of the locking disc 16. As shown in FIG. 2, it may be necessary to twist the neck 52 of the balloon prior to attaching the clip 40, to insure that air or gas does not escape.
When the clip 40 is in place, the resulting assembly is as shown in FIG. 4. The skirt 14 is then moved in a direction as shown by arrows A in FIG. 4 toward an end position as shown in 14' such that the skirt conceals the locking ring.
As the locking ring 32 encounters the locking disc 16, it should be understood that either the locking disc 16 or the skirt 14 (and the attached locking ring 32) must be slightly deformed in order to allow the locking disc 16 to pass through the locking ring 32.
If it is desired to deform the locking disc 16 to allow the locking disc to pass through the locking ring 32, the locking disc 16 may be folded and tilted somewhat relative to the locking ring to allow the locking disc to pass through the locking ring. If it is desired to deform the skirt 14 and attached locking ring 32, the locking ring 32 may be deformed by pressing inwardly on opposite sides of the skirt such that the skirt and locking ring assume an oval configuration, and the locking ring may be tilted and passed through the bore of the locking ring 32. As discussed later, in the preferred embodiment these elements are readily deformable as they are made of conventional paperboard, although alternate materials such as plastics may be readily substituted.
It should be understood that both the locking disc 16, the skirt 20, and the locking ring 32 may all be simultaneously deformed during assembly as described above if desired. It should also be understood that the configuration of the balloon 12, the locking disc 16, the skirt 14, and the locking ring 32 is such that the neck 52 of the balloon is slightly stretched as the disc is drawn through the bore of the skirt and the locking ring.
After the locking disc 16 passes through the locking ring 32, the locking disc, the locking ring 32, and the skirt 14 are all allowed to assume undeformed configurations. The locking ring is then released and the tension from the neck 52 of the balloon 12 seats the locking disc 16 against a shoulder provided by the lower planar surface of the locking ring, thus allowing the skirt 14 to assume an assembled position as shown in FIGS. 1, 2, and 3.
When the skirt 14 is in its assembled position, it should be understood that the upward force exerted upon the locking disc 16 is transferred through the locking disc 16 to the skirt 14, such that the upper edge 38 of the skirt fits snugly against the outside surface of the balloon 12. This is advantageous in that the mouth 22 of the balloon is concealed by the skirt 14, yet the skirt 14 fits snugly against the lower end of the balloon, providing a realistic imitation of a true hot air balloon, in which the envelope and the gondola are normally integrally joined by a sew line.
Other embodiments of the invention are shown in FIGS. 6, 7, 8, 9 and 10. FIG. 6 shows the configuration of FIG. 1 without gondola suspension cords or a gondola. This configuration may be placed upon a typical supporting surface 50.
FIG. 7 shows an alternate gondola assembly 110 which utilizes elements similar to the skirt 14, the locking disc 16, and the locking ring 32. Gondola shell 114 is similar to the skirt 14. Gondola locking floor 116 is similar in shape to the locking disc 16. Gondola locking ring 132 is similar in configuration to locking ring 32. Likewise, the cooperating relationship between elements 114, 116, and 132 is similar to the cooperation between elements 14, 16, and 32. Finally, the assembly of elements 114, 116, and 132 is similar to the assembly of elements 14, 16, and 32, as previously discussed, except that of course a balloon is not attached to the gondola locking floor 116. The gondola assembly 110 is suspended by the suspension cords 18 which are knotted at their lower ends at 136.
The configuration of gondola assembly 110 is advantageous in that the same of similar parts used in the other parts of the balloon assembly may be used to construct the gondola assembly. This results in savings in manufacturing costs in that a minimum amount of different parts are required.
As shown in FIGS. 8 and 9, the snug fit between the skirt 14 and the balloon 12 may be used to another advantage in that decorative articles may be readily attached to the balloon assembly 10 by lodging one portion of the decorative article between the skirt and the balloon. As shown in FIG. 8, ribbons 120 may be passed over the balloon 12 and have ends secured to opposite sides of the balloon assembly 115 between the skirt 14 and the balloon. As shown in FIG. 9, the balloon assembly 125 includes a decorative sheet of tissue paper 130 or the like placed over the entire balloon and "bunched" underneath the skirt 14 such that the balloon 12 is completely concealed, and the tissue simulates an actual balloon envelope even more effectively than would the balloon. It should be understood that in this configuration, the tissue paper is held in place between the skirt 14 and the balloon 12.
Referring now to FIG. 1, as previously discussed, the balloon 12 may be filled with air, or a gas, including a lighter-than-air gas. Should the balloon 12 be filled with air, it should be understood that the assembly 10 will be heavier than air. Therefore an assembly suspension cord 55 may be attached to the top of the balloon 12 by an adhesive element 60 or other suitable means to allow the assembly 10 to be suspended from above. If it is desired to fill the balloon 12 with a lighter-than-air gas such as helium, it should be understood that by using suitably light materials for the assembly 10, and by introducing a suitable amount of lighter-than-air gas within the balloon 12, the resulting assembly may be lighter than air. A tethering cord 65 may be used to tether such a lighter-than-air craft from below.
It should be understood that when the balloon assembly is fully assembled, the configuration of the balloon 12 could be such that the upper edge 38 does not fit snugly against the balloon, and therefore, there is not a snug fit between the skirt 14 and the balloon 12. In this event, the mouth 22 of the balloon 12 could be pulled further through the hole 34 in the skirt 16, and the clip 40 could be moved further along the neck 52 of the mouth of the balloon, until the skirt 14 fits snugly against the balloon 12.
The balloon 12 of the preferred embodiment is conventional and composed of latex rubber, which may be marked with indicia on its exterior surface. Although the material of the balloon 12 in the preferred embodiment is stretchable, this is not critical. For example, a metallic or foil-type balloon could also be used. However, it should be understood that the use of such a non-stretchable material would increase the probability that the previously discussed clip adjustment along the neck of the balloon would need to be performed.
The skirt 14 of the preferred embodiment is composed of paperboard which may be marked with indicia by conventional printing processes known in the art such as photocopying. However, other lightweight material such as plastic or thin sheet metal may also be used. The material used in the skirt 14 is not critical, although it should be able to withstand the slight compressive force which is exerted by the balloon as previously discussed. Also, should it be desired to deform the skirt 14 to allow the locking disc 16 to pass the locking ring 32, a suitably flexible material should be used.
The locking disc 16 is composed of paperboard, although other lightweight material such as plastic or thin sheet metal may also be used. Should it be desired to deform the skirt 14 to allow the locking disc 16 to pass the locking ring 32, a suitably flexible material should be used.
The locking ring 32 is composed of low-density polyethylene foam, although other materials may be used. For example, such a rim may be provided by "layering" a plurality of paper strips within the skirt 14. Also, plastic or wood may be used. As discussed in material requirements for the skirt 14, should it be desired to deform the locking ring 32 to allow the locking disc to pass through the locking ring, the locking ring should be made of a suitably flexible material.
The gondola suspension cords 18, the assembly suspension cord 55, and the tethering cord 65 may be made of conventional hemp, wire, or synthetic material such as a plastic. The material construction of these cords is not critical, except that the material should be able to withstand a tension force.
The gondola 20 may be composed of paperboard, plastic, straw, or even metal.
Of course, the selection of materials may depend on whether it is desired to construct a lighter-than-air craft. If such is an not an objective, weight considerations of material is not as important.
The clip 40 is conventional. The particular clip used in the preferred embodiment is a nylon clip which may be clipped around the neck 52 of the balloon.
It should be understood that it is not critical that a clip be used around the neck 52 of the balloon 12, as it could be possible to provide a knot in the neck which is sufficient in size to prevent the mouth 22 from passing through the hole 34. It is only desirable that the mouth be sealed, and that it is not able to pass through the hole 34 in the locking disc 16.
From the detailed description above, other embodiments of the present invention will be suggested to those skilled in the art. For example, it is not necessary that the balloon 12 be spherical, as the present invention also contemplates the use of a elongate, "dirigible-shaped" balloon.
It is also not necessary that the locking ring 32 be continuous around the inside surface 28 of the skirt 14. The locking ring 32 could include one or more gaps, or may even be reduced to a series of tabs extending inwardly from the skirt, which combine to prevent the locking disc from passing through the skirt as previously discussed.
It is also not critical that the skirt be cylindrical, or that the locking ring be circular. For example, it could be possible to provide a square or rectangular skirt, and an accompanying square or rectangular locking disc substitute.
Finally, some of the elements used in the preferred embodiments may be eliminated while still remaining within the spirit and scope of the present invention. FIG. 10 shows an alternative means of attaching the locking disc 16 to the skirt 14, the use of adhesive 135. It should be understood that a different method of assembly will be required than previously described should this configuration be used. To attach the balloon 12 to the locking disc 16 in FIG. 10, the balloon is first inflated, and than the neck of the balloon is passed into the bore of the skirt and then drawn through the hole in the locking disc. The mouth 22 of the balloon 12 is then sealed as previously described. Although this assembly method may be somewhat more awkward than the previously-discussed assembly method, savings are made in material costs as there is no need for a locking ring. It should also be understood that this locking disc-skirt combination could also be fabricated out of an integral piece of material such as a plastic, for further cost savings.
As previously discussed, different types of materials may also be substituted for materials used in the preferred embodiment. Accordingly, the scope of this invention is to be limited only by the claims below. | The present invention provides an imitation lighter-than-air craft having an improved skirt and gondola. The skirt includes an attachment assembly to ensure that the skirt is snugly positioned against a conventional inflatable balloon, such that the skirt and balloon combine to imitate the envelope of a true lighter-than-air craft. Also provided is an improved gondola which utilizes elements similar or identical to those used in the skirt and attachment assemblies, resulting in savings in manufacturing costs in that a minimum number of different parts are required. | 0 |
FIELD OF THE INVENTION
[0001] The technical proposal of the invention relates to a system capable of producing and measuring electric energy, in particular to a system for power generation and accumulated measurement and capital feedback of fitness apparatuses.
BACKGROUND OF THE INVENTION
[0002] With the development of the times, the rhythm of life of people is faster and faster. People must have good physical quality in order to be adapted to modern life and also deeply understand the importance of scientific body-building. In recent years, many subdistricts are provided with outdoor fitness apparatuses in order to meet people's body-building demands. And the application scope of the outdoor fitness apparatuses is more extensive. While the outdoor fitness apparatuses play a good role in body-building, most commonly used ones available only have the function of body building but waste the chemical energy consumed by people during the exercise. Some fitness apparatuses are also connected with power generation devices, but the electric energy produced is difficult to accumulate apart from being consumed in time, and in particular, the benefits cannot be fed back to exercisers.
SUMMARY OF THE INVENTION
[0003] The invention provides a system for energy on-site collection and measurement feedback with scale effect, capable of collecting chemical energy consumed by people during the exercise, converting the chemical energy into available energy, and performing benefit feedback simultaneously.
[0004] The technical proposal adopted by the invention to solve the traditional technical problem is that: the invention relates to a system for energy on-site collection and measurement feedback, which comprises fitness apparatuses capable of producing mechanical energy, generators, power meters and energy storage accumulators, wherein the fitness apparatuses are provided with moving parts for exercise which are connected with the generators and drive the generators to generate power; the generators are connected with the accumulators through the power meters for measuring the generating capacity; and each power meter comprises a bank card reader which has function of reading and updating data. The preferred technical proposal of the invention is that: the system also comprises a data processing host; data of the power meters are transmitted to the data processing host for summarization by wireless or wired means; and bank card readers for the power meters are two-step bank card readers for registration first and read/write later.
[0005] The preferred technical proposal of the invention is that: the system comprises a keyboard which is connected with the data processing host; and the interval between registration and read/write of the bank card readers is at least 5 minutes.
[0006] The preferred technical proposal of the invention is that: the data processing host is connected with the power meters of all the fitness apparatuses on an exercise site.
[0007] The preferred technical proposal of the invention is that: the system comprises light-emitting devices which are connected with the accumulators; and the operating state of each light-emitting device is controlled by a switch.
[0008] The preferred technical proposal of the invention is that: the fitness apparatuses include shoulder rehabilitation trainers, double-seat arm wheels, single-column double-seat rotating wheels, single-column riding machines, double-seat surfboard trainers, treadmills and exercycles.
[0009] The preferred technical proposal of the invention is that: the generators are DC generators or AC generators.
[0010] The preferred technical proposal of the invention is that: the power meters are provided with display screens for data display.
[0011] The preferred technical proposal of the invention is that: the accumulators are changeable accumulators and are provided with alarm systems for full-power alarm.
[0012] The preferred technical proposal of the invention is that: the data processing host can be used for changing the password and inquiring about the power storage capacity of a specified user and corresponding currency amount thereof.
[0013] The system is provided with switch-controlled light-emitting devices such as miniature bulbs, so that the miniature bulbs can be directly switched on during the nighttime exercise, thus providing convenience for exercisers.
[0014] The power meters are provided with the display screens for data display. The total electric quantity, namely the total electric energy produced by the exercise of the exercisers, recorded in the bank cards held by the exercisers can be directly read via the display screens. If the system is arranged inside a subdistrict, some incentive methods can be set in certain cases. For example, the accumulated electric quantity can be used to get corresponding small gifts in return.
[0015] The accumulators are changeable accumulators and are provided with the alarm systems for full-power alarm. When the accumulators are charged with full power, the alarm systems can remind of the timely replacement of the full-power accumulators by a bell and the like.
[0016] The data processing host and the keyboard can be used for changing the password and inquiring about the electric storage capacity of the specified user and the corresponding currency amount thereof, thus providing convenience for user management.
[0017] The invention also provides an on-site collection and measurement feedback method, which is used for converting mechanical energy into electric energy and converting the converted electric energy into the currency amount of energy for storage. The method comprises the following steps of: inserting bank cards into the power meters; allowing the electric quantity and the currency amount of electric energy in the bank cards to be read by the power meters and displayed on the display screens; allowing the data processing host to begin data statistics; allowing the users to begin taking exercise; converting chemical energy generated by the exercise of the users into electric energy by the generators; converting the electric quantity into the currency amount of electric energy by the data processing host, and charging the currency amount of electric energy into the bank cards of the users; and determining whether the light-emitting device on the site is in full-power state, wherein if not, the light-emitting devices on the site are charged; and if so, the accumulators are charged.
[0018] The invention has the advantages that: compared with the prior art, the system for energy on-site collection and measurement feedback provided by the invention can be used for collecting the chemical energy consumed by people during the exercise, converting the mechanical energy into the available electric energy by the generators, and storing the electric energy by the accumulators. Moreover, the power meters can count and display the energy produced by the exercise of each person each time and the data processing host can summarize, display and feed back energy values produced by different apparatuses on the same site, so that the exercisers are promoted to increase interest in exercise and take exercise regularly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is an overall structure diagram of the invention;
[0020] FIG. 2 is a structure diagram of a system for energy on-site collection and measurement feedback with foot pedal trainers as dominant fitness apparatuses;
[0021] FIG. 3 is a structure diagram of a system for energy on-site collection and measurement feedback with foot pedal trainers and arm rotation trainers as dominant fitness apparatuses;
[0022] FIG. 4 is a structure diagram of a system for energy on-site collection and measurement feedback with treadmills as dominant fitness apparatuses;
[0023] FIG. 5 is a structure diagram of a system for energy on-site collection and measurement feedback with pullover trainers as dominant fitness apparatuses;
[0024] FIG. 6 is a workflow diagram of a data processing host of the invention; and
[0025] FIG. 7 is a flowchart of an energy on-site collection and measurement feedback method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Further description is given to the technical proposal of the invention with the attached embodiments:
[0027] The invention relates to a system for energy on-site collection and measurement feedback, which comprises fitness apparatuses 10 , generators 20 , power meters 30 , accumulators 40 , a data processing host 60 , a keyboard and light-emitting devices (such as miniature bulbs), wherein the fitness apparatuses 10 are provided with moving parts for exercise and can be shoulder rehabilitation trainers, double-seat arm wheels, single-column double-seat rotating wheels, single-column riding machines, double-seat surfboard trainers, treadmills and exercycles but are not limited to the exemplified fitness apparatuses 10 .
[0028] The moving parts for exercise of the fitness apparatuses are connected with the generators 20 and drive the generators 20 to generate power (the generators 20 are DC generators 20 or AC generators 20 ); the generators 20 are connected with the accumulators 40 ; and the accumulators 40 are changeable accumulators 40 and are provided with alarm systems for full-power alarm.
[0029] The power meters 30 for measuring the generating capacity are connected between the generators 20 and the accumulators 40 ; each power meter 30 comprises a bank card reader which has the function of reading and updating data; the bank card readers of the power meters 30 are two-step or interval type bank card readers for registration first and read/write later; and the interval between registration and read/write of the bank card readers is at least 5 minutes. That is to say, during the exercise, the bank cards for ID identification are used for reading/writing first; the measurement begins; and the bank cards are used for reading/writing again after the exercise, wherein the total energy produced by the exercise or the converted currency amount thereof can be stored into the cards and accumulated. If the exercise time is less than 5 minutes, the measurement this time will be zero; and if the read/write operation of the cards for the second time is forgotten after the exercise, the measurement this time will be ignored.
[0030] The power meters 30 are provided with display screens for data display; data of the power meters 30 are transmitted to the data processing host 60 for summarization by wireless or wired means; the data processing host 60 is connected with the power meters 30 of all the fitness apparatuses on a certain exercise site; and the keyboard is connected with the data processing host 60 which can be used for changing the password and inquiring about the power storage capacity of a specified user.
[0031] The light-emitting devices are connected with the accumulators 40 and controlled by switches.
[0032] The structure and the operating principle of the generators 20 are as follows:
[0033] Each generator 20 generally comprises a stator, a rotor, an end cover and a bearing.
[0034] The stator consists of a stator core, a coil winding, a stator frame and other members for fixing the parts.
[0035] The rotor comprises a rotor core (or a magnetic pole or a yoke), a winding, a retaining ring, a center ring, a slip ring, a fan and a rotating shaft.
[0036] The stator and the rotor of the generator 20 are connected and assembled through the bearing and the end cover, so that the rotor can rotate in the stator and perform magnetic line cutting movement, thus the inductive electromotive force is generated and led out via a connection terminal and connected into a circuit, consequently the current is generated.
[0037] The operating principle of the power meter is as follows:
[0038] When the power meter is connected into a circuit under test, an alternating current flows across a current coil and a voltage coil respectively; an alternating magnetic flux is generated by the two alternating currents respectively in cores of the current coil and the voltage coil; the alternating magnetic fluxes pass through an aluminum disc; and an eddy current is induced in the aluminum disc and acted upon by a force in a magnetic field, so that the aluminum disc obtains a torque (active moment) and rotates. The larger the power consumption of a load, the larger the current of the current coil; the larger the eddy current induced in the aluminum disc; and the larger the torque of the aluminum disc. That is to say, the torque is in direct proportion to the power consumption of the load. The larger the power, the larger the torque; and the faster the rotation speed of the aluminum disc. While rotating, the aluminum disc is acted upon by a braking moment generated by a permanent magnet, and the braking moment is opposite to the active torque in direction. The braking moment is in direct proportion to the rotation speed of the aluminum disc. The faster the rotation speed of the aluminum disc, the larger the braking moment. When the active moment and the braking moment achieve temporary equilibrium, the aluminum disc will be subjected to uniform rotation. The electric energy consumed by the load is in direct proportion to the revolution number of the aluminum disc. When the aluminum disc rotates, a counter is driven to indicate the electric energy consumed. The above is the simple working process of the power meter.
[0039] It shall be noted when using the power meter that: the power meter can be directly connected into the circuit for measurement in the case of low voltage (not more than 500 volts) and low current (several amperes), and cannot be directly connected into the circuit and must be matched with a voltage transformer or a current transformer in the case of high voltage or high current. As for the power meter which is directly connected into the circuit, a power meter with appropriate specification must be selected based on the voltage and the current of the load, so that the rated voltage or the rated current of the power meter is equal to or slightly more than the voltage or the current of the load. In addition, the power consumption of the load must be more than 10% of the rated value of the power meter, or the measurement will not be accurate and even the aluminum disc cannot be driven to rotate sometimes. Therefore, the power meters selected cannot be too large and cannot be too small as small power meters are easy to be burn out.
[0040] Accumulators 40 :
[0041] Accumulators are one type of batteries and have the function of storing limited electric energy which is then applied at appropriate places. The working principle of the accumulators is to convert chemical energy into electric energy.
[0042] The accumulators take lead plates filled with spongy lead as cathodes, lead plates filled with lead dioxide as anodes, and 22-28% dilute sulfuric acid as electrolyte. The electric energy is converted into the chemical energy during the charge while the chemical energy is converted into the electric energy during the discharge. During the battery discharge, metallic lead is taken as the cathode, subjected to oxidation reaction and oxidized into lead sulfate while the lead dioxide is taken as the anode, subjected to reduction reaction and reduced into lead sulfate. When the batteries are charged by direct current, lead and lead dioxide are respectively generated at two poles. After a power source is removed, the batteries are restored to the state before discharge and combined into chemical batteries. Lead accumulators 40 are batteries capable of charging and discharging repeatedly and known as secondary batteries. The voltage of the lead accumulators 40 is 2V. In general, three lead accumulators 40 are connected with each other in series in use, and the voltage of the obtained product is 6V. A 12V battery pack formed by 6 lead accumulators 40 connected with each other in series is applied to motor vehicles. After the lead accumulators 40 are used for a period of time, distilled water must be replenished to maintain the electrolyte to contain 22-28% dilute sulfuric acid.
[0043] During the practical application, the typical working process of the system for energy on-site collection and measurement feedback is as follows:
[0044] An exerciser holding a card enters into an exercise center of a subdistrict and stands in front of a treadmill to prepare for taking exercise. A rotating shaft of the treadmill is connected with a power generation device of which output is connected with accumulators 40 for energy storage and meanwhile is connected to a bank card reader. The exerciser inserts the bank card with the functions of energy storage and measurement feedback into the bank card reader connected with the treadmill first, and the reader automatically performs logon and identification operations and waits for next instruction. After the exerciser begins running, the treadmill operates and the rotating shaft thereof drives a generator 20 connected therewith to generate power which is then used for charging the accumulators 40 immediately. The charged electric quantity is measured by a power meter and converted into the current currency, for example, RMB, at the interval of one time every minute, and the standby reader is notified to write the currency into the bank card of the exerciser. As for the traditional RMB amount in the bank card, the operation is accumulative.
[0045] When the operation is performed on a machine, in view of the factors of warming-up, trial operation and the like of the exerciser, the first read-in accumulative operation of the reader acted on a card logged on for the first time can only be performed after 5 minutes, so that misoperations are reduced and invalid operations are avoided. Therefore, in the case of numerous apparatuses in a fitness center of a subdistrict, the invalid operation number can be effectively reduced; the problem that centers at the level and higher level are busy to process summarization operation is avoided; and the phenomenon that halt and the like may not occur due to invalid data operation is guaranteed.
[0046] If the first exercise of one exerciser on a machine does not reach 5 minutes and the card is fetched, the record this time is regarded as invalid by the system, which is noted in an agreement for initializing the card and recognized by a card issuer and a card holder. After the first time, the operation of accumulating every minute and writing for one time is feasible, and the accumulative total of less than one minute at the last time is write into the card at one go when the card is fetched from the reader. In the case of rest during the exercise, the operation is at the interval of one minute as long as the card is not fetched.
[0047] Exercycles and the like among the fitness apparatuses adopt the mode of rotating at the same direction and adopt the same operations with the treadmill. Moreover, there is one type of fitness apparatuses performing reciprocating movement, for example, double-seat arm wheels. In order to achieve the effect of twisting the waist during the exercise, rotating wheels rotate towards two directions alternately. And an automatic phase inverter must be additionally arranged on the front of a generator which is connected with main shafts of the rotating wheels, so that a main shaft of the generator 20 always moves towards the same direction when the rotating wheels and the main shafts rotate towards different directions, thus the phenomenon that the kinetic energy may not be wasted due to backward movement is guaranteed.
[0048] As illustrated in FIG. 6 which is a workflow diagram of the data processing host 60 of the invention, in step S 100 , the data processing host 60 is connected with the power meters 30 of a plurality of the fitness apparatuses 10 , i.e. a power meter 301 , a power meter 302 . . . a power meter 30 n, wherein each power meter 30 comprises a data and bank card reader.
[0049] In step S 102 , when the users insert the bank cards into the power meters 30 , the data processing host 60 reads the currency amount of electric energy of the power meters 30 through the bank card readers.
[0050] In step S 104 , the data processing host 60 reads the data of a plurality of the power meters 30 in turn at the interval of 5 minutes, and the data refer to the electric quantity. In step S 106 , the data processing host 60 converts the electric quantity read into the currency amount of electric energy in turn.
[0051] In step S 108 , the data processing host 60 charges the currency amount of electric energy into the bank cards of the users in turn.
[0052] As illustrated in FIG. 7 which is a flowchart of the energy on-site collection and measurement feedback method, in step S 200 , the users insert the bank cards into the power meters 30 .
[0053] In step S 202 , the electric quantity and the currency amount of electric energy in the bank cards are read by the power meters 30 and displayed on the display screens.
[0054] In step S 204 , the data processing host 60 begins data statistics.
[0055] In step S 206 , the users begin taking exercise.
[0056] In step S 208 , the generators 20 convert the chemical energy produced by the exercise of the users into the electric energy.
[0057] In step S 210 , the data processing host 60 converts the electric quantity into the currency amount of electric energy and charges the currency amount of electric energy into the bank cards of the users.
[0058] In step S 212 , the data processing host 60 determines whether the light-emitting devices on the site are in full-power state. If not, execute step S 214 , wherein the light-emitting devices on the site are charged. If so, execute step S 216 , wherein the accumulators 40 are charged.
[0059] The above content is further detailed description given to the invention with the attached specific preferred technical proposal. It should not be appreciated that the embodiments of the invention are only limited to the description. Moreover, it should be understood by those skilled in the art that various simple deductions or replacements may be made without departing from the concept of the invention and should be also within the scope of protection of the invention. | The invention relates to a system for energy on-site collection and measurement feedback, which comprises fitness apparatuses capable of producing mechanical energy, generators, power meters and energy storage accumulators, wherein the fitness apparatuses are provided with moving parts for exercise which are connected with the generators and drive the generators to generate power; the generators are connected with the accumulators through the power meters for measuring the generating capacity; and each power meter comprises a bank card reader which has function of reading and updating data. The power meters can count and display energy produced by the excise of each person each time and a data processing host can summarize energy values produced by different apparatuses on the same site, so that exercisers are promoted to increase interest in exercise and take exercise regularly. | 0 |
This is a continuation of application Ser. No. 09/173,339, filed Oct. 15, 1998, which is a continuation-in-part of application Ser. No. 08/638,321,filed on Apr. 26, 1996, now U.S. Pat. No. 5,856,768 issued on Jan. 5, 1999, which is a file wrapper continuation of application Ser. No. 08/227,974, filed on Apr. 15, 1994, now abandoned. The priority of these prior applications is expressly claimed and their disclosures are hereby incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to signal interfaces, particularly coaxial cables and cable-to-circuit transitions (i.e., interconnects) which may preferably be used to interface cryogenic components and ambient-environment components which are at temperature differences of about 50-400 K (or ° C.). The invention is particularly useful in microwave or radio frequency applications of cold electronics or circuits which include high temperature superconductor material.
BACKGROUND OF THE INVENTION
There are many benefits to having circuitry that includes superconductive material. Superconductivity refers to that state of metals and materials in which the electrical resistivity is zero when the specimen is cooled to a sufficiently low temperature. The temperature at which a specimen undergoes a transition from a state of normal electrical resistivity to a state of superconductivity is known as the critical temperature (“T c ”). The use of superconductive material in circuits is advantageous because of the elimination of resistive losses.
Until recently, attaining the T c of known superconducting materials required the use of liquid helium and expensive cooling equipment. However, in 1986 a superconducting material having a T c of 30 K was announced. See, e.g., Bednorz and Muller, Possible High T c Superconductivity in the Ba—La—Cu—O System, Z.Phys. B-Condensed Matter 64, 189-193 (1986). Since that announcement superconducting materials having higher critical temperatures have been discovered. Collectively these are referred to as high temperature superconductors (HTSs). Currently, superconducting materials having critical temperatures in excess of the boiling point of liquid nitrogen, 77 K (i.e., about −196° C. or −321 ° F.) at atmospheric pressure, have been disclosed.
HTSs have been prepared in a number of forms. The earliest forms were preparation of bulk materials, which were sufficient to determine the existence of the superconducting state and phases. More recently, thin films on various substrates have been prepared which have proved to be useful for making practical superconducting devices. More particularly, the applicant's assignee has successfully produced thin film thallium superconductors which are epitaxial to the substrate. See, e.g., Olson, et al., Preparation of Superconducting TlCaBaCu Thin Films by Chemical Deposition, Appl. Phys. Lett. 55, No. 2, 189-190 (1989), incorporated herein by reference. Techniques for fabricating and improving thin film thallium superconductors are described in the following patent and copending applications: Olson, et al., U.S. Pat. No. 5,071,830, issued Dec. 10, 1991; Controlled Thallous Oxide Evaporation for Thallium Superconductor Films and Reactor Design, U.S. Pat. No. 5,139,998, issued Aug. 18, 1992; In Situ Growth of Superconducting Films, Ser. No. 598,134, filed Oct. 16, 1990, now abandoned, and Passivation Coating for Superconducting Thin Film Device, Ser. No. 697,660, filed May 8,1991, now abandoned, all incorporated herein by reference.
High temperature superconducting films are now routinely manufactured with surface resistances significantly below 500 μΩ measured at 10 GHz and 77 K. These films may be formed into circuits. Such superconducting films when formed as resonant circuits have an extremely high quality factor (“Q”). The Q of a device is a measure of its lossiness or power dissipation. In theory, a device with zero resistance (i.e., a lossless device) would have a Q of infinity. Superconducting devices manufactured and sold by applicant's assignee routinely achieve a Q in excess of 15,000. This is high in comparison to a Q of several hundred for the best known non-superconducting conductors having similar structure and operating under similar conditions.
A benefit of circuits including superconductive materials is that relatively long circuits may be fabricated without introducing significant loss. For example, an inductor coil of a detector circuit made from superconducting material can include more turns than a similar coil made of non-superconducting material without experiencing a significant increase in loss as would the non-superconducting coil. Therefore, a superconducting coil has increased signal pick-up and is much more sensitive than a non-superconducting coil.
Another benefit of superconducting thin films is that resonators formed from such films have the desirable property of having very high-energy storage in a relatively small physical space. Such superconducting resonators are compact and lightweight.
Although circuits made from HTSs enjoy increased signal-to-noise ratios and Q values, such circuits must be cooled to below T c temperatures (e.g. typically to 77 K or lower). In addition, it is desirable to directly interface or connect these cooled HTS circuits to other components or devices that might not be cooled. Most particularly, the signals from the cooled circuits often must be coupled to electronics at ambient temperatures.
Furthermore, low temperatures must be maintained when using cryo-cooled electronics and infrared detectors. In such situations an interface to couple signals between cooled and ambient temperatures is needed.
Generally, coaxial cables are used as signal interfaces. Coaxial cables are typically made of a central signal conductor (i.e., a center or inner conductor) covered with an insulating material (e.g., dielectric) which, in turn, is covered by an outer conductor. The entire assembly is usually covered with a jacket. Such a cable is “coaxial” because it includes two axial conductors that are separated by a dielectric core.
Although coaxial cables are generally used as signal interfaces, when connecting circuits which include HTS material, one end of the connecting coaxial cable might be in contact with a circuit cooled to 77 K, and the other end might be in contact with a device at a much higher temperature (e.g., room ambient temperature is about 300 K). Standard coaxial cables are not manufactured to operate under such conditions. When standard coaxial cables are used under such conditions, the signal losses may be quite high and the heat load by thermal conduction through the cable may be quite large.
Minimizing signal losses is important because the ability to transmit signals directly affects the sensitivity and accuracy of the devices. Insertion loss is a measure of such losses due to intermediary components. In equation form, if the output wattage of a circuit is P 1 without intermediary components and P 2 with intermediary components respectively, then the insertion loss L is given by the formula
L (dB)=10log 10 ( P 1 /P 2 )
Unless such losses are minimized, the benefits of using HTS or cryo-cooled materials may be lost.
Minimizing heat load is important because cryogenic coolers used to cool the HTS circuits generally have limited cooling capacity and are relatively inefficient. For example, the best cryocoolers currently available require the supply of approximately forty watts of power to a compressor to remove or lift approximately one watt of heat load. Therefore, it is preferable to limit heat load to 0.1 Watts or less.
Although minimizing heat load is important, it is also difficult. Standard coaxial cables are fabricated by extruding or swaging metal tubing (e.g. copper, gold, aluminum, stainless steel, or silver) over a dielectric (e.g., low-loss plastic materials, polyethylene materials, or Teflon™). The thinnest extruded tubing of which applicant is presently aware is about 0.005 inches (about 0.127 mm) thick.
In addition, as described above, one of the advantages of using HTS materials in circuits for microwave systems is the elimination of resistive losses. However, the advantage of reduced resistive loss can only be fully exploited if reflection or return losses (i.e., losses due to mismatches in characteristic impedances of the components) are minimized. This is especially true for components to be used at high frequencies (e.g., mm wave).
A primary candidate for mismatch problems in circuits including HTS materials is the transition through which a coaxial cable is connected to the circuit. In general, HTS material and circuits containing the same have optimal properties in a planar configuration. However, coaxial cable is cylindrically shielded. The transition between the planar circuit and the cylindrical cable may contribute significant reflection or return losses.
The circuit bonding process may also affect the geometry of the transition between the circuit and cable. Typical cables require a transition through which the cable may be attached or bonded to a circuit. Typical coaxial cable transitions use the inner conductor of the cable suspended in air.(e.g., forming a pin) where the air acts as a dielectric. The suspended conductor may be inadvertently slightly bent during a typical bonding process. The geometry of the transition may suffer from unsatisfactory reproducibility problems because of the mechanical stability (or instability) of the pin. A further disadvantage occurs when the contact is wrapped around the inner conductor pin, unnecessarily increasing inductance.
In addition, the geometry of the transition between the circuit and cable will directly affect the ease of assembly of the device using such components. To maximize ease of assembly the packaging of HTS circuits that are cooled to cryogenic temperatures must include special input and output leads. As explained above, HTS circuits must be cooled to below T c . Generally, such cooling is achieved by holding the circuits in contact with the cold head of a cryocooler (e.g. enclosed in a vacuum dewar). To connect cooled circuits contained in a dewar, interconnection points must be provided through a wall in the dewar. Such interconnections provide large thermal conduction paths for already inefficient cryocoolers.
The prior art has failed to provide a signal interface (including a transmission cable and cable-to-circuit transition) between cryogenic components and ambient-environment components for use in radio frequency applications of cold electronics and high temperature superconductors. The prior art has also failed to provide an interface and transmission cable which exhibit low thermal conduction and low electrical losses (e.g. impedance continuity and low reflection losses), and which work over a frequency range including UHF, microwave, and low millimeter-wave frequencies (e.g. up to 40 GHz). The prior art has further failed to provide such an interface which is also mechanically stable (and, therefore, reproducible) and relatively easy to use.
SUMMARY OF THE INVENTION
The present invention comprises a signal interface (including a transmission cable and a cable-to-circuit transition) for connecting cryogenic components and ambient-environment components that are to be used in radio frequency applications of cold electronics and high temperature superconductors. In the preferred embodiment, the transmission cable of the present invention comprises an inner conductor positioned within a dielectric which has a thin outer conductor plated on its outer surface. The preferred embodiment of the cable-to-circuit transition of the present invention is also generally cylindrical and comprises an inner conductor positioned within a dielectric which has a thin outer conductor plated on its outer surface. In addition, the transition also preferably includes a semi-circular end area that provides a flat surface at least for ease of bonding the transition to a cryo-cooled circuit and for impedance matching purposes. Preferably, the components are sized so as to balance heat load through the transmission cable and transition with the insertion loss.
As is mentioned above, outer conductors for coaxial cables are generally fabricated by extruding or swaging metal tubing over a dielectric. As is also mentioned above, the thinnest extruded tubing of which applicant is presently aware is about 0.005 inches (about 0.127 mm) thick. Such extruded tubing experiences higher heat conduction than would a thinner metal tubing. For example, tubing having a thickness of 0.005 inches (about 0.127 mm) experiences a heat load which is eight times the thermal conduction of a similar tubing having a thickness of about 0.0008 inches (about 20 μ) and twenty times the thermal conduction of a similar tubing having a thickness of about 0.00024 inches (about 6 μ).
In the most preferred embodiment, the transmission cable of the present invention comprises a coaxial cryocable having a center conductor surrounded by a dielectric (e.g., Teflon™) surrounded by an outer conductor which has a thickness between about 6 and 20 microns. The heat load is preferably less than one Watt, and most preferably less than one tenth of a Watt, with an insertion loss less than one decibel. The preferred overall geometry of the preferred embodiment of the cable is generally cylindrical, although other geometries are possible (e.g. stripline, microstrip, coplanar or slotline geometries).
The present signal interface (i.e., cable and transition) exhibits low thermal conduction, low electrical losses (e.g., impedance continuity and low reflection losses), and works over a frequency range including UHF (300-3000 MHz), microwave, and low millimeter-wave frequencies (e.g., up to 40 GHz). The present signal interface also is mechanically stable, reproducible, and relatively easy to use.
In another aspect of the present invention, a push-on connector may be provided at one or both ends of the cryocable. Such push-on connectors have not previously been used in high vacuum cryogenic applications. Mating connectors may also be provided to connect the cryocable to a hermetic feedthrough and/or to the HTS circuit. The push-on connector design allows fast, simple, and repeated connection and disconnection of the cryocable from the feedthrough and/or the HTS circuit.
It is a principal object of the present invention to provide an improved signal interface.
It is also an object of the present invention to provide a signal interface that exhibits desirable electrical properties (e.g., low electrical reflection, and power losses, and impedance continuity).
It is an additional object of the present invention to provide a signal interface that is mechanically stable and readily reproducible.
It is a further object of the present invention to provide a signal interface that is easy to assemble.
It is another object of the present invention to provide a signal interface for connecting cryogenic components and ambient-environment components that are to be used in radio frequency applications of cold electronics and high temperature superconductors.
It is also the object of the present invention to select appropriate materials, thereby providing very low outgassing materials which allows the vacuum integrity to be preserved for several years.
It is also an object of the present invention to provide a hermetic feed-through from the vacuum side of a dewar to the warm side of the dewar, which also allows for the vacuum integrity to be preserved for several years.
It is yet another object of the present invention to provide a push-on connector that allows easy connection and disconnection of a cryocable from an hermetic feedthrough and/or an HTS circuit.
It is also an object of the present invention to provide a clean cryocable with no entrapped contaminants that will compromise the vacuum integrity.
It is also an object of the present invention to provide a signal interface that exhibits low thermal conduction.
It is yet another object of the present invention to provide a signal interface that exhibits low electrical losses, impedance continuity and low reflection losses.
It is still another object of the present invention to provide a signal interface that works over a frequency range including UHF, microwave, and low millimeter-wave frequencies (e.g. up to 40 GHz).
It is a further object of the present invention to provide a signal interface that includes a coaxial cryocable having a central conductor surrounded by a dielectric having an outer conductor plated on its surface.
It is also a further object of the present invention to provide a signal interface which includes a cable-to-circuit transition having a coaxial connecting end to which a coaxial cable may be attached and a flat bonding surface end to which a circuit may be bonded.
Other objects and features of the present invention will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a preferred embodiment of the cryocable of the present invention.
FIG. 2 is a plot of heat load in Watts versus outer conductor upper plating thickness in microns for coaxial cables with various outer diameters.
FIG. 3 is a plot of attenuation in decibels per 10 centimeter length versus frequency in gigahertz for coaxial cables with various outer diameters.
FIG. 4 is a cross-sectional view of an embodiment of the coaxial cryocable of the present invention having connectors on each end and of a preferred embodiment of the glass feed through of the present invention.
FIG. 5 is a cross-sectional view of an embodiment of the coaxial cryocable of the present invention having a similar connector to those shown in FIG. 4 on one end and of an embodiment of the trough line of the present invention that mates to this connector. On the other end of the cable is a fired-in glass feedthrough through which a continuous center conductor passes that continues all the way to the connector that mates with the trough line interface.
FIG. 6 is a top view of an embodiment of the trough line launch of the present invention.
FIG. 7 is a side view of the trough line launch of FIG. 6 .
FIG. 8 is a front view of the trough line launch of FIG. 6 .
FIG. 9 is a top view of a fixture for determining the sensitivity of a coaxial line's impedance.
FIG. 10 is a side view of the fixture of FIG. 9 .
FIG. 11 is a chart showing an exemplary flow for the production and assembly of a trough line of the present invention.
FIG. 12 is a perspective view of a stripline cryocable of the present invention.
FIG. 13 is a perspective view of a second embodiment of a stripline cryocable of the present invention.
FIG. 14 is a perspective view of a microstrip cryocable of the present invention.
FIG. 15 is a perspective view of a balanced microstrip cryocable of the present invention.
FIG. 16 is a perspective view of a coplanar slot line cryocable of the present invention.
FIG. 17 is a perspective view of a coplanar slot line cryocable of the present invention.
FIG. 18 is a perspective view of a first end of a flat cryocable in accordance with the present invention.
FIG. 19 is a perspective view of a second end of the flat cryocable of FIG. 18 .
FIG. 20 is a perspective view of a push-on connector in accordance with a preferred embodiment of the present invention.
FIG. 21 is a cross-sectional view of a push-on connector in accordance with a preferred embodiment of the present invention.
FIG. 21A is an end view of the push-on connector of FIG. 21 .
FIG. 22 is a cross-sectional view of the push-on connector of FIG. 21 connected to a mating receptacle and feedthrough in accordance with a preferred embodiment of the present invention.
FIG. 23 is a cross-sectional view of a feedthrough in accordance with a preferred embodiment of the present invention.
FIG. 23A is an end view of the feedthrough of FIG. 23 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 5, the preferred signal interface of the present invention comprises a cryocable 10 and a cryocable transition 20 . Like reference labels appearing in the figures refer to the same elements from figure to figure and may not be explicitly described for all of the figures. The transition 20 is preferably both co-planar and coaxial. The transition 20 may be used to transition circuitry to the cryocable 10 of the present invention or other coaxial cables as are known in the art.
The present invention provides a coaxial cryocable 10 which may be used to connect devices held at widely differing temperatures (e.g., up to temperature differences of about 50 to 400 K (° C.) (i.e., temperature differences of about 90 to 720° F.)) while minimizing signal losses and thermal conduction. As shown in FIG. 1, the present invention provides a coaxial cryocable 10 comprising an inner conductor 11 . The inner conductor 11 is a wire, preferably solid, of very low thermal conductivity which is preferably copper, gold or silver plated by electroplating to a thickness which can easily be controlled and/or varied to match the operating frequency of the system.
The cryocable 10 also comprises a dielectric 12 that is preferably, made of Teflon™ or other dielectrics that are well known in the art. The dielectric constant of Teflon™ is substantially constant from about 800 MHz through 40 GHz. The dielectric 12 is preferably an extruded tubing such as is available from Zeus Industrial Products, Inc., 501 Boulevard St., Orangeburg, S.C. 29115, U.S.A. The inner conductor 11 should fit inside the dielectric tube 12 .
The cryocable 10 further comprises an outer conductor 13 . The outer conductor 13 is preferably a copper, gold, or silver layer which is preferably formed by electroplating the outer surface of the dielectric tube 12 with the desired metal. The thickness of the outer conductor 13 may be accurately controlled by the electroplating process. Electroplating the dielectric may be accomplished by plating firms such as Polyflon Company, 35 River St., New Rochelle, N.Y. 10801, U.S.A.
In determining optimal dimensions of the inner conductor 11 , the dielectric 12 , and the outer conductor 13 the following must be considered: (1) the heat load provided by various thicknesses of outer conductor 13 and various diameters of inner conductor 11 (FIG. 2 ); and (2) the attenuation experienced by various diameters of inner conductor 11 at various operating frequencies (FIG. 3 ).
FIG. 2 shows the heat load provided by outer conductors having various diameters when the inner conductor has various diameters and when the cryocable is 5 cm long. Table 1 shows the dimensions and materials used for the cryocables from which the information for FIG. 2 was generated.
TABLE 1
INNER CONDUCTOR
OUTER CONDUCTOR
LINE
DIAMETER
MATERIAL
DIAMETER
MATERIAL
A
0.010″
COPPER*
0.0335″
COPPER
B
0.012″
COPPER*
0.040″
COPPER
C
0.017″
COPPER*
0.057″
COPPER
D
0.020″
COPPER*
0.067″
COPPER
Copper Plated CRES (Corrosion Resistant Steel)
As explained above, it is preferable to keep the heat load below 0.10 Watts. Therefore, an extrapolation of line A of FIG. 2 indicates that a cryocable 10 having an inner conductor 11 about 0.010 inches thick, should have an outer conductor 13 which is preferably no more than about 20 microns thick to keep the heat load to no more than about 0.10 Watts. As indicated by line D of FIG. 2 the maximum thickness for the outer conductor 13 of a cryocable 10 having an inner conductor 11 about 0.020 inches thick for a heat load of 0.1 Watt is preferably no more than about 7.5 microns thick.
FIG. 3 shows the attenuation or insertion loss experienced by various cryocables operating at various operating frequencies. Table 2 shows the dimensions and materials used for the cryocables which were tested for FIG. 3 . In all examples the copper plating is about 6 microns thick (i.e., 3 skin depths).
TABLE 2
INNER CONDUCTOR
OUTER CONDUCTOR
LINE
DIAMETER
MATERIAL
DIAMETER
MATERIAL
E
0.020″
COPPER
0.067″
COPPER
F
0.017″
COPPER
0.057″
COPPER
G
0.012″
COPPER
0.040″
COPPER
H
0.012″
COPPER
0.040″
CRES
I
0.0045″
SPCW**
0.015″
CRES
Silver Plated Copper Clad Steel
FIG. 3 shows that as the conductors of the cryocables get smaller and smaller the attenuation gets larger and larger. Therefore, although smaller conductors are preferred to minimize heat load (see FIG. 2 ), smaller conductors may also lead to unacceptably high insertion losses.
For microwave and radio frequency operations of cold electronics or circuits that include high temperature superconductor material a preferred operating frequency range is up to about 40 GHz. In addition, for such applications it is preferable that the attenuation amount to no more than about 0.7 dB for a 10 cm length of cryocable. Cryocables represented by lines E, F, and G, in FIG. 3, have no more than 0.7 dB attenuation when operating at 40 GHz. As explained above, the smaller cryocables have smaller thermal conduction. Therefore, the preferred cryocable is the smaller cryocable such as that represented by line G.
In addition, the ratio of the outer diameter of the inner conductor 11 (i.e., the inner diameter, ID, of the dielectric 12 ) and the inner diameter of the outer conductor 13 (i.e., the outer diameter, OD, of the dielectric) is relatively fixed, by formula, depending on the range of operating frequencies of the cryocable 10 , the impedance of the cryocable 10 , and on the dielectric constant of the dielectric 12 . For example, for an impedance of 50 Ω, the ratio of OD to ID is approximately 3.35. The desired ratio is easily calculated by those skilled in the art according to the known formula:
Z 0 =(138/E r) log 10 ( OD/ID )
wherein Z 0 is the characteristic impedance of the coaxial cable and E r is the dielectric constant. Furthermore, the sum of the ID and OD relate to the maximum voltage of operation. For example, if the sum of an ID and OD amounts to 0.12 inches, the signal will start deteriorating at about 40 GHz.
Taking into consideration all of the above, the features of the cryocable 10 of the present invention having the following dimensions. The inner conductor 11 preferably has a diameter of about 0.012 inches (i.e., 0.30 mm), and the plating on the inner conductor 11 is preferably no thicker than 20 microns. The dielectric tubing 12 preferably has an inner diameter of about 0.012 inches (i.e., 0.30 mm) and an outer diameter of about 0.040 inches (1.02 mm). To reduce thermal conductivity, the outer conductor 13 is preferably on the order of between about twenty and about six microns thick. This thickness should allow for at least a few skin depths. For example, if the plating is copper, it is preferably at least about 0.00024 inches (i.e., 6μ) which is about three skin depths thick at 1 GHz.
The coaxial cryocable 10 comprising the structure and materials described above is semirigid and can be bent slightly to facilitate connecting the cryocable 10 to components. In addition, a service loop may be provided to allow for thermal contraction of the cryocable 10 when it is cooled from a room ambient temperature of about 300 K (i.e., about 27° C. or 80° F.) to a cryogenic temperature of 77 K (i.e., about −196° C. or −321° F.).
As is explained above, a typical coaxial cable requires a transition and a typical transition comprises an inner conductor suspended in air (e.g. forming a pin) where the air acts as a dielectric for the inner conductor. As is also explained above, wire bonding reproducibility may be affected where the suspended conductor is bent during the process of attaching or wire bonding the cable to a circuit. Mechanical stability of the pin is greatly increased if the dielectric material under the pin were solid, rather than air. Bonding to the pin is easier when the pin has a flat surface to which to bond. The present invention utilizes these structures.
As shown in FIGS. 4 and 5, it is preferred that the coaxial cryocable 10 of the present invention be connectable at each end. One end of the cryocable 10 should be connectable to cold electronics or circuits containing high temperature superconductors, preferably through the cable transition 20 of the present invention which is described below and shown in FIG. 5 . The other end of the cryocable 10 should be connectable to ambient environment electronics, preferably through a connection which would maintain an hermetic vacuum seal so the cryocable 10 may be positioned within a dewar holding cooled components without providing a vacuum leak as is described below and shown in FIGS. 4 and 5.
Generally, as is explained above, circuits which must be held at cryogenic temperatures (e.g., 77 K, −196° C., −321° F.) are placed in contact with a cold plate in a vacuum dewar or similar holding device. The cryocable 10 of the present invention must be connectable through the dewar to ambient environment while maintaining the vacuum within the dewar.
As shown in FIGS. 5-8, the present invention includes a cable transition 20 that has a cylindrical portion 21 and a semi-cylindrical portion 22 . The cylindrical portion 21 includes a cylindrical inner conductor 23 , a cylindrical solid dielectric 24 , and an outer conductor 25 on the curved outer surface of the cylindrical dielectric 24 .
Also shown in FIGS. 5-8, the semi-cylindrical portion 22 includes a semi-cylindrical inner conductor 26 and a semi-cylindrical solid dielectric 27 . The semi-cylindrical inner conductor 26 and dielectric 27 form a flat exposed surface 28 . The semi-cylindrical portion 22 includes a semi-cylindrical surface 29 and an outer conductor 30 preferably plated on the curved outer semi-cylindrical surface 29 of the semi-cylindrical dielectric 27 . The outer conductors 25 and 30 provide metal surfaces that may be soldered to a metal circuit housing 31 as shown in FIG. 5 . The dielectric 24 and 27 could be made of any suitable material and is preferably made from a hard plastic such as PEEK available from Victrex® of ICI Advanced Materials, 475 Creamery Way, Exton, Pa. 19341, U.S.A.
Because the outer conductor 30 is located only on the semi-cylindrical surface 29 of the dielectric 27 , the outer conductor 30 does not completely shield the semi-cylindrical inner conductor 26 electrically. In addition, the overall dielectric constant of the dielectric surrounding the inner conductor 26 (solid dielectric 27 on one side and air on the other) will no longer be uniform. Therefore, the transition 20 will have an impedance which is a function of a dielectric constant which is somewhere between that of the two dielectrics around the inner conductor 26 (solid dielectric 27 and air).
Because air (with a dielectric constant of 1) is the dielectric for about one-half of the semi-cylinder inner conductor 26 , the effective dielectric constant of the transition 20 will be lower at the semi-cylindrical portion 22 than it is at the full cylindrical portion 21 . Therefore, it is preferable that the diameter d (shown in FIGS. 6 ) of the semi-cylindrical portion 22 be smaller than the diameter D (also shown in FIGS. 6) of the full cylindrical portion 21 . The portion of the transition 20 which is semi-cylindrical will be referred to as the cable trough line or CTL 22 , as is shown in FIGS. 6 and 7.
A small number of variables have been used to describe the transition 20 of the present invention for the purposes of devising a model. A simple model has been devised to find the impedance of each segment of the transition 20 so that dimensions could be determined for experimentation purposes. D 1 , D 2 , and D 3 respectively represent the diameters of the semi-cylindrical dielectric 27 at the cable trough line 22 , the coaxial inner conductor 23 , and the coaxial outer conductor 25 (shown in FIG. 8 ). E r represents the dielectric constant of the solid dielectric 24 in the cylindrical portion 21 and the solid dielectric 27 in the stabilized half of the semi-cylindrical or cable trough line portion 22 .
A number of dielectric materials have been considered for use as the solid dielectric 24 and 27 . There are many good candidates. The solid dielectric 24 and 27 must bond to the inner conductor 23 and 26 , and be suitable for production to small tolerances (possibly 0.001 inches or less (i.e., 0.025 mm or less)). The material is preferably grindable with conventional grinding equipment. Other requirements further narrow the list of possible dielectrics. These requirements include frequency of operation, the nature of the connection cable (and its impedance), vacuum compatibility, temperature exposures, and stability through thermal cycling. Although many materials may be used for the dielectric 24 (e.g. hard plastic such as PEEK), Table 3 below illustrates the output of the model using dense Teflon™ as the dielectric 24 .
TABLE 3
TROUGH/COAX LINE EVALUATION
TROUGH COAX LINE OUTER DIA, D 1
0.0258″
COAX INNER DIA, D 2
0.0120″
COAX OUTER DIA, D 3
0.0402″
1ST SECTION COAX REL DIEL CONST, E r
2.100
1ST SECTION COAX LINE IMPEDANCE
50.00Ω
IMPEDANCE OF TROUGH LINE
50.00Ω
TOTAL CAP/UNIT L OF TROUGH LINE
0.8959E − 10 F/m
EFFECTIVE DIEL CONST OF TROUGH LINE
1.806
TROUGH LINE RELATIVE PHASE VELOCITY
0.7442
Some of the benefits of using a material such as PEEK or Teflon™ as the dielectric include that these materials may be produced by injection molding or conventional machining and grinding of a solid piece. In addition, precise dimensions may be obtained. Thus, a transition 20 made with a PEEK or Teflon™ dielectric is easy and inexpensive to produce. The flat surface 28 of the cable trough line 22 , shown in FIGS. 5-8, provides a bonding surface which may also be produced inexpensively and in large numbers despite its small size. Therefore, the preferable material for the dielectric 24 and 27 for the transition 20 is a material such as PEEK or Teflon™.
The degree of precision necessary for the dimensions of the transition 20 must be determined for the particular material used for the dielectric 24 and 27 , with consideration of the methods used for constructing the cable trough line 22 . FIGS. 9 and 10 show a fixture 40 that may be used to determine the sensitivity of a coaxial line's impedance to the dimensions of the cable trough line 22 . K-connectors™, which are well known in the art, may be used to interface the fixture 40 with test equipment. The return loss of the fixture 40 is monitored as a fixture-trough 41 (which is to become the cable trough line 22 ) is ground down. The depth of the fixture trough 41 will be monitored as the grinding progresses so that voltage standing wave ratio (VSWR) at a given frequency can be measured as a function of depth of the trough 41 and used to prove the design dimensions. The dimensions of the fixture 40 may be determined using information such as that in Table 3.
Once dimensional specifications are determined for the dielectric 24 and 27 and inner conductor 23 and 26 (see FIG. 9 ), a method of manufacturing the transition 20 can be determined. For a solid dielectric material with a strong interface to the inner conductor 23 and 26 (such as sealing glass), a grinding process could be used once the dielectric 24 and 27 is attached to a housing. For a softer dielectric material, such as Teflon™ or PEEK, the dielectric 24 and 27 could be manufactured separate from the inner conductor 23 and 26 and used as a standard part for any variety of housings.
The transition 20 may be manufactured through a process similar to that described above for the cryocable 10 . However, before the outer conductors 25 and 30 (shown in FIGS. 5-8) are plated on the cylindrical surfaces of the dielectric 24 and 27 , the transition 20 is turned to form the portion with the smaller diameter d (see FIG. 6 ). After the portion having the smaller diameter d is formed, the outer conductors 25 and 30 may be plated on the exterior surfaces of the dielectric 24 and 27 . After the plating is completed, the portion of the transition 20 with the smaller diameter d is then ground down or chopped to form the semi-cylindrical portion 22 and the flat surface 28 of the semi-cylindrical portion 22 (shown in FIGS. 5 - 8 ).
FIG. 11 provides an exemplary flow chart for the production and assembly of a transition 20 including a cable trough line 22 using Teflon™ as the dielectric 24 and 27 material. First, as is described above, a designed is used in which a model of the transition 20 may be tested for its impedance at various dimensions. Then, the particular components may be designed. Next, the inner conductor 23 and 26 and the dielectric 24 and 27 are manufactured. Then, the inner conductor 23 and 26 and the outer curved surfaces of the dielectric 24 and 27 are plated. Finally, the inner conductor 23 and 26 is positioned in the dielectric 24 and 27 and glued, bonded, epoxied, soldered, or held by friction in place. The transition 20 is now ready to be assembled in a housing and bonded to a circuit as shown in FIG. 5 .
Coaxial connectors enable the cryocable 10 to connect to the transition 20 and/or to electronics held at ambient temperatures. FIGS. 4 and 5 show an exemplary cold housing connector 50 that provides an appropriate coaxial connection between the cryocable 10 and the transition 20 . The cold housing connector 50 includes an end receptacle or sleeve 51 which accepts both the inner conductor 11 from the cryocable 10 and the inner conductor 23 from the transition 20 (see FIG. 5 ). The inner conductors 11 and 23 may be soldered together within the end receptacle 51 . The end receptacle 51 may be provided with a spring finger contact 52 to provide a snug fit between the inner conductor 23 and the end receptacle 51 .
As shown in FIGS. 4 and 5, axially surrounding the end receptacle 51 is a dielectric 53 and axially surrounding the dielectric 53 is a metal connector housing 54 . The dielectric 53 must be sized to provide the cold housing connector 50 with the appropriate impedance (i.e., with an impedance which matches that of the cryocable 10 and the transition 20 ). One would expect that to provide the cold housing connector 50 with the appropriate impedance, the dielectric 53 would be of a larger diameter than the dielectric 12 of the cryocable 10 due to the end receptacle 51 having a larger diameter than the inner conductor 11 . The connector housing 54 is preferably made from metal and preferably acts as an outer conductor for the connector 50 .
FIGS. 4 and 5 each show an embodiment of an exemplary warm housing connector 55 that may provide an appropriate coaxial connection between the cryocable 10 and electronics held at ambient temperatures. The warm housing connector 55 shown in FIG. 4 includes an end receptacle or sleeve 56 which accepts both the inner conductor 11 of the cryocable 10 and a feed through inner conductor 57 . As is mentioned above, it is preferable that the connection between the cryocable 10 and ambient temperature electronics have a vacuum seal so, for example, the connection may extend through the wall of a vacuum dewar. The feed through inner conductor 57 shown in FIG. 4 is provided with a soldered in glass bead 58 surrounding the inner conductor 57 and thereby providing a vacuum seal. The glass bead 58 may then be attached to the wall of the dewar to provide a vacuum tight seal. The glass bead 58 has a metal outer coating to enable the glass bead 58 to be soldered into the dewar wall to thereby provide a vacuum tight seal. The inner conductors 11 and 57 may be soldered together within the end receptacle 56 . The end receptacle 56 may be provided with a spring finger contact 59 (see FIG. 4) to provide a snug fit between the inner conductor 57 and the receptacle 56 .
The warm housing connector 55 shown in FIG. 4 also includes a dielectric 60 axially surrounding the end receptacle 56 and a metal connector housing 61 axially surrounding the dielectric 60 . As with the dielectric 53 of the cold housing connector 50 described above, the dielectric 60 of the warm housing connector 55 must be properly sized to provide the connector 55 with the appropriate inductance. As with the connector housing 54 of the cold housing connector 50 described above, the connector housing 61 of the warm housing connector 55 is preferably made from metal and is preferably gold plated so it acts as an outer conductor for the connector 55 .
The warm housing connector 55 shown in FIG. 5 incorporates the inner conductor 11 of the cryocable 10 as a continuous inner conductor. The inner conductor 11 extends through a fired in glass bead 62 . The fired in glass bead 62 provides a vacuum seal between the inner conductor 11 and a metal connector housing 63 . The metal connector housing 63 may then be directly attached to the dewar housing 64 via, for example, electron beam or laser welded.
As shown in FIGS. 4 and 5, the cryocable 10 is preferably connected to the cold housing connector 50 and the warm housing connectors 55 via separate protective jacket 65 and a threaded collar 66 arrangements. The protective jackets 65 are preferably provided over a portion of the outer conductor 13 of the cryocable 10 that is to be covered by the threaded collars 66 . The protective jackets 65 protect the thin outer conductor 13 from being damaged by the connection. The threaded collars 66 preferably fit over the protective jackets 65 and by pressure contact caused by the collar 66 threadedly screwing into the housing 54 , connect the cryocable 10 to the cold housing connector 50 and the warm housing connector 55 . The threaded collars 66 provide mechanical rigidity and electrical integrity to the cryocable 10 at the connections.
The cold housing connector 50 and the warm housing connectors 55 may be provided with bolt apertures 67 (shown in FIGS. 4 and 5) to enable the cold housing connector 50 to be bolted to the circuit housing 31 and the dewar housing 64 respectively. However, as is explained above, the warm housing connector 55 shown in FIG. 5 may be directly connected to the dewar housing 64 by means other than bolting (i.e., by soldering, gluing, electron beam welding or laser welding).
Embodiments of interconnects other than a coaxial cable geometry may be used to accomplish the present invention. Specifically, the cryocable 10 may be produced as a stripline (with or without side grounds) as shown in FIGS. 12 and 13 respectively. Such stripline cryocables 10 , as are shown in FIGS. 12 and 13, would include a center conductor 11 , a surrounding dielectric 12 , and an outer conductor 13 which may completely surround the dielectric 12 as is shown in FIG. 12 or which may exist only on two sides of the dielectric 12 as is shown in FIG. 13 .
In another variation of the stripline configuration, the cryocable may be configured as a flat cryocable 100 as shown in FIG. 18 . The flat cryocable 100 is very similar to the cryocable 10 shown in FIG. 13 and likewise includes a center conductor 11 surrounded by a surrounding dielectric 12 . The dielectric 12 may be formed by two strips of dielectric, such as PTFE sandwiching the center conductor 11 . Outer conductors 13 are attached to two sides of the dielectric 12 .
One or both ends of the flat cryocable 100 may be configured as shown in FIG. 18 for attachment to a warm housing connector and /or a cold housing connector. A slot 102 is cut out of the conductor 13 and through the dielectric to expose the center conductor 11 from the top and/or bottom of the cryocable 100 (only a top slot 102 is shown in FIG. 18, with the understanding that a similar slot may be formed in the bottom of the cryocable 100 ). The method of attachment to a housing connector is described below in detail in conjunction with the description of a push-on connector.
The opposite end of the flat cryocable 100 may also be configured as shown in FIG. 18, and may additionally be fitted with a T-shaped connector 104 as shown in FIG. 19 . The T-shaped connector 104 has a bottom-plate 106 which is bonded to the conductor 13 . The T-shaped connector 104 has an access hole 108 to provide access for a connecting HTS circuit to the center conductor 11 . Two mounting holes 110 are provided for bolting the T-shaped connector 104 to a structure such as the circuit housing 31 (see FIG. 5 ).
In addition, the cryocable 10 may be produced in a microstrip configuration or a balanced microstrip configuration as is shown in FIGS. 14 and 15 respectively. Such microstrip cryocables 10 , as are shown in FIGS. 14 and 15, would include a first conductor 11 which acts as a center conductor, a dielectric 12 , and a second conductor 13 which acts as an outer conductor. The first conductor 11 of the microstrip cryocable 10 shown in FIG. 14 is smaller in size than that second conductor 13 . As shown in FIG. 15, the first and second conductors 11 and 13 of the balanced microstrip crypcable 10 are of approximately the same size.
Furthermore, the cryocable 10 may be produced in a coplanar waveguide or a coplanar slotline configuration as are shown in FIGS. 16 and 17 respectively. Such coplanar cryocables 10 , as are shown in FIGS. 16 and 17, would include a first conductor 11 which acts as a center conductor, a dielectric 12 , and a second conductor 13 which acts as an outer conductor. These cryocables 10 are coplanar because both conductors 11 and 13 are positioned on the same side of a planar dielectric 12 , as is shown in FIGS. 16 and 17. The coplanar waveguide cryocable 10 , as shown in FIG. 16, includes two-second conductors 13 that are positioned on the dielectric 12 on either side of the first conductor 11 . As shown in FIG. 17, the first and second conductors 11 and 13 of the coplanar slotline cryocable 10 are singular and lie next to each other on the dielectric 12 .
The use of stripline, microstrip, or coplanar or slotline transmission lines instead of coaxial cables does not change the mode of operation of the cryogenic cables. The basic change is that the stripline interconnects, the microstrip interconnects, and the coplanar or slotline interconnects are rectangular (rather than round as for the coaxial case described above). This means that the stripline, the microstrip, or the coplanar or slotline realization can be manufactured from standard circuit patterning and etching of thin copper conductors on a dielectric substrate (for example, RT Duroid from Rogers Corporation, 100 S. Roosevelt Ave., Chandler, Ariz. 85226, U.S.A.).
In another embodiment of the cryocable 10 shown in FIGS. 4 and 5, the warm housing connector and/or the cold housing connector may be replaced by push-on connectors 120 as shown in FIGS. 20, 21 , 21 A, 22 . Instead of the threaded connectors 50 and 55 , a push-on connector 120 may be provided at one or both ends of the cryocable 10 . The push-on connector 120 of the present invention allows faster and simpler assembly and disassembly of the cryocable 10 to the HTS circuit and/or the feedthrough than the threaded connectors 50 and 55 described above or bonded connections such as soldering or adhesive.
The push-on connector 120 disconnectably mates with a receptacle 122 as shown in FIGS. 22, 23 , 23 A. At the warm housing side of the cryocable 10 , the receptacle 122 may be housed in an ultrahigh vacuum hermetic feedthrough 124 . On the cold housing side of the cryocable 10 , the receptacle 122 may be integrated with the transition 20 , or alternatively, the receptacle 122 may be configured with another connection (not shown) which mates with the transition 20 . In the still another embodiment (not shown), an interface connector may be provided which connects the receptacle 122 to the transition 20 .
Returning to FIGS. 20, 21 , 21 A, the preferred embodiment of the push-on connector 120 will be described in detail. The push-on connector 120 comprises an outer shell 126 , which is made of an electrically conductive material, preferably BeCu as shown in FIG. 21 . The outer shell 126 has a spring-loaded locking portion 128 . The locking portion 128 preferably comprises a flared cylinder having longitudinal slots thereby forming a plurality of flexible detents 130 . For example, four slots will form four detents 130 (see FIG. 21) as shown in the end view of FIG. 21 A. The number of slots may be varied to adjust the flexibility or stiffness desired. A raised lip 132 is provided at the end of the locking portion 128 and is shaped to fit within a recess 134 (see FIGS. 22, 23 ) of the receptacle
The end of the outer shell 126 opposite the locking portion 128 is a cable connection 136 . The cable connection 136 on the push-on connector embodiment shown in FIGS. 20, 21 , 21 A, 22 is configured for attachment to the flat cryocable 100 as shown in FIGS. 18-19. It is to be understood, however, that the cable connection 136 may be configured for a coaxial cryocable as shown in FIGS. 4-5, or any other suitable cable, for example, the cables shown in FIGS. 12-15.
The cable connection 136 , as shown for the flat cryocable 100 , comprises a solid section of a cylinder 138 , the section cut just below the center axis 140 of the cylinder to create a flat ledge 142 . The flat ledge 142 effectively receives the flat cryocable 100 .
A dielectric 144 is inserted into the locking portion 128 and extends to the edge of the ledge 142 . The dielectric 144 can be made of any suitable material and is preferably made from PTFE. The dielectric 144 has a center bore which accommodates a center conductor 146 and a spring contact 148 (as shown in FIG. 21 ). The center conductor 146 and the spring contact 148 are electrically conductive and are electrically connected to each other. A portion of the center conductor 146 extends out of the dielectric 144 to form a pin 150 which is easily accessible so it can be connected to the center conductor 11 of the flat cryocable 100 .
Referring to FIGS. 22, 23 , 23 A, the push-on connector 120 is connected mechanically and electrically to the flat cryocable 100 by sliding the slotted end of the cryocable 100 onto the ledge 142 . The pin 150 of the push-on connector 120 fits into the slot 102 of the cryocable 100 such that the pin 150 sits on or over the cryocable center conductor 11 that is exposed through the slot 102 .
The cryocable center conductor 11 may be attached to the pin 150 via a ribbon wire by ultrasonic bonding, gap welding or any other suitable method. Alternatively, it may be attached directly with solder or conductive adhesive. The cryocable center conductor 11 of the cryocable 100 is attached to ledge 142 by solder or conductive adhesive.
Returning to FIG. 22, the push-on connector 120 is shown connected to a mating receptacle 122 which is shown integrated with a vacuum feedthrough 124 . Although the receptacle 122 is shown in FIGS. 22 and 23 and described herein as integrated within a vacuum feedthrough 124 , it is contemplated that the receptacle 122 may be a stand alone connector without the vacuum feedthrough 124 . For example, a similar receptacle may be used to connect the cold side of the cryocable 10 to the HTS circuit wherein there is no need for a hermetically sealed feedthrough.
As is shown in FIGS. 23 and 23A, the receptacle 122 has a body 152 , preferably formed of Kovar. The body 152 has a substantially cylindrical cavity sized to receive the locking portion 128 of the push-on connector 120 . The receptacle 122 further includes a lead-in chamfer 154 and the recess 134 shaped to receive the raised lip 132 of the locking portion 128 . Another chamfer 156 is provided to facilitate removal of the locking portion 128 from the receptacle 122 . The chamfers 154 and 156 bias the detents 130 upon insertion and removal of the push-on connector 120 from the receptacle 122 .
The feedthrough 124 further comprises a dielectric 158 bonded to the body 152 in a manner which provides a high vacuum tight seal between the dielectric 158 and the body 152 . The dielectric is preferably made of glass, for example Corning 7052. Suitable glass-to-metal (e.g., Kovar to Corning 7052) sealing techniques are described in E. B. Shand, Glass Engineering Handbook , 2nd Edition, McGraw-Hill Book Co., copyright 1958, which is hereby incorporated herein by reference. Such techniques have not previously been applied in high frequency electronics applications. A feedthrough center conductor 160 is bonded within the dielectric. 158 using a vacuum tight sealing method.
The feedthrough 124 may be attached to the dewar housing 64 in a manner providing a vacuum tight seal between the body 152 and the housing 64 , via, for example, electron beam welding, laser welding, or other known suitable methods. The body 152 of the receptacle 122 may be provided with a groove 162 to facilitate welding of the feedthrough 124 to the wall of the dewar housing 64 . Suitable sealing methods are well-known in the art and therefore, they are not described in detail herein. In a preferred embodiment, the feedthrough 124 has a leak rate of less than 1.0×10 −14 cc/second for Helium.
As with the threaded connectors 50 and 55 described above, the components of the push-on connector 120 are configured to be impedance matched to the cryocables 10 and 100 , the transition 20 , and the feedthrough 124 , as the case may be. This may be accomplished by approximately matching the ratios of the diameters of the respective conductors and dielectrics at each of the interfaces between the push-on connector 120 , the cryocables 10 and 100 , and the feedthrough 124 . For example, at the interface between the push-on connector 120 and the feedthrough 124 , the diameter of the dielectric 144 of the connector 120 should be larger than the diameter of the dielectric 158 of the feedthrough 124 because the spring contact 148 has a larger diameter than the feedthrough center conductor 160 .
The method of connecting the push-on connector 120 to the receptacle 122 and feedthrough 124 is quite simple. The lip 132 of the locking portion 128 of the connector 120 is first aligned with the lead-in chamfer 154 of the receptacle 122 . As the connector 120 is pushed into the receptacle 122 , the lead-in chamfer 154 forces the flexible detents 130 inward, thereby allowing the connector 120 to be further inserted. As the connector 120 is further inserted, the spring contact 148 receives the feedthrough center conductor 160 . Upon full insertion, the raised lip 132 reaches the recess 134 and the detents 130 expand outward radially such that the raised lip 132 locks into the recess 134 as shown in FIG. 22 . The connector is disconnected by simply pulling the connector 120 out of the receptacle 122 .
While embodiments of the present invention have been shown and described, various modifications may be made without departing from the scope of the present invention, and all such modifications and equivalents are intended to be covered. | An electrical interconnect provides a path between cryogenic or cryocooled circuitry and ambient temperatures. As a system, a cryocable 10 is combined with a trough-line contact or transition 20 . In the preferred embodiment, the cryocable 10 comprises a conductor 11 disposed adjacent an insulator 12 which is in turn disposed adjacent another conductor 13 . The components are sized so as to balance heat load through the cryocable 10 with the insertion loss. In the most preferred embodiment, a coaxial cryocable 10 has a center conductor 11 surrounded by a dielectric 12 (e.g. Teflon™) surrounded by an outer conductor 13 which has a thickness between about 6 and 20 microns. The heat load is preferably less than one Watt, and most preferably less than one tenth of a Watt, with an insertion loss less than one decibel. In another aspect of the invention, a trough-line contact or transition 20 is provided in which the center conductor 11 is partially enveloped by dielectric 12 to form a relatively flat portion 28 . The preferred overall geometry of the preferred embodiment of the cable is generally cylindrical, although other geometries are possible (e.g., stripline, microstrip, coplanar or slotline geometries). In a further aspect of the present invention, a push-on connector 120 is provided to facilitate connection and disconnection of the cryocable from an HTS circuit and/or a mating feedthrough 124. | 8 |
FIELD OF THE INVENTION
The invention relates to a sheet and a molded object made from a thermoplastic material based on polyurethanes, also comprising at least one further modifying polymer or elastomer or combinations thereof and, optionally, comprising further additives.
BACKGROUND OF THE INVENTION
A sheet of the type of the present invention is disclosed by German Auslegeschrift 40 18 716. It is manufactured using a rubber-elastic mixture of special Shore A hardness of less than 85 which can be processed thermoplastically, and contains a thermoplastic polyurethane elastomer (TPU) and an ethylene/vinyl acetate copolymer (EVA). The vinyl acetate (VA) content of the EVA is taught to be between 78 and 95% by weight. In the rubber-elastic mixture there should be 50 to 99% by weight of TPU and 1 to 50% by weight of EVA, wherein the sum of the percentages is equal to 100%. The mixture is used to produce molded objects and sheets which are soft and elastic, and are readily processed (that is, without sticking), yet they also have a high strength, a good elongation at break, a high abrasion resistance, and show little swelling in fuels and lubricants.
The VA content of the EVA materials which are presently commercially available is of the order of 40 percent by weight. These materials can be calendered. If such an EVA is used in a thermally-processible mixture in accordance with the information of the German Auslegeschrift 40 18 716, the resulting mixture cannot readily be processed into sheets by calendering because the melt strength is too low. Moreover, calendering of this mixture results in a sheet with unacceptable sticking qualities.
It is therefore an object of the invention to develop an improved thermoplastic material having the desirable properties of the material of German Auslegeschrift 40 18 716, as well as having the capability of being processed into sheets, for example, by calendering.
SUMMARY OF THE INVENTION
According to the present invention, a thermoplastic material more easily processed is produced by the use of a pure polyvinyl acetate in place of EVA in the compositions of the prior art. The processing qualities are also improved by the addition of a flow modifier to the thermoplastic material composition. Therefore, the thermoplastic material of the present invention comprises, in addition to component A, a thermoplastic polyurethane, and component B, a polyvinyl acetate, a component C, a flow modifier in the form of a further thermoplastic material, such as an elastomer-modified thermoplastic material or a rubber or mixtures thereof. There is about 10 to 35 parts by weight of component B and about 1 to 50 parts by weight of component C per about 100 parts by weight of component A.
DETAILED DESCRIPTION OF THE INVENTION
Within the scope of the invention, the concept "thermoplastic material" shall have the widest possible meaning. It is to include, for example, mixtures of thermoplastic synthetic resins, polymer blends, polymer alloys or graft copolymers and similar compositions. Within the scope of the invention, thermoplastic polyurethane can be used, including the thermoplastic polyurethanes which are described in the German Auslegeschrift 40 18 716, that is, the products which are described as "TPU" in this Auslegeschrift. Preferred conventional thermoplastic polyurethanes, as well as of those with elastomeric properties, are those which contain as polyols, either linear polyether diols or linear polyether diols, and those which contain polyester diols or slightly branched polyhydroxy compounds having a functionality of at least 2. For calendering, extruding, and similar treatments, thermoplastic polyether-polyester polyurethanes or mixtures thereof have proven to be particularly advantageous. These predominantly aliphatic, aromatic, or combinations thereof of polyether-polyester polyurethanes are derived preferably from hexamethylene glycol (hexamethylene ether), from polyesters of adipic acid and butylene glycol, or from isophorone diisocyanate and hexylene glycol. The polyurethanes are polycondensed and can be subsequently compounded in a suitable mixer to the desired alloys or mixtures. For about 40 to 60 percent by weight of ether, about 60 to 30 percent by weight of ester is required, in addition to about 10 to 20 percent by weight of urethane. It is advantageous to mix or alloy the TPU, described above, with various other aliphatic, aliphatic, or aromatic TPUs or combinations thereof.
The present invention deviates from the above-described state of the art in that, within the scope of the invention, pure polyvinyl acetate is used instead of EVA. Preferably, this has a Kraemer-Sarnow-Nagel softening range between 92° and 220° C., that is, for example, between 92° and 94° C. or between 195° C. and 201° C., and a K value according to DIN 53 726 (1% acetone at +20° C.) from about 40 to 120.
Essential to optimizing the properties of the inventive sheet or molded object is the inclusion of the above-described component C in the form of a thermoplastic modifier, an elastomer-modified thermoplastic material or a rubber or combinations thereof. The modifier serves to adjust the melt strength and melt viscosity, the tenacity, the ability to calender the material, the ability to extrude the material and other similar properties. It can, however, also adversely effect the resistance to chemicals and solvents, the wetting properties, and the ability to glue or weld the material. In some cases, the miscibility and compatibility of the individual components in the multiphase system must also be considered when designing the compositions. However, these relationships are well known to those of ordinary skill so such adjustments would not require an undue amount of experimentation, especially given the quantitative and qualitative guidelines of the present disclosure. Through the well-directed choice of modifier, a whole series of molding compositions with the desired properties can be produced, such as a high elongation at break, a high abrasion resistance, and low swelling in fuels and lubricants. Rubber-like modifiers can additionally serve as internal or external plasticizers, while hard thermoplastic materials are suitable as internal or external reinforcing components.
The thermoplastic modifier also affects the flow and processing properties. For calendering, thermoplastic materials with a softening range of 152° to 210° C. and a melt index (235° C./1 kg)of 1 to 7 g/10 minutes are preferred. For extrusion, thermoplastic materials with a melt index of 1.5 to 15 g/10 minutes are particularly suitable. Particularly preferred are fuel- and mineral oil-resistant thermoplastic materials, such as nylon 6, nylon 12, nylon 66, nylon 69, polyether block amides, polyacrylonitriles, or other such resistant materials well known in the prior art. If a nylon material is selected, then those which have a mass average molecular weight (MW) of more than 18,000 and an elongation at break of at least 150% are preferred. Additionally, the materials are preferably filled with hydrophobic fillers, such as silica, potassium aluminum silicate, calcium carbonate or other fillers well known in the prior art. The addition of fillers improves, for example, the calendering properties of nylon 6, as well as its resistance to the action of oils, fats, fuels, and other such solvents.
Component C can also be an elastomer-modified thermoplastic material. According to the present invention, the concept of "elastomer modified thermoplastic material" includes a plurality of compounds. Preferably an elastomer-modified styrene copolymer is used as the elastomer-modified thermoplastic material, particularly an elastomer-modified styrene-acrylonitrile (SAN) copolymer. Of these, rubber-grafted SAN copolymers, which are grafted with an acrylate ester or ethylene-propylene diene monomer (EDPM) rubber, are preferred. Further, particularly suitable elastomer-modified styrene copolymers are styrene-ethylene-butadiene (hydrogenated) styrene or styrene-ethylene-propylene block copolymers and combination thereof. Furthermore, polycaprolactone, ethylene-vinyl acetate copolymers, polyvinyl acetate or ethylene-vinyl acetate-carbon monoxide terpolymer and combinations thereof are also suitable.
Component C can also be a rubber, a pre-cross- linked rubber or combinations thereof. In particular, rubbers which are resistant to the effect of fuel and oil, such as an acrylonitrile-butadiene copolymer (NBR), an NBR containing carboxyl groups, a fluorinated rubber (FKM), CO-epichlorohydrin homopolymers or copolymers, or their mixtures are preferred. If a NBR or a NBR containing carboxyl groups is used, then the preferred types are those which are pre-cross-linked and have a Mooney value (ML 1+4 at 100° C.) of 38 to 88 and a higher acrylonitrile content of about 30 to 50%, preferably of about 38 to 45%. The thermoplastic modifier C can be a nylon, an acrylonitrile/methyl methacrylate copolymer, a polycarbonate, a polypropylene, a polypropylene functionalized with maleic anhydride, a polycarbonate, a polyether block amide, or other similar thermoplastic compounds.
Beyond the qualitative requirements mentioned with respect to the components A, B, and C, component C must also fulfill the already described basic quantitative conditions to accomplish the objective of this invention. For every approximately 100 parts by weight of component A, there must be about 10 to 35 parts by weight of component B as well as about 1 to 50 parts by weight of component C. It is preferred if, for about every 100 parts by weight of component A, there are about 15 to 35 of component B and about 3 to 35 parts by weight of component C.
In order to undertake an extensive optimization within the scope of the present invention, the components A, B and C should be selected so that they exhibit little if any swelling in fuels and lubricants, with the result that the finished product has optimum properties.
The properties of the thermoplastic synthetic resin sheet, of the composite sheet produced therewith, and also of the thermoplastic molded article can be modified by different additives, which are incorporated in the thermoplastic material. Examples of materials which can be added are fillers, such as calcined (preferably hydrophobized) silica, potassium aluminum silicates, French chalk, calcium carbonate, metal oxides (preferably titanium oxide), various metal powders, or furnace blacks (such as conductive furnace black); lubricants, such as C 12 to C 26 fatty acids, fatty alcohols, fatty acid esters or fatty acid amides or mixtures of these; dyes, such as organic dyes or pigments (such as phthalocyanines or furnace black); stabilizers, such as antioxidants; heat stabilizers, such as sterically hindered phenols, hydroquinones, substituted representatives of this group, phosphites, phosphonites or mixtures of these; stabilizers, particularly UV stabilizers, such as various low molecular weight but also low molecular weight resorcinols, salicylates, benzotriazoles or benzophenones or mixture of these; as well as other conventional modifiers well known to those of ordinary skill. Various processing aids (PMMA, high molecular weight), delustering agents (PMMA-silica mixture), antistatic agents, flame retardants, which lower the flammability of the sheet (examples of which are hydrophobized magnesium hydroxide, ammonium polyphosphate and other similar compound well known in the prior art) can also be enlisted as additives. These additives can be admixed with the required components A, B and C in conventional mixers, such as kneaders, continuous one-shaft kneaders, one- or two-shaft mixing extruders, or other well known apparatus. The sheet or molded object can be produced from this homogenized starting mixture in the conventional manner, for example, by means of conventional calendering techniques, in suitable extruders and melt casting equipment and also by injection molding.
The advantage associated with the invention over the present state of the art described herein, is the higher melt strength of the synthetic resin. Additionally, there are also no interfering sticking effects during calendering.
The invention is described in even greater detail in the following by means of examples. However, the scope of the present invention is not to be limited to the embodiments discussed.
Examples 1 to 3
A basic sheet, about 0.8 mm thick, was produced with a 4-roll calender using the formulations given in the Table. The various properties of this sheet were measured and the results of the measurements are also given in the Table.
Raw Materials for the Formulations of Examples 1 to 3
______________________________________A1 (TPU-1): linear, aromatic TPU based on polyester diol (adipate ester), methylene diisocyanate and 1,4- butylene glycolProperties:melt index (MFI) = 2.5 g/10 min (190° C./10 kg) (DIN 53735)hardness = 85-90 Shore A (DIN 53505)elongation at break = 600% (DIN 52910)modulus of elasticity (at 300% extension) = (DIN 52910)12 MPaA2 (TPU-2): linear, aliphatic TPU based on hexamethylene ether, polyester synthesized from adipic acid, butylene glycol, isophorone diisocyanate and hexylene glycol, with an ether:ester:urethane ratio of 60:30:10Properties:MFI = 1.5-4 g/10 minutes (190° C./10 kg) (DIN 53735)hardness = 80-85 Shore A (DIN 53505)elongation at break = 420% (DIN 52910)B (Polyvinyl Acetate):Properties:softening range (Kraemer-Sarnow-Nagel method): 209°-211°C.K value (1% in acetone at +20° C.) (DIN 53523): 90 ± 3C1 (ASA): 40%; AN: 18%; rubber: 45%Properties:Mooney viscosity (ML 1 + 4/100° C.): 50 (DIN 53523)Tb (determined with DSC): -10° C.C2 (Polyether Block Amide):Properties:MFI = 4 ± 2 g/10 min (235° C./1 kg) (DIN 53735)hardness: 69 Shore D (DIN 53505)elongation at break: 380% (DIN 52910)C3 (NBR rubber, pre-cross linked):Properties:Mooney viscosity (ML 1 + 4/100° C.) (DIN 53523)ACN content: 42%______________________________________
TABLE______________________________________ Example 1 2 3 (parts by (parts by (parts byFormulations weight) weight) weight)______________________________________A1: TPU-1 (linear aromatic 77 50 70polyester)A2: TPU-2 (linear aliphatic 23 50 30polyether/polyester)B: Polyvinyl acetate 12 15 12C1: ASA 12 -- --C2: Polyether block amide -- -- 12C3: Pre-cross linked NBR -- 10 --rubberFiller: hydrophobized 10 10 10calcium carbonateLubricant: ethyl 0.4 0.4 0.4nonacosanoateCarbon black (conductive) 5 5 5Delustering agent: 3 3 3mixture of PMMA/silicaProcessing aid: 1.5 1.5 1.5high molecular weight PMMAPropertiesElongation at break 561 524 579(DIN 52910) (%)Tensile strength 23 24 20(DIN 52910) (MPa)Modulus of elasticity 23 20 29(DIN 52910) (MPa)______________________________________ | A sheet or a molded object is described, which is made of a thermoplastic material comprising a polyurethane, a modified polymer and, optionally, conventional additives. This thermoplastic material thus comprises component A in the form of the thermoplastic polyurethane, the polyvinyl acetate in the form of polyvinyl acetate as well as, as flow modifier, the component C in the form of a further thermoplastic material, an elastomer-modified thermoplastic material or a rubber or combinations thereof. This material has about 10 to 35 parts by weight of polyvinyl acetate and about 1 to 50 parts by weight of component C per about 100 parts by weight of component A. The material advantageously shows an improved melt strength. When this material is calendered, no interfering sticking effects occur. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of and claims priority to U.S. patent application Ser. No. 12/958,268 filed Dec. 1, 2010 (now U.S. Pat. No. 8,150,308), which is a continuation of U.S. application Ser. No. 12/647,585 filed Dec. 28, 2009 (now U.S. Pat. No. 7,865,134), which is a continuation of U.S. application Ser. No. 11/934,938 filed Nov. 5, 2007 (now U.S. Pat. No. 7,697,887), which is a continuation of U.S. application Ser. No. 10/730,577 filed Dec. 8, 2003 (now U.S. Pat. No. 7,369,838), which is a continuation of U.S. application Ser. No. 09/678,522 filed Oct. 3, 2000 (now U.S. Pat. No. 6,751,441), the disclosures of which are all incorporated herein by reference.
FIELD OF THE DISCLOSURE
This invention relates to provision of broadband services within premises supplied with cable service such as a small office or a residence. It is specifically concerned with wireless distribution of these broadband services within the premises. A particular variant of this distribution system concerns the use of existing coaxial cable within the premises for distribution of these services by wireless radiation and the modes of distributing this radiation within the premises.
BACKGROUND
Broadband communication systems (e.g., cable systems) provide the capability of delivering various bundles of voice, video, and data services to premises. Once delivered to a premises it must be distributed to various applications within the premises. This often requires added wiring to be routed within the premises at an added expense that may result in some potential customers not accepting such service when offered or in a large expense to the service provider. To provide this added wiring is an expensive and extensive undertaking since the added wiring must traverse the various interior regions of the house is order to connect to the varied devices capable of broadband services.
One method of achieving delivery of broadband services without the undesirable rewiring of the premises may be able to be accomplished by a means of a wireless transmitter. When the transceiver is located inside the structure, no additional wiring is needed, but wireless radiation to various sections of the premises is often impeded by internal structural elements of the premises.
When the wireless transceiver is affixed to an outside wall of the premises, lifeline power can be supplied to the wireless device from the service provider's plant. But by locating the device on the outside of the premises, the outer wall structure becomes an added barrier to adequate radiation to many locations within the premises.
Hence, receiving a signal from a single fixed wireless transmitter, through structure within or without the premises, results in an attenuated signal with inferior signal quality at many internal locations. To overcome the additional attenuation, due to structural impedance, may require the use of an undesirably high transmission level.
SUMMARY OF THE INVENTION
Typically, premises receiving broadband cable services are or need to be internally wired to provide standard broadcast and broadband services to a plurality of devices throughout the premises. By using the existing coaxial cable to distribute services, by localized wireless transmission throughout the premises, a single wireless access node may be used to transport the broadband services via the existing coax cabling. This provides a method for distribution of the broadband services without adding any new dedicated wiring in the premises.
In one exemplary embodiment, a broadband signal access point (which may be located internally or external to the premises) in combination with the existing cabling is used with some added radiation devices to provide cost effective distribution of broadband services within the premises.
A premises, which is configured to receive broadband services through an existing standard broadcast cable system, is provided with a broadband interface unit (i.e. Set-top box, Broadband Termination Interface, or cable modem) that connects to the in-premises cabling to consumer devices such as a television set, telephone PDAs etc. Connected to the broadband interface is an adjunct or built-in wireless transceiver. The transceiver transmits broadband data, digitized voice and digital multimedia signals or any other broadband service through the in-premises cable system to an antenna located within the premises. The antenna then wirelessly radiates to the client devices. This system provides broadband data, voice and multimedia signals or any other broadband service to the applications by a wireless signal as distinguished from the signals supplied by the cable and internal wiring that are directly connected to the consumer devices.
The adjunct or built-in device formats the broadband data, multimedia and voice signals into a packet data format then converts it to a RF signal suitable for transmission. The output of the device then is coupled to the in-premises cabling, via a diplexer (i.e., typically at the BT 1 , cable modem or gateway). At a second or nth convenient location in the in-premises cable, a second diplexer is connected to the cable. The diplexer couples only the RF signal containing the broadband data, multimedia and voice signals (not the standard broadcast services) to a signal radiation device (i.e., an RF antenna or via the signal radiation leaking from a coaxial cable itself) which radiates the signal to the immediate surrounding location. Various application wireless devices, near the radiating cable location, receives the RF signal containing the specific services from the radiating antenna or leaking source. Applications at the second or nth location may radiate application generated signals back through the antenna and diplexer (or filter) for transmission through the in-premises cable to the adjunct device and back to the BT 1 , cable modem or gateway into the cable system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an in-premises broadband system for distributing broadband data, multimedia and telephony voice signals from inside the premises.
FIG. 2 is a block diagram of an in-premises broadband system for distributing broadband data, multimedia and telephony voice from outside the premises through a broadband termination interface.
DETAILED DESCRIPTION
A typical exemplary broadband distribution architecture for delivery of broadband services in residential premises, as shown in the FIG. 1 , receives broadband input, including multimedia, data and voice, via cable link 101 . This cable link is shown connected to a set top box 103 within the premises. Device 103 converts the incoming RF frequencies containing the broadband and broadcast signals to the format necessary to accommodate the devices to be serviced within the premises. Set top boxes and cable modems are a well-known item and further discussion of their operation is not believed necessary.
A broadband wireless device 105 is attached to the cable modem section of device 103 via a data access port, which in FIG. 1 is included within the cable modem section of device 103 . Such a connection may alternatively comprise a USB (Universal Serial Bus), an Ethernet connection or similar connection port used as a direct connection. The connection port is capable of bi-directional communication with the cable and includes simultaneously connecting services from and to the cable input 101 and includes such services as streaming video, video on demand, voice telephony and other services which may be provided.
In accord with the invention, the wireless device 105 formats the digital broadband data, multimedia and voice signals, that has been converted from the RF signals by device 103 , into a packet data format and modulates an RF signal suitable for transmission. In the illustrative embodiment the wireless device 103 has its RF output connected to the internal cable system's coaxial cable 107 , via a diplexer 109 . Cable 107 is connected to a splitter 111 and is shown in the illustrative embodiment branching into two cable links 113 and 115 . Cable 113 is shown connected to a first TV receiver 117 and cable 115 is shown connected to a second TV receiver 119 located in another area of the premises. Diplexer filter or Duplexer filter 121 and 123 are shown connected in series with the cables 113 and 115 respectively just prior to connection to the receivers 117 and 119 , respectively. The Diplexer/Duplexer filter isolates the RF frequencies containing the broadband data signals from the RF frequencies containing the broadcast signals at the outputs of the Diplexer/Duplexer filter from the combined cable RF signal complex. Each Diplexer/Duplexer has an RF radiating antenna 112 and 114 for radiating the RF frequencies containing the digitized broadband data signals intended for the wireless devices such as cordless telephones 126 , 127 and LAN connected PCs 125 .
Another arrangement for distributing broadband data, multimedia, telephony voice or any broadband services inside the structure 250 uses a Broadband Termination Interface 201 located outside the premises as illustrated in the FIG. 2 .
For explanatory purposes illustrative signal frequencies are discussed. No limitation to the scope of the invention is intended beyond the claimed limitations. This arrangement uses a Broadband Termination Interface (BTI) Device 201 , normally affixed on an outside wall of the premises, and which is positioned to be conveniently connected to the incoming cable 203 . The BTI 201 includes a cable modem 207 as standard equipment and, as shown in FIG. 2 , a supplementary wireless access port 205 and diplexer 209 , which are included as additions to a standard BTI Diplexer/Duplexer 209 consists of a 1 GHz filter 211 and a 2.4 GHz filter 213 which connects the input from cable 203 and the wireless access port cable 257 through a splitter 210 to cabling ( 231 , etc) located within the premises 250 . The Diplexer/Duplexer 209 combines the standard broadcast frequencies and the broadband data frequencies from the wireless access port on to the coax cable 214 .
The input cabling 203 , which carries RF frequencies that consist of a combination of analog TV broadcast signals, voice analog signals and digital data signals, is connected to the cable modem section 207 of the BTI 201 and the diplexer through the splitter 215 . Normal broadcast signals intended for wired delivery within the premises are applied to the 1 GHz filter section of the Diplexer/Duplexer 209 which couples these signals to cabling 231 , 233 within the premises.
Cable modem 207 converts input analog radio frequency signals carrying the broadband services to digital signals of Ethernet or USB compatible format having different address headers than Ethernet signals intended for wired distribution within the premises. The modem applies these digital signals to the wireless access port 205 on lead 239 . The lead 209 is connected to the wireless access port controller section 241 which converts the Ethernet format packets to data streams that are readable by the Media Access Controller (MAC) in the wireless access port. The wireless access port controller is coupled to the Wireless Interface 253 to the media access controller (MAC) 254 which supplies the appropriate headers to data packets supplied to the radio interface 255 . The output of the radio section 255 is lead 257 (i.e., coax cable) which corresponds to a point at which the conventional output is an antenna, however the output lead 257 is connected to the input of the Diplexer/Duplexers 209 2.4 GHz filter section. The filtered radio output is distributed to antennas 261 and 263 located within the premises via internal coaxial cabling 231 , 233 originally intended for cable TV reception. Cable 233 is connected to a diplexer 259 , which supplies signals to a set top box and to antenna 262 . Cable 231 is directly connected to antenna 263 by way of a 2.4 GHz filter 264 .
A further radiation distribution technique may take advantage of a leaky cable that radiates the broadband signals along the cable length. This may be explicitly exploited by use of leaky cables to service intermediately located wireless applications. Use of cables as a radiative/antenna device is a well-known technique and an extended discussion is not believed necessary.
The wireless broadband signals are distributed by wireless radiation to the wireless receivers within the premises. In a conventional wireless distribution using one BTI the perimeter and in-building construction features include many metallic barriers requiring significant radiative power to penetrate. By distributing the wireless radiation sources, the necessary RF output levels to cover the entire premises is greatly reduced. These distributed radiation devices also act as distributed receptors for picking up return radio signals. This greatly enhances broad band reception and transmission within the premises.
While the exemplary embodiment discloses delivery of broadband via external cable ( 101 , 203 ), it is to be understood that alternate delivery apparatus and methods are also included. One type of broadband delivery contemplated is by fixed wireless where a wireless receiver is used instead of the external cable input. Another delivery system contemplated is DSL (digital subscriber line) in place of the external cable input. Many further variations will suggest themselves to those skilled in the art, which do not depart from the spirit and scope of the invention. | A system that incorporates teachings of the present disclosure may include, for example, includes a broadband signal access point, which may be located internally or externally to the premises, in combination with the existing cabling is used with radiation device(s) to provide distribution of services, including broadband services, within the premises. Additional embodiments are disclosed. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority based on Japanese Patent Applications No. 2007-162216 filed on Jun. 20, 2007 and No. 2008-133804 filed on May 22, 2008, the disclosures of which are hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a fluid ejection device for ejecting a fluid, and particularly to a structure by which fluid-containing packs containing fluid for ejection are positioned within the fluid ejection device.
[0004] 2. Related Art
[0005] Printers of ink jet format, which eject drops of ink onto thin sheets of a recording medium such as paper or plastic in order to record text or images thereon, are a representative type of fluid ejection device. Other types of fluid ejection devices include those adapted for use in display production systems employed in the production of liquid crystal displays, plasma displays, organic EL (Electro Luminescence) displays, field emission displays (FED), and the like, and used for ejecting various types of liquid materials to form coloring material, electrodes, etc. in the pixel regions or electrode regions.
[0006] A typical fluid ejection device is equipped with a carriage on which rides an ejection head for ejecting fluid onto an ejection target; the location for fluid ejection onto the ejection target is adjusted by moving either the carriage or the recording medium, or both. Where a fluid ejection device employs a system in which a container portion containing fluid for ejection is positioned apart from the carriage (known as an off-carriage system) it will be possible to reduce the load associated with driving the carriage. Patent Citation JP 2005-47258 A discloses such a printer of off-carriage type in which an ink cartridge containing ink packs is inserted into the printer unit.
SUMMARY
[0007] However, in the past, sufficient consideration was not given to a design able to accommodate fluid containers of larger capacity. For example, there were problems such as the difficulty of ensuring sufficient space within the unit between the fluid containers and other structures; and damage to other structures inside the unit due to operator error when installing the fluid container within the unit.
[0008] In view of the issues discussed above, it is an object of the invention to provide a fluid ejection device able to accommodate larger capacity fluid containers.
[0009] An advantage of some aspects of the invention is intended to address this issue at least in part, and can be reduced to practice as described below.
[0010] A fluid ejection device according to an aspect of the invention is a fluid ejection device ejecting a fluid, the fluid ejection device includes: a fluid container; a fluid ejection unit; a delivery needle; a guard cover; and a guide. The fluid container includes a container portion and a withdrawal portion. The container portion contains a fluid for ejection, and the withdrawal portion allows withdrawal of the fluid contained in the container portion. The fluid ejection unit ejects a fluid onto an ejection target. The delivery needle provides a flow passage which communicates with the fluid ejection unit. The guard cover projects over the delivery needle. The guide mates with the fluid container, and then slidably guides the withdrawal portion toward a locking position where the delivery needle sticks through the withdrawal portion. According to the above-mentioned fluid ejection device, since the guard cover is disposed projecting out so as to cover the delivery needle, it is possible to prevent accidental damage to the delivery needle during securing of the fluid container to the container case.
[0011] A method of manufacturing according to an aspect of the invention is a method of manufacturing a fluid ejection device including a fluid ejection unit that ejects a fluid onto an ejection target, a delivery needle that provides a flow passage which communicates with the fluid ejection unit, and a guard cover that projects over the delivery needle, the method comprising: providing a fluid container that includes a container portion and a withdrawal portion, wherein the container portion contains a fluid for ejection, and the withdrawal portion allows withdrawal of the fluid contained in the container portion; mating the fluid container with a guide that extends approximately aligned with a center axis of the delivery needle; and sliding the fluid container mated with the guide toward a locking position where the delivery needle sticks through the withdrawal portion away from the guard cover. According to the above-mentioned method, since the fluid container is mated with the guide at a location away from the guard cover disposed projecting so as to cover the delivery needle, and the fluid container can then be subsequently slid into the locking position and secured, it is possible to prevent damage to the delivery needle during securing of the fluid container to the container case.
[0012] The invention is not limited to being embodied as a fluid ejection device, and may be reduced to practice as a method for manufacture thereof, or other mode having a structure for accommodating fluid-containing packs. The invention should not be construed as limited to the embodiments set forth hereinabove, and naturally various modifications such as the following may be made herein without departing from the scope of the invention.
[0013] These and other objects, features, aspects, and advantages of the invention will become more apparent from the following detailed description of the preferred embodiments with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The invention will be described with reference to the accompanying drawings in which:
[0015] FIG. 1 is an illustration depicting in simplified form a configuration of a printer;
[0016] FIG. 2 is a sectional view depicting in simplified form the configuration of the printer with the upper chassis unit closed;
[0017] FIG. 3 is a sectional view depicting in simplified form the configuration of the printer with the upper chassis unit open;
[0018] FIG. 4 is a top view showing the interior of the upper chassis unit;
[0019] FIG. 5 is an illustration depicting fastening of holders carrying ink packs within the upper chassis unit;
[0020] FIG. 6 is an illustration depicting an ink pack prior to connection with the ink delivery section, viewed in A-A cross section in FIG. 4 ;
[0021] FIG. 7 is an illustration depicting an ink pack connected with the ink delivery section, viewed in A-A cross section in FIG. 4 ;
[0022] FIG. 8 is an illustration depicting a configuration of a printing mechanism section of a printer;
[0023] FIG. 9 is a flowchart depicting a method of manufacturing the printer;
[0024] FIG. 10 is a top view showing the interior of the upper chassis unit; and
[0025] FIG. 11 is a sectional view depicting in simplified form the configuration of a printer, shown with the upper chassis unit closed;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] A better understanding of the constitution and advantages of the invention set forth above will be provided through the following description of the invention embodied in a fluid ejection device. In the embodiment, a printer of ink-jet type will be described as an example representative of a picture recording device, as one embodiment of a fluid ejection device.
A. Embodiment
[0027] FIG. 1 is an illustration depicting in simplified form the design of a printer 10 . The printer 10 is a printer of ink-jet type which records text and images by ejecting ink drops onto a recording medium, namely, printer paper 900 . The printer 10 includes a main chassis unit 20 which houses a printing mechanism section 50 constituting the fluid ejecting portion for ejecting ink drops onto the printer paper 900 ; the main chassis unit 20 houses a paper feed tray 12 for loading into the interior of the main chassis unit 20 the printer paper 900 which is to be supplied to the printing mechanism section 50 , as well as a paper output tray 14 for guiding out from the main chassis unit 20 the printer paper 90 which has been discharged from the printing mechanism section 50 . The specifics of the design of the printing mechanism section 50 will be discussed later.
[0028] Also housed in the main chassis unit 20 is a controller section 40 for controlling the various parts of the printer 10 . In the embodiment, the controller section 40 includes ASICs (Application Specific Integrated Circuits) furnished with hardware such as a central processing unit (CPU), read only memory (ROM), and random access memory (RAM). Software for accomplishing the various functions of the printer 10 is installed in the controller section 40 .
[0029] On the upper face of the main chassis unit 20 is installed an upper chassis unit 30 which constitutes the container case for accommodating a plurality of ink packs 310 which constitute the container portions respectively containing liquid inks of different colors. The upper chassis unit 30 is pivotably attached to the main chassis unit 20 so as to open and close about a rotation shaft 350 .
[0030] In the embodiment, the ink packs 310 take the form of flat bag portions of generally rectangular shape made of pliable sheeting and having generally elliptical cross section; a pack aperture 60 serving as the withdrawal opening from which ink may be withdrawn is provided on one of the short sides. The specific design of the pack aperture 60 will be discussed later. In the embodiment, the plurality of ink packs 310 are held stacked on an incline with one long side thereof upraised. In the embodiment, the upper chassis unit 30 accommodates four ink packs 310 for individual inks of the four colors black, cyan, magenta, and yellow. In an alternative embodiment, in a printer adapted to carry out printing with light cyan and light magenta in addition to these four colors for a total of six colors, the upper chassis unit 30 could be designed to accommodate six ink packs 310 for individual inks of six colors including the additional light cyan and light magenta.
[0031] The upper chassis unit 30 which constitutes the ink delivery unit for the printing mechanism section 50 has an ink delivery section 330 which connects to the ink packs 310 so as to enable ink to be dispensed from them. A delivery tube 340 which defines a fluid passage allowing the ink dispensed from the ink packs 310 to flow down to the printing mechanism section 50 connects with the ink delivery section 330 . The delivery tube 340 can be fabricated of material having gas barrier properties, for example, a thermoplastic elastomer such as an olefin or styrene.
[0032] FIG. 2 is a sectional view depicting in simplified form the configuration of the printer 10 with the upper chassis unit 30 closed. FIG. 3 is a sectional view depicting in simplified form the configuration of the printer 10 with the upper chassis unit 30 open. FIG. 4 is a top view showing the interior of the upper chassis unit 30 . The upper chassis unit 30 has a lower housing 360 which constitutes the inside lower face of the upper chassis unit 30 ; and an upper housing 370 which constitutes the inside top wall of the upper chassis unit 30 . Inside the lower housing 360 are disposed a plurality of holder guides 362 constituted in sections of the inside lower face defined by the lower housing 360 , and extending approximately parallel to the rotation shaft 350 and spaced at approximately equal intervals apart from one another. As shown in FIG. 3 , in the embodiment, the upper part of the printing mechanism section 50 housed within the main chassis unit 20 will lie exposed by opening the upper chassis unit 30 .
[0033] As shown in FIG. 2 , a plurality of holders 380 on which the ink packs 310 rest are provided as liquid containers within the upper chassis unit 30 . The holders 380 have inclined panels 381 which are inclined with respect to the holder guides 362 . The ink packs 310 are arranged resting against the upper faces of the inclined panels 381 of the holders 380 , with one side face of the flat bag which makes up the ink pack 310 in contact therewith. In the embodiment, the ink packs 310 are attached with double-sided tape on at least a portion of the face thereof contacting the inclined panel 381 of the holder 380 . In the lower section of the inclined panel 381 of the holder 380 there is formed a base section 382 which is fittable within the holder guide 362 . After the base section 382 has been fitted into the holder guide 362 , the holder 380 will be secured fastened to the lower housing 360 by fastening screws 388 , 389 which constitute the fastening components. The plurality of holders 380 are positioned in a row staggered along the inside lower face of the lower housing 360 , with the inclined panel 381 of one holder 380 overlapping the top of the ink pack 310 which rests on another holder situated adjacently in the direction of incline of the inclined panels 381 . As depicted in FIGS. 2 and 3 , the inclined panels 381 of the holders 380 are inclined with respect to the holder guides 362 of the lower housing 360 , by an angle of incline Oh enabling them to remain in contact with the ink packs 310 from below in the direction of gravity as the upper chassis unit 30 moves from the closed position to the open position. In the embodiment, the allowable rotation angle θc for opening and closing of the upper chassis unit 30 about the rotation shaft 350 is approximately 45 degrees, whereas the angle of incline θh of the inclined panels 381 with respect to the holder guides 362 is approximately 40 degrees.
[0034] As shown in FIG. 2 , on the back face of the inclined panel 381 of each holder 380 is pendently disposed a back face reinforcing rib 384 having a tabular contour which extends along the ink pack 310 resting on the adjacent holder 380 . On the inside lower face of the lower housing 360 is disposed a holder reinforcing rib 364 of tabular contours which rises up to meet the bottom of the inclined panel 381 of the holder 380 situated at the end in the direction of incline of the inclined panels 381 in the row of holders 380 . In the embodiment, the upper part of the holder reinforcing rib 364 abuts the back face of the inclined panel 381 of this holder 380 . On the inside top wall of the upper chassis unit 30 is pendently disposed an end portion reinforcing rib 374 having a tabular contour which extends towards the upside of the ink pack 310 resting on the holder 380 situated at the end opposite from the direction of incline of the inclined panels 381 in the row of holders 380 . On the inside top wall of the upper chassis unit 30 is also pendently disposed a medial reinforcing rib of tabular contours which extends along the upside of the ink pack 310 resting on the holder 380 , along a zone sandwiched between two of the holders 380 . Also disposed on the inside top wall of the upper chassis unit 30 is a mating portion 373 which mates with the upper edge portion 383 of the inclined panel 381 of a holder 380 .
[0035] As shown in FIG. 4 , the ink delivery section 330 has a guard cover 332 disposed covering the upside of the connector portions with the pack apertures 60 of the ink packs 310 . The guard cover 332 has openings 333 to permit insertion of a tool for tightening fastening screws 388 which fasten the holders 380 to the lower housing 360 .
[0036] FIG. 5 is an illustration depicting fastening of holders 380 carrying ink packs 310 within the upper chassis unit 30 . In each of the holders 380 , a through hole 386 adapted for passage and engagement of a fastening screw 388 is formed at a location adjacent to the pack aperture 60 of the ink pack 310 , and a through hole 387 adapted for passage and engagement of a fastening screw 388 is formed at a location adjacent to the opposite end from the pack aperture 60 of the ink pack 310 . In the lower housing of the upper chassis unit 30 , at fastening locations where the holders 380 carrying the ink packs 310 are to be fastened, there are formed screw holes 368 for threadably engaging the fastening screws 388 passed through the through holes 386 of the holders 380 , as well as screw holes 369 for threadably engaging the fastening screws 389 passed through the through holes 387 of the holders 380 .
[0037] During the process of fastening the holders 380 carrying the ink packs 310 in the interior of the upper chassis unit 30 , first, the base portion 382 of the holder 360 carrying the ink pack 310 is fitted from above into one of the holder guides 362 of the lower housing 360 . Then, the holder 380 is slid along the holder guide towards a delivery needle 321 until the delivery needle 321 is threaded through the aperture of the ink pack 310 . The holder 380 is then fastened to the lower housing 360 with the fastening screws 388 , 389 .
[0038] FIG. 6 is an illustration depicting an ink pack 310 prior to connection with the ink delivery section 330 , viewed in A-A cross section in FIG. 4 . FIG. 7 is an illustration depicting an ink pack 310 connected with the ink delivery section 330 , viewed in A-A cross section in FIG. 4 . The delivery needles 320 , each of which has a hollow flow passage 322 communicating with the delivery tube 340 , are provided to the ink delivery section 330 . A first end of the delivery needle 320 has a tip 324 of tapered shape. A delivery channel 326 which communicates with the hollow flow passage 322 is formed in the tip 324 of the delivery needle 320 . The delivery channel 326 is formed from the tip of the delivery needle 320 to a side wall 321 which extends generally along the center axis of the delivery needle 320 . As shown in FIG. 7 , the delivery channel 326 of the delivery needle 320 is defined by a vertical face 326 a which extends generally along the center axis of the delivery needle 320 , and a lateral face 326 b which intersects the center axis of the delivery needle 320 . In the embodiment, the delivery channel 326 of the delivery needle 320 is formed with a cross shape (“+(plus)” shape) having its intersection point at the center axis of the delivery needle 320 . In the embodiment, the delivery needle 320 is a resin component which has been integrally molded with the ink delivery section 330 using a mold.
[0039] The pack aperture 60 provided to each of the ink packs 310 is provided with a delivery aperture portion 610 having formed therein a delivery aperture 612 which communicates with the interior of the ink pack 310 . A cylindrical gasket 640 having a through hole 642 which mates intimately with the delivery needle 320 threaded through the delivery aperture 612 is disposed at the inlet of the delivery aperture 612 . The gasket 640 installed in the delivery aperture 612 is forced into the delivery aperture 612 by a cap 620 which fits onto the delivery aperture portion 610 .
[0040] A valve body 630 having a sealing face 634 that intimately attaches to the gasket 640 is housed within the delivery aperture 612 . The valve body 630 housed within the delivery aperture 612 is urged towards the gasket 640 from the interior of the delivery aperture 612 by a coil spring 650 which constitutes a resilient member, and seals off the through hole 642 of the gasket 640 . The valve body 630 is provided with a plurality of guides 638 disposed contacting the inside wall of the delivery aperture 612 generally along the center axis of the delivery aperture 612 ; between the plurality of guides 638 are defined offset faces 636 which are offset from the inside face of the delivery aperture 612 . A mating face 632 adapted to mate with the tip 324 of the delivery needle 320 is formed on the valve body 630 on the side thereof which abuts the gasket 640 .
[0041] As shown in FIG. 7 , when the delivery needle 320 is threaded through the through-hole 642 of the gasket 640 , with the tip 324 of the delivery needle 320 mated with the mating face 632 of the valve body 630 , the valve body 630 will be pushed inward towards the ink pack 310 within the delivery aperture 612 . During this process, since the delivery channel 326 of the delivery needle 320 has been formed so as to extend from the tip 324 to the side wall 321 and beyond the mating face 632 of the valve body 630 , the channel will now communicate with the delivery aperture 612 . The interior of the ink pack 310 will thereby be placed in communication with the hollow flow passage 322 of the delivery needle 320 , via the offset faces 636 of the valve body 630 and the delivery channel 326 of the delivery needle 320 .
[0042] FIG. 8 is an illustration depicting a configuration of the printing mechanism section 50 of the printer 10 . The printing mechanism section 50 has a platen 530 of rectangular shape disposed in a printing area where ejection of ink drops onto the printer paper 900 will be carried out. The printer paper 900 is transported over the platen 530 by a paper feed mechanism (not shown). The printing mechanism section 50 also has a carriage 80 which is connected to the delivery tube 340 and which carries an ejection head 810 . The carriage 80 is moveably supported in the lengthwise direction of the platen 530 along a guide rod 520 , and is driven via a timing belt 512 by a carriage motor 510 which constitutes the carriage driving section. The carriage 80 thereby undergoes reciprocating motion in the lengthwise direction over the platen 530 . In the interior of the main chassis unit 20 , a home position where the carriage 80 waits in standby is provided in a nonprinting area away to one side of the printing area where the platen 530 is located. A maintenance mechanism section 70 for maintenance of the carriage 80 is disposed at this home position.
[0043] FIG. 9 is a flowchart depicting a method of manufacturing the printer 10 . When installing the ink packs 310 in the printer 10 , first, the ink-filled ink packs 310 are positioned on the inclined panels 381 of the holders 380 (Step S 110 ). The holders 380 carrying the ink packs 310 are then fitted into the holder guides 362 of the lower housing 360 , and the holders 380 are fastened to the lower housing 360 with the fastening screws 388 , 389 so that the plurality of holders 380 are arranged on the lower housing 360 (Step S 120 ). Subsequently, the lower housing in which the plurality of holders 380 have been arranged is sealed with the upper housing 370 , whereby the plurality of ink packs 310 are housed in the interior of the main chassis unit 30 (Step S 130 ).
[0044] According to the printer 10 of the embodiment described above, since the guard cover 332 is disposed projecting out over the delivery needle 321 , it is possible to prevent accidental damage to the delivery needle 321 when the holder 380 carrying the ink pack 310 is secured to the lower housing 360 . Additionally, by working through the openings 333 provided in the guard cover 332 the fastening screws 388 can be passed through the through holes 386 of the holders 380 and fastened into the screw holes 386 of the lower housing 360 , and thus while preventing accidental damage to the delivery needle 321 when the holder 380 carrying the ink pack 310 is secured to the lower housing 360 , the holder 380 can be secured to the lower housing 360 in the vicinity of connection between the delivery needle 321 and the pack aperture 60 .
[0045] Moreover, because by opening the upper chassis unit 30 it is possible to access parts of the main chassis unit 20 which are normally covered by the upper chassis unit 30 , the degree of freedom in positioning of the ink packs 310 can be improved. Moreover, because the upper chassis unit 30 is pivotably attached to the main chassis unit 20 allowing the top part of the printing mechanism section 50 to be opened or closed, the upper chassis unit 30 which houses the ink packs 310 can be utilized as the cover for the printing mechanism section 60 ; and by opening the upper chassis unit 30 it will be possible to easily perform maintenance on the printing mechanism section 50 housed within the main chassis unit 20 .
[0046] Moreover, because the individual ink packs 310 respectively rest on the inclined panels 381 of the holders 380 , the plurality of ink packs 310 can be stacked and accommodated efficiently, while preventing the weight of ink packs 310 from bearing on neighboring ink packs 310 . Additionally, because the ink packs 310 are retained from below as the upper chassis unit 30 moves from the closed state to the open state, the ink packs 310 can be prevented from pushing with excessive force against neighboring holders 380 due to gravity.
[0047] Furthermore, by disposing the holder reinforcing rib 364 on the lower housing 360 , the holder 380 can be reinforced with respect to force acting in the direction of incline of the inclined panels 381 . Moreover, by disposing the end portion reinforcing rib 374 on the upper housing 370 , it will be possible to avoid excessive deformation of the ink pack 310 carried on the holder 380 which is situated at the end opposite the direction of incline of the inclined panels 381 . Additionally, by disposing the medial reinforcing rib 376 on the upper housing 370 , it will be possible to avoid excessive deformation at the upside of an ink pack 310 unsupported by the back face of the inclined panel 381 of the adjacent holder. Furthermore, because the upper edge portion 383 of the inclined panel 381 of the holder 380 mates with the mating portion 373 disposed on the upper housing 370 , it is possible to prevent the holder 380 from experiencing excessive deformation.
B. Alternative Embodiments
[0048] The foregoing description of the invention based on certain preferred embodiments should not be construed as limiting of the invention, and various modifications will of course be possible without departing from the scope of the invention. For example, the upper chassis unit 30 need not be pivotably attached to the main chassis unit 20 , and the upper chassis unit 30 may instead by slidably attached to the main chassis unit 20 . With this design, the ink packs 310 can be housed in a more stable condition within the upper chassis unit 30 .
[0049] Another possible orientation of the holders 380 on the lower housing 360 is that depicted in FIG. 10 wherein the holders 380 are arranged generally along the direction of the axis of the rotation shaft 350 . According to the embodiment illustrated in FIG. 10 , because the individual ink packs 310 held in the upper chassis unit 30 are maintained at generally identical height as the upper chassis unit 30 moves from the closed state to the open state, generally identical pressure head can be maintained in the inks contained in the individual ink packs 310 . The ejection quality of the ink ejected from the ejection head 810 can be improved thereby. Alternatively, the holders 380 may be positioned with the direction of incline of the inclined panels 381 oriented towards the rotation shaft 350 as depicted in FIG. 11 . According to the embodiment illustrated in FIG. 11 , with the upper chassis unit 30 in the opened state the ink packs 310 rest in a more stable condition on the inclined panels 381 of the holders 380 , as compared with the arrangement of the holders 380 depicted in FIGS. 2 and 3 in which the inclined panels 381 incline in the direction opposite from the rotation shaft 350 .
[0050] The fluid targeted by the fluid ejection device of the invention is not limited to liquids such as the ink mentioned above, and various fluids such as metal pastes, powders, or liquid crystals may be targeted as well. The ink-jet recording device equipped with an ink-jet recording head for picture recording purposes like that described above is but one representative example of an fluid ejection device; the invention is not limited to recording devices of ink-jet type, and has potential implementation in printers or other picture recording devices; in coloring matter ejection devices employed in manufacture of color filters for liquid crystal displays and the like; in electrode material devices employed in formation of electrodes in organic EL (Electro Luminescence) displays or FED (Field Emission Displays); in liquid ejection devices for ejection of liquids containing bioorganic substances used in biochip manufacture; or in specimen ejection devices for precision pipette applications.
[0051] According to the aspect of the invention, the fluid ejection device may further comprise: a container case that houses the fluid-containing pack; and a fastening member that fastens the fluid container at the locking position to the container case, wherein: the fluid container includes a mating portion that mates with the fastening member in proximity to the withdrawal portion; and the guard cover includes a through-hole portion that locates corresponding to the mating portion of the fluid container at the locking position. According to the above-mentioned fluid ejection device, since the guard cover is disposed projecting so as to cover the delivery needle, while preventing accidental damage to the delivery needle during securing of the fluid container to the container case, the fluid container can be secured to the container case in the vicinity of connection between the delivery needle and the withdrawal opening.
[0052] According to the aspect of the invention, the fluid container may be a plurality of fluid containers; the fluid container may include a holder that inclines and holds the container portion; and the plurality of fluid containers may be arranged spaced apart with a part of one fluid container overlapping a holder of another fluid container. According to the above-mentioned fluid ejection device, the individual fluid containers are positioned at an incline, thereby allowing a plurality of fluid containers to be stacked and accommodated efficiently.
[0053] According to the aspect of the invention, the fluid ejection device may further comprise: a container case that houses the fluid-containing pack; and a main chassis case that houses the fluid ejection unit, wherein the container case is pivotably attached to the main chassis case and openable by rotation about a rotation shaft. According to the above-mentioned fluid ejection device, by opening the container case it will be possible to access the parts of the main chassis unit which are normally covered by the container case, thereby improving the degree of freedom in positioning of the fluid containers.
[0054] According to the aspect of the invention, the fluid container may incline by an angle which affords hold against the container portion from below in a direction of gravity as the container case moves from a closed position to a open position. According to the above-mentioned fluid ejection device, because the container portions of the fluid containers are retained from below as the container case moves from the closed state to the open state, the fluid container portions can be prevented from pushing with excessive force against other adjacent structures.
[0055] According to the aspect of the invention, the fluid container may be a plurality of fluid containers; and each of the withdrawal portions of the plurality of fluid containers may be arranged approximately along an axis of the rotation shaft. According to the above-mentioned fluid ejection device, as the container case moves from the closed state to the open state the individual fluid containers retained in the container case will be positioned at approximately identical height, thereby maintaining approximately identical pressure head of the fluid contained in the individual fluid containers. The fluid ejection quality can be improved thereby.
[0056] Although the 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 invention being limited only by the terms of the appended claims. | A fluid ejection device ejecting a fluid, the fluid ejection device includes: a fluid container; a fluid ejection unit; a delivery needle; a guard cover; and a guide. The fluid container includes a container portion and a withdrawal portion. The container portion contains a fluid for ejection, and the withdrawal portion allows withdrawal of the fluid contained in the container portion. The fluid ejection unit ejects a fluid onto an ejection target. The delivery needle provides a flow passage which communicates with the fluid ejection unit. The guard cover projects over the delivery needle. The guide mates with the fluid container, and then slidably guides the withdrawal portion toward a locking position where the delivery needle sticks through the withdrawal portion. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No.: 60/338,488 filed Nov. 3, 2001.
BACKGROUND OF INVENTION
Our patents and copending applications have described how laser beams may be used to process materials in order to change the look of those materials. For example, our U.S. Pat. No. 5,990,444 teaches a way in which the density of applied laser energy per each unit time (“EDPUT”) of the output of a laser can be controlled to change the look of a material, without actually unintentionally damaging the material. The surface characteristics and hence look of the material may be changed by this processing without burning through or otherwise unintentionally damaging the material. Our other patent applications also describe user interfaces that can be used to form various features on the material. By appropriate selection of the way that a numerically controlled laser is driven, it becomes possible to form new designs on the material which have not been previously possible to form.
Other patent applications,and patents describe special designs that can be formed.
The present application describes processing these materials in bulk. In an embodiment, a conveyor concept of processing materials of this type may be extended to form special kinds of materials and material handling techniques in a way such that standard sized textile materials, typically formed on textile rolls, can be processed in bulk.
SUMMARY OF INVENTION
The present application teaches a number of techniques associated with processing the material in bulk, and after such processing, using the material to form final products.
The present application teaches different size rolls of conventional sizes, current textile sizes of which may include 60 inches, 62 inches, 70 inches, 72 inches and 108 inches, and other conventional sizes, can be processed as a single unit. Different techniques are disclosed, including handling the current textile width, as well as different conveyor systems which can be used for this textile.
A process of scan and index is disclosed, in which either a rectangular section or a square section can be processed. The technique of forming panels can be used to form different types of panels.
A process of scribing on-the-fly is also described.
Different applications are described for this system.
Another technique describes a digital process that can uniquely change the processing on-the-fly.
BRIEF DESCRIPTION OF DRAWINGS
These and other aspects will now the described in detail with reference to the accompanying drawings, wherein:
FIG. 1 shows a first embodiment of a conveyor system according to the present application;
FIG. 2 shows a vertical conveyor system;
FIG. 3 shows a way in which scribe and index techniques may be used to form a panel that can be cut to form an item of apparel;
FIG. 4 diagrams compensation for movement of the conveyor during laser operations;
FIG. 5 shows a system which allows formation of different patterns on a single continuous roll of material;
FIG. 6 shows how material can be lased in a way that forms a single garment;
FIGS. 7A-7B show specific patterns formed using digital enhancement techniques; and
FIGS. 8A-8C show formation of different effects on specified materials.
DETAILED DESCRIPTION
An embodiment is shown in FIG. 1, including a conveyor which may be used to form different kinds of apparel and materials for use in apparel.
The conveyor is shown in FIG. 1 includes a numerically controlled laser which operates to form patterns on bulk textiles. Specified patterns are described as being formed. However, it should be understood that other patterns can alternatively be formed, and in the embodiment disclosed herein, the specific disclosed patterns which are disclosed can also be formed on other textiles including pre cut (non-bulk) textiles. The basic first embodiment of the conveyor is shown in FIG. 1 . FIG. 1 shows a roll of material 100 , where the roll is a conventional size roll of material having a size 102 of conventional width. The width is greater than 50 inches, preferably greater than 55 inches, and is preferably one of the “standard” material widths of 60 inches, 62 inches, 70 inches, or another standard width.
The roll rotates on the rotation device 110 and is pulled by the take up reel 120 . Alternatively, a more active driving mechanism like a motor may be provided as part of 110 . The roll is unrolled as material web 115 , which is guided to the lasing area 125 where the material will be lased by the laser beam. The material web is lased at full width, that is the laser operates to form the pattern over the entire desired part of the standard width of 60 inches or the like.
The laser operates as described in our U.S. Pat. No. 5,990,444, and specifically to change the look of the material at desired locations according to control signals that are formed as a digital file that drives the laser. This means, of course, that the laser need not process every location of the material. In fact, many times the pattern will be formed by the interaction between the lased portions of the material, which have been lased to produce color changes, and the un lased portion of the material which may stay its original color. In addition, it may be desired to leave a small margin of some desired size of un lased material around the edges of the material web.
The laser 130 is controlled by a computer shown as 150 . The computer may be suitably controlled according to a user interface 160 , which may run programs as disclosed in our other applications.
The material web is guided to and by edge guides shown as 121 , 122 , 123 , 124 , which align the edges of the material with the desired area that corresponds to the lasing area. The material is eventually guided to the lasing area which is adjacent numerically controlled laser 130 which includes mirrors and/or optics 135 that can guide the output of the laser beam to a number of different locations. The laser beam can be scanned over the entire width of the material but it may be desirable to leave a small border area shown as 130 around the edge of the material. The “entire width of the material therefore may include that border. Alternatively, the laser beam can be guided to the entire surface of the material, e.g. the entire 60 inch width. In this embodiment, the material is indexed, that is, it is moved in stages, and then stopped to allow lasing to occur. The lasing may occur over a 60 by 60 square. Therefore, the material is indexed by 60 inches each time it is moved. The material may be brought to rest in the area shown.
The laser beam forms the 60×60 basic pattern unit shown as 140 . After lasing, the material is then indexed. The already lased units such as 145 , 150 are advanced towards the take up roll 120 . Each time the material is indexed, another unit of material is brought to the active area 125 .
The basic material units can be any kind of design, including any of the designs described herein or the designs described in our copending applications and previous patents, including a simulated sandblasted design, a fractal design, or any other design that can be defined as a computer file.
The above embodiment has described a process of lase and index. An alternative embodiment may use a continuous feed technique. Also, since the laser beam is capable of numerical controlled scanning to a width of 60 inches, it may also be capable of scanning to a length of 60 inches. Therefore, scanning of a square pattern may be used. However, a rectangular pattern may also be formed using this technique.
The guides 121 and 124 may maintain the material in the desired location for lasing. In addition, a sensor 134 , which may be an infrared sensor or an optical sensor, may be located in a location to sense whether the material is misaligned. Misalignment of the material may trigger an alarm that may stop the conveyor and allow the operator and opportunity to manually reconfigure the material.
This embodiment discloses forming the material and forming the conveyor such that the material is conveyed in a horizontal direction. An alternative embodiment shown in FIG. 2 may save on floor space by forming the conveyor in a way where the material is conveyed vertically. The embodiment of FIG. 2 is formed on a special frame shown as 200 . The frame 200 includes the basic top piece 201 and bottom piece 202 . The top piece 201 includes a cross frame structure that holds the unmarked material roll 210 . The material roll 210 is allowed to rotate on a roll holder 212 . As in the first embodiment, tension may be placed on this roll in order to keep the web tight at all locations. The take up reel 220 is motorized, and held on the bottom support structure 202 . A center support structure 220 may hold the numerically controlled laser apparatus 224 .
The laser 224 is controlled by a control line 226 , which can be for example a network cable carrying data from a computer 230 which is remotely located relative to the laser. The web of material 250 is conveyed along the surface formed by support structure 260 . Support structure 260 may also include guides 262 , 264 as in the first embodiment. In addition, support structure 260 may include elements which attract the material web 250 , to hold the material against the surface 261 . In one embodiment, this can be formed by a light vacuum, with holes shown as 265 , 266 which are periodically located along the surface 261 . A light vacuum force may be applied to the center of the structure 260 by the vacuum pump 268 . Other techniques may be used to hold the material edge against the surface 261 , including electrostatic attraction, or different kinds of force. Preferably the clamps only clamp the edges, to avoid the clamp leaving a residue on the material or a shadow of the way or the laser was unable to lase around the clamp.
In operation, material from the roll 210 is unrolled as web 250 . This is brought to the area of the laser beam 224 , shown as the active area 270 . The laser beam may form a pattern on the material shown as unit pattern 272 . In this embodiment, the unit pattern is continuous, with no spaces between the different units that are formed. The unit pattern is formed, and eventually appears on the material on the take up roll 220 . As in the first embodiment, this system may also include optical sensors that sense the position of the material on the web to prevent errors.
In addition more than one type of pattern may be formed on the same roll. For example, the computer may instruct that 900 of the specified kinds of unit patterns be first formed. Then, another 900 of the second kind of unit pattern can be formed.
The above has described the index and lase mode in which the material is indexed, held in position, and scribed while in position. The alternative mode is illustrated in FIG. 3 which shows scribing “on-the-fly”. In this embodiment, the material edge 300 is continually moving. However, the movement of the material web is slow relative to the movement of the laser beam. At each location of movement, the laser beam scribes a one “pixel” wide swath of the pattern shown as 310 . The term pixel is used herein to represent the narrowest width element that the laser beam can form; and may simply mean the way that the laser beam forms a unit element. In this way, the pattern is substantially continuously formed, one pixel wide at a time. The laser beam may be controlled to move much faster than the movement of the material, so that the pattern does not appear to 'smear”. However, this requires some sophistication. Either the computer must be able to provide the instructions for each pixel wide swath very quickly, or alternatively, the computer may download a plurality of different instructions which are streamed in advance. While the instructions describing line 310 are being executed, the instructions for lines 312 , 314 , 316 , 318 may be stored in a working memory 330 . These instructions are effectively streamed in advance into the working memory 330 . The laser beam 32 S continually looks to the memory 330 in order to obtain its next set of instructions. In this way, the software instructions are streamed n advance, and this enables the material to be continually lased. This system may produce advantages especially in a continuously formed pattern.
In another modification, it may be recognized that the laser might not be traveling fast relative to the conveyor. This could cause smear in the image. Accordingly, this system may compensate for the speed of the Web relative to the speed of the laser. Say that one wants to form the pattern shown as 400 in FIG. 4 . This pattern is simply a set of vertical lines along with the surface of the web. However, this will be formed while the web is moving. If the patterns are formed from top to bottom, then the web will have moved some amount between the time that 402 is formed, and the time that 404 is formed. The value x is determined as the amount that the web will move in the time it takes the laser beam to scan from 402 to 404 . Since this is linear, (assuming that the web moves at a linear pace), a linear function can be defined which defines the angle of this line 399 in order that corresponds to the real and desired straight line 398 . Thus, the system identifies the distortion in the image that will be formed, and compensates the image prior to applying it to the computer. The inverse of the image 410 is taken shown as 415 , and applied to the computer. By driving the laser beam with its inverse 415 , the speed of the laser may be compensated in the final formed product.
Applications of this system may include any of the devices for materials shown above, and can be used for auto interiors such as trunk and liner panels, home furnishings, any marine application, upholstery for a vehicle including airlines, and the like. Many different systems are described in our patents and co pending applications for using a laser to form of multiple different effects on materials. These effects maybe formed on materials that are being laser machined “in bulk”, i.e. materials which are machines in large rolls, such as 60 inch roles, or the like. Many different effects are known and described.
The system as described herein also enables special advantages which are not possible using conventional techniques. In this embodiment, the pattern is stored in a memory 345 that is associated with the computer 340 . This memory may store information about running lengths of patterns. These patterns that may differ within the overall pattern. For example, the memory may store, as shown in FIG. 5, a first file part 500 which indicates 250 yards of the pattern called matrix. The next file in the memory may indicate 100 yards of the pattern called wire bottom in 352 . The next length 354 may be 500 yards of the pattern called x. This information is read by the computer 510 and the information is sent to computer 510 , and from computer 510 is sent to a numerically controlled laser, of the type described in our previous patents.
This numerically controlled laser may lase patterns onto the material by controlling the energy density per unit time, in a way that does not undesirably damage the material.
The result of lasing the shown as the material web 530 . This one continuous web, which may be a 60 inch or greater width material of any textile, but preferably denim, has a 250 yard section of matrix shown as 542 , 100 yards section of wine bottom shown as 544 , and 500 yard section of pattern x. This may be especially important since certain patterns may need to be lased in certain directions. One such effect, is an effect of local abrasion. Local abrasion is often formed, as explained in our U.S. Pat. No. 6,002,099 by going over different areas multiple times in order to increase the intensity of the effect. This is often done by forming two or more different images and driving the laser with those images to change the look of the material.
In this embodiment, the inventors recognized that if the scribing were done in two separate passes, the resulting pattern could look unnatural at overlap where the material was hit by the laser twice. Accordingly, in this embodiment, the two patterns are fused into a single composite image.
The image is used to drive the laser. A laser is used which has the capability of changing its output power density per-unit time and unique area, in the middle of each scan line. The composite image therefore drives the laser according to one or multiple images which are mathematically added. In another embodiment, the area of overlap between different parts of the image may also be modified to follow a Gaussian, for example.
Any number of different patterns can be continuously formed on the same roll. The process is usually defined in the memory, and this system can uniquely change the pattern on-the-fly.
The above has described the digital information being stored in the memory associated with computer 510 . This digital information can be stored in any form, and specifically can be stored as either raster information, or as vector information. In the case of raster information, the pattern will be lased by the numerically controlled laser moving back and forth as commanded by the raster information. In the case of vector information, the software instructions take into account the specific shape or shapes of the pattern to be formed, which are defined as vector objects. The vector information may be more appropriate for the first embodiment in which the material is indexed, lased and then indexed.
Another aspect which is extremely important is the aspect of twills. Many different materials, including conventional denim, has twills when the fabric is weaved. These twills are effectively ridges in the material which are all parallel and all extend in substantially the same direction. Other materials, referred to herein as crosshatched fabrics, extend in both directions. In one embodiment, the materials can be formed by replicating a crosshatch on the material itself. For example, this may follow the technique shown in FIGS. 8A-C. FIG. 8A shows a twilled fabric, with the twill lines 800 extending across the fabric. This may be for example on a roll or the like. Also on, the roll, the present system uses a laser to mark cross lines. Alternatively, or in addition to the cross lines, this system may be used to mark dots or dashes in an opposite direction to the twill. This can be used to form a crosshatched material. Other materials, such as the velvet or others can be marked in a similar way using a laser. When materials such as velvet are used, often the lines may take the form of the dots in 804 . Even when a line is formed, however, that line is really formed of a number of dots. If the material is looked at closely, it actually looks like the representation in FIG. 8, where the dots as being formed by the laser. In an embodiment, the lines per inch are compressed so that the dots overlap by for example one-third of their diameter. This forms the line shown in FIG. 8C, which is representative of the new marking.
In this case, the laser can freely move relative to the material in any desired way. In a second embodiment in which continuous movement is carried out, a raster scan may be more advantageous.
By forming materials in this way, it becomes possible to produce new materials at relatively low-cost, which are different then any previously-formed materials. Examples of these new materials may include a 60 by 60 wall hanging formed of denim. This wall hanging is lased to include a specified pattern. The pattern may be formed as one large pattern, and then sold as basically a tapestry to appear on the user's wall. The wall hanging may include any of the patterns described in our other applications and patents, including random patterns, tiled patterns, fractal patterns, or textual patterns to include a few.
Some patterns require washing, others not. The system may use an in-line rinsing station.
In addition, both this and other materials may include additive materials of the type that changes their look. For example, the materials may include a glow in the dark type substance called Optiglo. This may cause the materials to glow. The Optiglo material may be selectively absorbed by different parts of the materials more than others. The absorption of the Optiglo can be based on, for example, the way in which the material is lased. If for example, different types of lasing operations change the surface characteristic, and cause the additive to be absorbed at different rates. This by itself may produce a desired effect.
Another advantage of the 60 by 60 frames will be explained relative to FIG. 6 . FIG. 6 shows the specific 60 by 60 frames which may be lased; each frame representing a single or multiple pair of apparel. For example, the frame 600 may include for a pair of pants, a rear leg part 602 , a front leg part 604 , pocket parts 606 , 608 , belt loops, and all of the other parts which will be sewn together in order to form the final apparel. A number of these panels may be lased; for example FIG. 6 shows three adjacent panels 600 , 615 , 616 . It should be understood that as described above, this kind of panel and any other kind of panel can be lased in a series. A number of these panels may be formed, and each of the panels may also include an alignment indicia shown as 612 . The alignment indicia can be simply a pattern part, or could actually be a hole formed through the material. This represents step 599 of the overall process.
After forming these multiple panels, at 620 , the panels are separated and aligned at 620 . This forms a stack shown generally at 624 . At 625 , the aligned stack is cut to remove each of the separated portions. Since presumably each of these portions are substantially identical, the portions may simply be assembled at 630 into finished apparel.
For example, this system may be used to form a three-dimensional effect on materials like and including fabrics, formats, velvet and other similar materials. This may use the techniques described above with regard to twills. Moreover, by varying the amount of energy that is applied to the material at any given time, a three-dimensional effect that is controlled by applied energy may be obtained. This is different than anything done in the prior art. For example, the prior art is not capable of forming a three-dimensional effect using conventional printing technology. The present system may be used to form such a three-dimensional effect on materials.
Without meaning to limit this system, it can be used for the following applications.
Reversible Materials This system can be used to form reversible products. For example, a reversible product may be formed by marking a first pattern on a first side of the roll of material. The roll can then be reversed, and a second pattern may be marked on the second side.
KhakisStretch marks have been painted onto such materials. A problem is that over time, the painted on stretch marks may actually crack. This system may use a laser to form a phantom stretch mark by chemically altering the material. In this way, the laser result will not crack over time.
EmbroideryThis system may be used to form embroidery of a specified type. Usually embroidery is formed all the way through a specified material. In this system, the embroidery is formed on one side only. In this way, the user cannot feel the embroidery when it is being worn, since the inside of the material is totally unchanged. However, the outside has parts which are altered in the shape of the embroidery.
Materials can be used not only for formed materials but also for griege goods. Griege goods may be lazed prior to coloring and then the color selected at the end.
Grayscaleln certain types of material, including certain fabrics, the color is adopted depending on how the material is wove. For example, the grayscale may change the color. This system may be used on bulk rolls for example.
This technique may be used with any of the previously-described techniques which is included but not limited to formation of fractal patterns on textiles. Another embodiment of his system relates specifically to the kinds of patterns which can be formed using the digital technique. One of the advantages of this system is its ability to simulate patterns which are otherwise formed using manual processes. As described in our previous applications, many previous systems used sandblasting which was carried out by a user holding a sandblast gun, and pointing that gun directly at the denim material. Other techniques have been carried out using hand sanding, where a worker actually sands patterns by hand into the material. Other techniques, called “whisker-shapes” have been formed by tracing a tool across apparel, and causing that tool to make whisker shaped patterns on the material.
One embodiment of this application relates to the way in which these otherwise naturally formed patterns can be re-formed in the digital domain. One aspect relates to forming these patterns in reverse. An aspect described herein forms marking patterns which are a digital pattern that is added to the actual pattern to be formed. This marking pattern is then used to modify the original image and formed an image on the textile material which corresponds to a combination of the original image and the marking pattern. Examples of marking patterns are provided herein.
FIG. 7A-7C relates to the way in which the materials may be formed. In FIG. 7A, a pattern 700 is intended to be formed, using techniques that will simulate hand standing. When the inventors investigated hand sanding techniques, they found image parts that look like white lines, going through the patterns. These white lines were formed by the hand sanding and the way it left marks on the material.
In this embodiment, the pattern may be modified to include some of these noise lines that are often left by hand sanding. The pattern 700 corresponds to the original pattern to be formed, which may be, for example, a pattern indicative of sandblasting. Pattern 705 represents a pattern of random white lines such as would be formed by the hand sanding process. Each of the pattern portions such as 706 effectively represents any residue of the pattern at that location. The two patterns, that is the desired pattern 700 and the marking pattern 705 are added together to remove the patterns 705 from the pattern 700 . The resultant pattern 710 is formed as a combination of the two, that is desired pattern 700 , added to marking pattern 705 .
Other patterns which were formed in conventional denim, such as whiskers, can only be formed in one way. In the embodiment shown in FIG. 7B, reverse whiskers may be formed. In FIG. 7B, the whiskers are defined as conventional whisker shapes shown as 725 . However, instead of these whiskers being whiskers that formed as usual on the pattern, they may actually be removals from the pattern in a whisker shape. The pattern 720 may represent the desired pattern, which again may include random noise components. The shape of the whiskers 725 is removed from the desired pattern, to form the resultant pattern 730 . As such a whisker shaped area is removed from the resultant pattern. These whisker shaped areas are actually blanks in the pattern, and although they are shown in dotted lines in the right most portion of FIG. 7B, in fact they would only be blank areas.
In a similar way, any other feature that is usually formed by a hand formation technique may be formed in reverse or and more generally, in any formation. For example, these may be formed as grayscale images, they may be formed in colored patterns, and the like.
Although only a few embodiments have been disclosed in detail above, other modifications are possible. All such modifications are intended to the be encompassed within the following claims, in which | 60-inch-TL-SCH2660-Inch-TL-SCHTechniques of writing information onto a material Web of at least 50 inches in width. The entire material web is written at once. The material written by a continuous scanning technique in which the web continuously moves and the laser writes on the moving web. In an alternative embodiment, the web stops and goes. The web may be formed horizontally in which case the rolls form a horizontal line between them. In another embodiment, the rolls form a vertical line. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Utility Application is being filed concurrently with US Design Application titled “Fluid Dispenser”; having Attorney Docket No. W69.2J-15479-US01; and inventors James Richards, Loren Brelje, and Michael Maher; the contents of which are herein incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention generally relate to devices and methods for dispensing fluids, and more particularly, to a self-venting fluid dispensing assembly and method of production.
BACKGROUND
[0004] Various types of push-button actuated dispensing valves for dispensing liquids from a relatively large capacity container are known in the art. Where the dispensing valve or tap is used with a flexible wall container (e.g., collapsible wall), it is unnecessary for the container to be vented because no pressure differential is created upon emptying of the container through the tap.
[0005] In contrast, with a rigid container, a vent, or other system, must be provided for equalizing the pressure differential created as the contents of the rigid container are dispensed.
[0006] There remains a need for a low cost, easy to assemble, reliable, and self-venting dispensing valve that can be actuated by an operator with a single hand. Further, there remains a need for such a dispensing valve that can be used with liquids of varying viscosity, having an automatic shut-off function to prevent inadvertent dispensing.
[0007] All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.
[0008] Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention, below.
[0009] A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims.
SUMMARY OF THE INVENTION
[0010] In some embodiments, a fluid dispensing valve assembly comprises a housing defining a fluid dispensing port and a vent opening. The valve assembly further comprises a lever extending from the housing over at least a portion of the fluid dispensing port, an elastically deformable resilient member and a seal. In some embodiments, the seal comprises a base portion, a stem extending from the base portion, and a sealing arm extending from the base portion. At least a portion of the seal extends through the fluid dispensing port. Further, in some embodiments, at least a portion of the elastically deformable resilient member and at least a portion of the stem contact the lever.
[0011] In some embodiments, the lever is hingedly attached to the housing.
[0012] In some embodiments, the valve assembly further has an open configuration and a sealed configuration. The resilient member further comprises a sealing tab. In some embodiments, at least a portion of the sealing tab is configured to cover the vent opening when the assembly is in the sealed configuration.
[0013] In some embodiments, the resilient member comprises a dome-shaped portion and a retaining catch.
[0014] In some embodiments, the housing defines a hole through which at least a portion of the resilient member extends.
[0015] In some embodiments, the housing comprises a channel and the seal comprises a guide, the guide slidably disposed within the channel.
[0016] In some embodiments, the housing comprises two channels that are arranged in a facing, opposed relationship, one on either side of the fluid dispensing port.
[0017] In some embodiments, the seal comprises two guides, each guide slidably disposed within one of the two channels.
[0018] In some embodiments, the portion of the stem that contacts the lever is configured to move in an arc and the guides are configured to move linearly.
[0019] In some embodiments, the housing further comprises a pair of flared grip members.
[0020] In some embodiments, the lever is connected to the seal.
[0021] In some embodiments, a fluid dispensing valve assembly has a sealed configuration and a fluid flow configuration. The valve assembly comprises a housing defining a fluid dispensing port and a vent opening. Further, the valve assembly comprises a lever extending from the housing over at least a portion of the fluid dispensing port, an elastically deformable resilient member, and a seal. The elastically deformable resilient member comprises a sealing tab and a dome portion. The sealing tab is configured to cover the vent opening when the valve assembly is in the sealed configuration. In some embodiments, the seal is disposed within the fluid dispensing port and at least a portion of the seal contacts the sealing tab when the valve assembly is in the sealed configuration. In some embodiments, at least a portion of the elastically deformable resilient member and at least a portion of the seal contact the lever.
[0022] In some embodiments, the seal comprises a base portion, a stem extending from the base portion, and a sealing arm extending from the base portion.
[0023] In some embodiments, at least a portion of the sealing arm contacts the sealing tab when the valve assembly is in the sealed configuration.
[0024] In some embodiments, the lever is connected to the seal.
[0025] In some embodiments, the housing comprises at least one channel and the seal comprises at least one guide. The guide is slidably disposed within the channel.
[0026] In some embodiments, the resilient member comprises a retaining catch.
[0027] In some embodiments, the housing comprises a cork seal and a retaining ring opposed to the cork seal.
[0028] In some embodiments, the lever comprises an actuator and the actuator engages the dome portion of the resilient member.
[0029] In some embodiments, a fluid dispensing valve assembly has a sealed configuration and a fluid flow configuration. In some embodiments, the fluid dispensing valve assembly consists of three components. A first component comprises a housing and a lever, a second component comprises a resilient member, and a third component comprises a seal. In some embodiments, at least a portion of the lever is moveable with respect to the housing. The housing defines a fluid dispensing port. In some embodiments, at least a portion of the lever contacts the resilient member and at least a portion of the seal contacts at least a portion of the lever. The seal is moveable within the fluid dispensing port to selectively dispense fluid.
[0030] In some embodiments, the housing defines a vent opening and the resilient member comprises a sealing tab. In some embodiments, the sealing tab covers the vent opening when the valve assembly is in the sealed configuration.
DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1A shows a front perspective view of an embodiment of the valve assembly 10 .
[0032] FIG. 1B shows a back perspective view of the valve assembly of FIG. 1A .
[0033] FIG. 1C shows a side perspective view of the valve assembly of FIG. 1A .
[0034] FIG. 2A shows a front perspective view of an embodiment of the resilient member 16 .
[0035] FIG. 2B shows a cross-sectional view of the resilient member of FIG. 2A .
[0036] FIG. 2C shows a back perspective view of the resilient member of FIG. 2A .
[0037] FIG. 3A shows a perspective view of an embodiment of the seal 18 .
[0038] FIG. 3B shows a side view of the seal 18 of FIG. 3A .
[0039] FIG. 3C shows a back perspective view of the seal 18 of FIG. 3A .
[0040] FIG. 4A shows a cross-sectional view of an embodiment of the valve assembly 10 in the sealed configuration.
[0041] FIG. 4B shows a cross-sectional view of the valve assembly of FIG. 4A in a fluid flow configuration.
[0042] FIG. 5 shows a perspective view of the valve assembly 10 of FIG. 4A .
[0043] FIG. 6A shows a front perspective view of the valve assembly 10 with protective cap 82 .
[0044] FIG. 6B shows a back perspective view of the protective cap 82 of FIG. 6A without valve assembly 10 .
DETAILED DESCRIPTION
[0045] While this invention may be embodied in many different forms, there are described herein specific embodiments. This description is an exemplification of the principles of the invention and is not intended to limit it to the particular embodiments illustrated.
[0046] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated.
[0047] Shown in FIGS. 1A-1C is an embodiment of a fluid dispensing valve assembly 10 , which may also be referred to herein as “valve assembly” or “assembly.” In some embodiments, the valve assembly 10 comprises a housing 12 , a lever 14 , a resilient member 16 , and a seal 18 . As shown in FIGS. 1A-1C , the housing 12 is in an “as-molded” configuration. In the as-molded configuration, the lever 14 has not been yet been folded about hinge 28 (discussed in greater detail below).
[0048] In some embodiments, the housing 12 comprises a cylindrical body 20 and a grip 22 . The cylindrical body 20 is formed to attach to an outlet port on a fluid container, which may contain, for example, a consumable liquid such as water, juice, dairy products, edible oils, and sports drinks. Of course, other liquids of various viscosities are also contemplated.
[0049] In some embodiments, the grip 22 comprises a pair of flared grip members 24 . The flared grip members 24 are contoured to permit the operator to operate the valve assembly 10 with a single hand, for example by placing an index finger and middle finger between a respective grip member 24 and the face 26 of the cylindrical body 20 , as will be apparent from FIG. 1C .
[0050] With further reference to FIGS. 1A-1C , in some embodiments, the lever 14 is hingedly connected to the housing 12 via hinge 28 . In some embodiments, the lever 14 and the housing 12 are formed in the same molding process, and the hinge 28 comprises a section of reduced material thickness connecting the lever 14 to the housing 12 .
[0051] In some embodiments, the lever 14 further comprises a lip 30 and an actuator 32 . The actuator 32 contacts the resilient member 16 when the assembly 10 is in the “as-used” configuration, shown for example in FIGS. 4A and 4B .
[0052] Turning to FIGS. 2A-2C , an embodiment of the resilient member 16 is shown therein. The resilient member 16 comprises a body portion 34 and a sealing tab 36 . The sealing tab 36 is desirably connected to the body portion 34 via tab hinge 38 . In this way, in some embodiments, the sealing tab 36 is hingedly attached to the body portion 34 . Further, the resilient member 16 may be formed in a single molding process, for example by injection molding. Other suitable manufacturing techniques may also be used. In some embodiments, the resilient member 16 is made from a thermoplastic elastomer (TPE), for example a copolyester elastomer such as Arnitel® EM 400. In some embodiments, the resilient member 16 has a durometer of between 25 and 36 shore D, inclusive. In some embodiments, the resilient member 16 has a durometer of 27 shore D and in some embodiments has a durometer of 35 shore D. Additionally, in some embodiments, the resilient member 16 is formed from Arnitel® EL250. The resilient members 16 can also be made from Dynaflex™ TPE or any other suitable material.
[0053] As shown in FIG. 2B , in some embodiments, the tab hinge 38 is a region of decreased material thickness, t, spanning between the body portion 34 and the sealing tab 36 . The material thickness, t, is measured, as shown in FIG. 2B , in cross-section perpendicular to the wall.
[0054] The body portion 34 further comprises a dome portion 40 and a retaining catch 42 . The dome portion 40 is elastically deformable and acts as a spring when pressed on by actuator 32 , as is shown in greater detail in FIGS. 4A and 4B . With particular regard to FIG. 2B , in some embodiments, the retaining catch 42 comprises a barb-like projection or region of increased material thickness, which is measured in cross-section. Adjacent to the retaining catch 42 is recess 44 . As shown in FIGS. 4A and 4B , the resilient member 16 is retained in housing 12 via retaining catch 42 ; a portion of the housing 12 snaps into the recess 44 to hold the resilient member 16 in place.
[0055] Finally, as shown in FIG. 2B , the resilient member 16 comprises reinforced region 46 having increased material thickness. The reinforced region 46 provides an area of increased strength for the actuator 32 ( FIG. 1A ) to contact. And, as shown in FIGS. 2A and 2C , the resilient member 16 comprises a cutout 47 . The cutout 47 fits around fluid dispensing port 48 , as shown in FIGS. 1B , 4 A, and 4 B.
[0056] Turning now to FIGS. 3A-3C , an embodiment of the seal 18 is shown therein. The seal 18 comprises a base portion 50 , a stem 52 extending from the base portion 50 , and a sealing arm 54 extending from the base portion 50 . In some embodiments, the base portion 50 comprises a sealing surface 56 that mates with fluid dispensing port 48 to create a fluid-tight seal between the housing 12 and the seal 18 , as is shown in greater detail in FIG. 4A . Additionally, in some embodiments, the base portion 50 comprises at least one guide 58 ; in some embodiments, for example as shown in FIGS. 3A and 3C , the seal comprises two guides 58 that are located on opposite sides of the base portion 50 . Returning to FIG. 1B , guides 58 are slidably disposed in channels 60 on housing 12 . In this way, as the seal 18 is moved from a sealed configuration ( FIG. 4A ) to a fluid flow configuration ( FIG. 4B ) and vice-versa, the seal 18 tracks along channels 60 ( FIG. 1B ), ensuring proper alignment of the sealing surface 56 with the fluid dispensing port 48 .
[0057] In some embodiments, the stem 52 comprises a latch 62 . The latch 62 engages a keeper 64 on lever 14 ( FIG. 1A ). Keeper 64 retains latch 62 via a snap-fit connection, allowing for easy assembly of the housing 12 and seal 18 . Further, the lever 14 and seal 18 are linked via keeper 64 and latch 62 ( FIG. 1A ) such that as the lever 14 is pushed, the seal 18 moves along channels 60 ( FIG. 1B ), permitting fluid to flow out of the valve assembly 10 . In particular, in some embodiments, as the lever 14 pushes on the stem 52 , moving the seal 18 along channels 60 , the channels 60 restrain the seal 18 from becoming misaligned. Additionally, in some embodiments, the stem 52 elastically deforms as the seal 18 moves along the channels 60 . In this regard, it will be appreciated that the keeper 64 sweeps an arc about hinge 28 . Consequently, the latch 62 of stem 52 moves along the arc of the keeper 64 . Nonetheless, the guides 58 ( FIG. 1A ) move along channels 60 , thereby assuring that the base portion 50 of the seal 18 moves with respect to the housing 12 in a linear, non-arching fashion. This, in turn, promotes a higher rate of flow out of fluid dispensing port 48 ( FIG. 4B ). In some embodiments, because the stem 52 is elastically deformable the latch 62 sweeps an arc with keeper 64 and the base portion 50 of the seal 18 moves linearly along channels 60 .
[0058] With further regard to FIGS. 3A-3C , in some embodiments, the sealing arm 54 extends upwardly at a cant. In some embodiments, the seal 18 comprises a gusset 66 extending between the sealing arm 54 and the base portion 50 . The gusset 66 provides additional strength to the sealing arm 54 . Additionally, the sealing arm 54 has an end portion 68 . In some embodiments, the end portion 68 is angled relative to the sealing arm 54 . In this way, the end portion 68 contacts the sealing tab 36 of the resilient member 16 , for example as shown in FIG. 4A . In some embodiments, when the seal 18 is in the sealed configuration, for example as shown in FIG. 4A , the end portion 68 exerts a force on the sealing tab 36 to maintain the sealing tab 36 in the sealed configuration. In some embodiments, the sealing arm 54 is elastically deformable and acts as a spring, applying pressure to the sealing tab 36 when the valve assembly 10 is in the sealed configuration.
[0059] It will be appreciated that, in some embodiments, the seal 18 and sealing tab 36 need to hermetically seal with the housing 12 in close temporal relationship. In particular, the seal 18 and sealing tab 36 should seal at nearly the same time. Therefore, in some embodiments, the sealing arm 54 is made from a flexible material to prevent leakage and provide tolerance for variation in timing between closure of the seal 18 and sealing tab 36 .
[0060] In some embodiments, the seal 18 is made from High Density Polyethylene (HDPE), for example Dow® DMDA-8409 NT 7 . In some embodiments, the seal is made from a material having a hardness of 59 Shore D. Any other suitable material may also be used.
[0061] In some embodiments, the housing 12 is formed from polypropylene, for example Flint Hills Resources® polypropylene AP5520-HA. In some embodiments, the housing is formed from a material having a hardness of 100 Rockwell R. Other suitable materials with the same hardness or different other hardnesses may also be used, as will be appreciated by the skilled artisan. Moreover, in some embodiments, the housing 12 is formed from a different material than the seal 18 . In particular, in some embodiments, the seal 18 comprises a softer and/or more flexible material than the material of the housing 12 . The softer material of the seal 18 results in the seal 18 elastically deforming to the contour of the housing 12 at contacting locations. For example, the sealing surface 56 of the seal 18 deforms to provide a hermetic seal against the adjacent surface of the fluid dispensing port 48 .
[0062] Turning to FIG. 4A , a cross-section of the valve assembly 10 is shown therein with the valve assembly 10 in the sealed configuration. For the purposes of illustration, however, the keeper 64 on hinge 14 is shown in cutaway. As shown in FIG. 4A , in some embodiments, the housing 12 defines a hole 86 , which may also be referred to herein as a through hole. In some embodiments, a portion of the resilient member 16 extends through the through hole 86 . In this way, the resilient member 16 can be formed from a single piece of material and function as a spring to interact with the lever 14 while also having sealing tab 36 disposed on the inside of the housing 12 . In the sealed configuration, the sealing surface 56 of the seal 18 mates with the adjacent surface of the fluid dispensing port 48 to prevent fluid from exiting valve assembly 10 . Furthermore, the sealing tab 36 covers vent opening 70 .
[0063] In some embodiments, the resilient member 16 is partially deformed when the valve assembly 10 is in the sealed configuration. The resilient member 16 thereby pushes outwardly on the lever 14 via actuator 32 . In turn, the keeper 64 pulls on the seal 18 to maintain a fluid tight seal between the fluid dispensing port 48 and the adjacent sealing surface 56 . Additionally, in some embodiments, the sealing arm 54 applies pressure to the sealing tab 36 .
[0064] Turning to FIG. 4B , when a force, F, is applied to the lever 14 , for example with the operator's thumb, the lever 14 pushes inwardly on the seal 18 . This, in turn, moves the seal 18 inwardly, guided by guides 58 and channels 60 ( FIG. 1B ). Fluid is thereby allowed to flow out of fluid dispensing port 48 , as illustrated by arrows 72 . Meanwhile, to equalize the pressure in the container, as fluid flows out of the container, air is allowed to flow into the container via the vent opening 70 . The sealing tab 36 is allowed to move away from previously obstructed vent opening 70 as the sealing arm 54 moves inwardly toward the container. Air moving into the container is illustrated by arrow 74 .
[0065] In some embodiments, the sealing tab 36 does not open immediately after the lever 14 is pushed inwardly. Instead, due to the fluid pressure on the backside of the sealing tab 36 , it is initially forced closed. This, in turn, prevents a rush of liquid out through the fluid dispensing port 48 . Once the pressure differential between the outside atmosphere and the inside of the container is sufficient, however, the sealing tab 36 opens, and air is allowed to flow into the container.
[0066] When the operator wants to stop fluid from flowing out of the container, the operator merely needs to stop applying force, F, to the lever 14 . After force, F, is no longer applied, the resilient member 16 pushes on actuator 32 and the seal 18 is pulled outwardly via keeper 64 and latch 62 . The valve assembly then reverts to the sealed configuration, as shown in FIG. 4A , when the lever 14 is released.
[0067] With the foregoing in mind, and returning now to FIG. 1A , in some embodiments, the housing 12 further comprises a shroud 76 surrounding the fluid dispensing port 48 . The shroud 76 provides a flow path for fluid exiting the fluid dispensing port 48 and helps to keep contaminants away from fluid dispensing port 48 . With reference to FIG. 1B , in some embodiments, the housing 12 further comprises a cork seal 78 and retaining ring 80 . The cork seal 78 and retaining ring 80 permit the valve assembly 10 to be attached to a container having the appropriate interface, for example a cylindrical collar that snaps into place and is retained via cork seal 78 and retaining ring 80 , as will be appreciated by one of skill in the art. The valve assembly 10 can also be attached to a container via other suitable methods, for example threads, an interference fit, ultrasonic welding, or adhesive. Other suitable options will be appreciated by the skilled artisan.
[0068] Turning to FIG. 5 , the valve assembly 10 is shown therein in an “as-used” and sealed configuration. The lever 14 has been folded about hinge 28 from the “as-molded” configuration of FIG. 1A . Further, as shown in the cross-sectional view of FIG. 4A , the latch 62 has been snapped into place to attach to keeper 64 . An operator can operate the valve assembly by placing his/her thumb on lever 14 and a forefinger and middle finger, respectively, on the outside of a flared grip member 24 .
[0069] FIG. 6A shows the valve assembly 10 with a protective cap 82 covering the lever 14 (not visible) and the face 26 (not visible) of the housing 12 . In some embodiments, the cap 82 has a removable tear strip 84 which is removed prior to use of the valve assembly 10 . The tear strip 84 can show evidence of tampering.
[0070] The cap 82 can be used during shipping of the valve assembly 10 , during attachment of the valve assembly 10 to the container, or during storage, for example. The cap 82 helps to protect against contaminants or debris from interfering with the valve assembly 10 prior to use. Additionally, as shown in FIG. 6B , the cap 82 further comprises a plurality of ribs 90 . The ribs 90 provide strength for the cap 82 , for example, so valve assemblies 10 with protective caps 82 thereon can be stacked during shipping or storage.
[0071] In some embodiments, the valve assembly 10 consists of three components which are manufactured separately and assembled together. In particular, in some embodiments, the valve assembly 10 consists of a first component, comprising the housing 12 and the lever 14 , a second component, comprising the resilient member 16 , and a third component, comprising the seal 18 . In some embodiments, these three components are formed in independent injection molding processes and are subsequently assembled into the valve assembly 10 .
[0072] In some embodiments, the protective cap 82 is formed in another independent injection molding process. After assembly of the first, second, and third components into the valve assembly 10 , the cap 82 is added thereto.
[0073] In addition to the foregoing, some embodiments are directed to a combination of the valve assembly 10 and container, for example a rigid container. In some embodiments, the valve assembly 10 can also be used with a flexible container or package.
[0074] U.S. application Ser. No. 12/839,860, filed on Jul. 20, 2010, and titled “Dispenser Assembly,” is herein incorporated by reference.
[0075] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this field of art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to.” Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0076] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
[0077] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto. | A fluid dispensing valve assembly comprises a housing, a lever, a resilient member, and a seal. The housing defines a fluid dispensing port and a vent opening. The fluid dispensing valve can be operated with a single hand to dispense liquid from a container. Further, upon release of the lever, the fluid dispensing valve automatically returns to a sealed configuration, thereby preventing fluid from leaking out of the container. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates generally to the radiator grilles for automobiles and, more particularly, to a non-opaque grille structure that provides a decorative function for the vehicle.
BACKGROUND OF THE INVENTION
[0002] Presently, the automotive industry is employing opaque radiator grilles that are either chromed, painted to match the body color of the vehicle, or molded in an accent color, such as black. Achieving a body matching color for styling purposes is costly, but is has proven to be important in the view of the consumer. Thus, automotive manufacturers are providing radiator grilles that match the color of the vehicle body to remain competitive with the other manufacturers. Other than primarily directing air flow onto the radiator, the radiator grille performs little other function than decoration. Providing decorative radiator grilles, however, can be rather costly. For example, in a vehicle model in which twelve body colors are provided as an option to the consumer, the manufacturer must keep in inventory a corresponding twelve uniquely painted radiator grilles. Accordingly, it would be desirable to reduce the costs associated with the overall radiator grille costs, yet maintain a competitive styling and marketing image to the consumers.
[0003] In U.S. Pat. No. 4,977,695, granted to Joseph Armbruster on Dec. 18, 1990, an illuminated medallion is deployed on the radiator grille to provide decoration for the front of the vehicle. The Armbruster medallion has a translucent or transparent plastic diffusion panel or cover that allows the passage of light from a bulb mounted within the medallion. Similarly, an illuminated emblem comprised of a plastic housing covered by a translucent or transparent cover to allow the diffusion from a light bulb mounted in the housing and illuminate the emblem is disclosed in U.S. Pat. No. 6,190,026, issued on Feb. 20, 2001, to Matthew Moore. However, an illuminated emblem or medallion is not a radiator grille, but a decoration that can be mounted on or near a radiator grille of a vehicle.
[0004] Illuminated decorative emblems are not confined to the front of the vehicle. As can be seen in U.S. Pat. Publication No. 2002/0105812, by Werner Zimmerman, published on Aug. 8, 2002, on a patent application filed in the U. S. on Dec. 10, 2001. In the Zimmerman patent publication, the illuminated emblem is located on the trunk lid of the automotive vehicle and is formed with a light-transmissive plastic material to allow the illumination of the emblem from LEDs or other light sources housed below the light-transmissive lens covering. In U.S. Pat. Publication No. 2006/0104074, published on May 18, 2006, from a U.S. Pat. Application filed on Sep. 10, 2004, by Robert Boniface, et al, a similar lighted emblem is shown to be deployed on the radiator grille or on the rear trunk lid.
[0005] In U.S. Pat. No. 4,310,872, issued to Henry de S. Lauve on Jan. 12, 1982, a front end for an automotive vehicle is disclosed in which an airfoil band 42 is disposed on the front grille area of the vehicle. The airfoil band is fabricated from clean, untinted glass or plastic that makes the structure beneath the band invisible to the casual observer whether in day or in night. The clear band also allows the light from the headlamps to pass through. A transparent deflector shield is mounted on the front of a vehicle at the radiator grille in U.S. Pat. No. 4,627,657, granted on Dec. 9, 1986, to John Daniels to deflect insects away from the windshield of the vehicle.
[0006] None of the known prior art discloses a radiator grille formed of non-opaque material that would provide many decorative opportunities in the styling of the automotive vehicle. Accordingly, it would be desirable to provide a non-opaque radiator grille for deployment on any automotive vehicle.
SUMMARY OF THE INVENTION
[0007] It is an object of this invention to overcome the aforementioned disadvantages of the known prior art by providing a non-opaque radiator grille for deployment on the forward end of an automotive vehicle to provide the operative function of directing the flow of air onto the radiator, while providing a variety of styling opportunities for the vehicle.
[0008] It is another object of this invention to provide a radiator grille that is cooperative with sensor technology.
[0009] It is an advantage of this invention that the use of non-opaque radiator grilles will result in a reduced cost for an automobile manufacturer.
[0010] It is a feature of this invention that the non-opaque radiator grille can be treated in a variety of ways to provide a differentiation in series or models of vehicles.
[0011] It is another feature of this invention that the non-opaque radiator grille can be adapted with low visibility illumination or carbon fiber or fiberglass mesh graphics that will provide a unique ornamentation for the vehicle.
[0012] It is another advantage of this invention that the use of non-opaque materials for the construction of a radiator grille enables stress risers, defects and knit lines to be more visible to improve quality in radiator grilles.
[0013] It is still another feature of this invention that the radiator grille can be color-keyed to adjacent structural components of the vehicle, such as lamps, housings and bug deflectors.
[0014] It is still another advantage of this invention that the manufacture of the radiator grille can be accomplished in a single step without requiring secondary processes to paint the exterior surface of the grille.
[0015] It is still another advantage of this invention that the lack of secondary processes in the manufacture of the radiator grille provides a more predictable end result by avoiding aberrations due to chroming and painting and avoids chrome reflection and the burning of adjacent parts.
[0016] It is yet another advantage of this invention that secondary finishing processes, such as painting or chroming, can be optionally provided even when using non-opaque materials to construct the radiator grille.
[0017] It is yet another feature of this invention that the non-opaque radiator grille can incorporate luminescent lighting technologies, or be provided with diffused lighting.
[0018] It is still another advantage of this invention that the non-opaque radiator grille can be surface treated on the internal surface of the grille material to provide a textured grille look while maintaining a smooth exterior surface.
[0019] It is yet another advantage of this invention that the radiator grille can be co-injected with light/dark plastic materials.
[0020] It is a further advantage of this invention that the lack of exterior surface treating, such as chroming or painting, eliminates the exposure of the radiator grille to color degradation due to stone impingement.
[0021] It is still a further advantage of this invention that the lack of exterior surface treating, such as chroming or painting, makes recycling of the grille easier to accomplish.
[0022] It is yet another feature of this invention that the non-opaque radiator grille can be formed with ribbing, fluting or lamp-like optics to provide distinctions in appearance.
[0023] It is a further object of this invention to provide a non-opaque radiator grille for an automotive vehicle that is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use.
[0024] These and other objects, features and advantages are accomplished according to the instant invention by providing a non-opaque radiator grille for deployment on an automotive vehicle. The use of non-opaque materials enables the radiator grille to incorporate a variety of different features for styling distinctions, including low visibility illumination, frosting, graphics, ribbing, fluting or other texturing. The grille can be treated or textured on an interior surface of the material to provide the desired textured look, instead of on the exterior surface. The non-opaque grille can be liquid filled, sand blasted and/or incorporate luminescence or diffused lighting. A single grille configuration can be treated internally to provide different styling looks for model or series differentiations. The non-opaque nature of the grille material opens the grille for sensing technology to be incorporated directly into the grille. If secondary external treatment processes are still desired, the use of the non-opaque materials would not prevent the chroming or painting of the radiator grilles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The advantages of this invention will become apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
[0026] FIG. 1A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0027] FIG. 1B is an enlarged partial view of the radiator grille of FIG. 1A corresponding to the circle A in FIG. 1A , and incorporating a first embodiment of the instant invention to provide a textured surface on a select portion of the exterior of the radiator grille;
[0028] FIG. 1C is an enlarged partial view of the radiator grille similar to that of FIG. 1B , but depicting the exterior textured surface treatment placed on a different part of the grille structure;
[0029] FIG. 2A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0030] FIG. 2B is an enlarged partial view of the radiator grille of FIG. 2A corresponding to the circle A in FIG. 2A , and incorporating a second embodiment of the instant invention to provide a textured surface on a select portion of the interior of the radiator grille;
[0031] FIG. 2C is an enlarged partial view of the radiator grille similar to that of FIG. 2B , but depicting the interior textured surface treatment placed on a different part of the grille structure;
[0032] FIG. 3A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0033] FIG. 3B is an enlarged partial view of the radiator grille of FIG. 3A corresponding to the circle A in FIG. 3A , and incorporating a third embodiment of the instant invention to provide a bubbled appearance on a select portion of the radiator grille;
[0034] FIG. 3C is an enlarged partial view of the radiator grille similar to that of FIG. 3B , but depicting the bubbled appearance for the grille structure;
[0035] FIG. 4A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0036] FIG. 4B is an enlarged partial view of the radiator grille of FIG. 4A corresponding to the circle A in FIG. 4A , and incorporating a fourth embodiment of the instant invention to provide a portion of the radiator grille filled with liquid, gas or other media;
[0037] FIG. 4C is an enlarged partial view of the radiator grille similar to that of FIG. 4B , but depicting the different part of the grille structure that is filled with liquid, gas or other media;
[0038] FIG. 5A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0039] FIG. 5B is an enlarged partial view of the radiator grille of FIG. 5A corresponding to the circle A in FIG. 5A , and incorporating a fifth embodiment of the instant invention to provide carbon fiber or fiberglass mesh graphics within or on a select portion of the radiator grille;
[0040] FIG. 5C is an enlarged partial view of the radiator grille similar to that of FIG. 5B , but depicting carbon fiber or fiberglass mesh being placed at a different part of the grille structure;
[0041] FIG. 6A is a perspective view of a radiator grille for an automobile incorporating the principles of the instant invention;
[0042] FIG. 6B is an enlarged partial view of the radiator grille of FIG. 6A corresponding to the circle A in FIG. 6A , and incorporating a sixth embodiment of the instant invention to provide a ribbing or fluting on a select portion of the interior or exterior of the radiator grille;
[0043] FIG. 6C is an enlarged partial view of the radiator grille similar to that of FIG. 6B , but depicting the ribbing or fluting being associated with a different part of the grille structure;
[0044] FIG. 7 is a perspective view of a radiator grille for an automobile in which the non-opaque grille has been co-injected with light and dark plastics to provide a distinctive styling appearance for the grille;
[0045] FIG. 8 is a perspective view of a radiator grille for an automobile in which the non-opaque grille is associated with a low visibility diffused or luminescent lighting on selected portions of the grille;
[0046] FIG. 9 is an enlarged portion of the radiator grille to reflect the ease of identifying defects, such as stress risers and knit lines in the grille structure;
[0047] FIG. 10 is an enlarged portion of the radiator grille incorporating the principles of the instant invention to be associated with sensor technologies;
[0048] FIGS. 11-16 are perspective representations of emblems that can be formed from non-opaque material to incorporate the same treatments reflected in FIGS. 1-6 above; and
[0049] FIGS. 17-20 depict the utilization of the principles of the instant invention on grilles found on the front, rear, top and sides of the automotive vehicle on which the instant invention is deployed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0050] Referring to FIGS. 1A-20 , a radiator grille for deployment on an automotive vehicle and incorporating the principles of the instant invention can best be seen. The body of the radiator grille 10 is formed of non-opaque plastic material, such as ABS or polycarbonate, and may be formed as a hollow body, to define and interior surface and an exterior surface shaped into the desired shape or configuration, such as the radiator grille 10 shown in FIGS. 1A-6C , which can be utilized on a sport utility vehicle (SUV). The radiator grille 10 is preferably injection molded, but could be formed through rotational molding techniques, as well. Furthermore, portions of the radiator grille 10 could be extruded. During the formation of the radiator grille, or once the radiator grille 10 is formed, from non-opaque material, the grille 10 can be subjected to a variety of different treatments to obtain the desired appearance for the styling considerations placed on a particular vehicle, or series or model of vehicle.
[0051] A first treatment for the radiator grille 10 is depicted in FIGS. 1A-1C and corresponds to a textured exterior surface 12 for all or selected portions of the grille structure. Treatment of the exterior surface 12 could include a frosting appearance that can be obtained through sand blasting. Other treatment options could include a graining or dimpling, or other specific texture placed onto the exterior surface 12 . Another treatment is no treatment at all, which can provide a clear, translucent appearance to the radiator grille 10 . As is reflected in a comparison between FIGS. 1B and 1C , the treatment to the exterior surface can be applied to selected portions, such as the outer band 13 or the grille mesh 15 , as is shown in FIG. 1B , or to the interior band portions 14 of the grille 10 , as is depicted in FIG. 1C .
[0052] Since the grille 10 is non-opaque, a frosted appearance can also be attained by treating the interior surface of the grille structure 10 , leaving the exterior surface 12 smooth so that the exterior surface will not accumulate extraneous materials, such as a buildup of car wax. Substantially the same treatments that can be made to the exterior surface 12 can be made to the interior surface 16 of the grille, including graining, dimpling, sand blasting, etc. to provide the desired styling appearance. As with the exterior surface treatments depicted in FIGS. 1B-1C , the interior surface treatments shown in FIGS. 2B-2C can be placed on all of the interior surface 16 or just on selected portions of the interior surface 16 , such as the outer band 13 or the interior band portions 14 .
[0053] As is reflected in FIGS. 3A-3C , the grille structure 10 can be formed with internal bubbles placed in a regular pattern to provide a styling appearance that cannot be obtained with conventional opaque radiator grilles. As with the surface treatments represented in FIGS. 1A-2C , the internal bubbles formed in the grille structure 10 can be placed into all of the grille structure 10 or into only selected portions of the grille structure 10 , such as the outer band 14 and/or grille mesh 15 , as depicted in FIG. 3B , or on the interior band 14 as is depicted in FIG. 3C .
[0054] If the radiator grille 10 is formed as a hollow body, the interior can be filled with liquid, gas or other media, as is depicted in FIGS. 4A-4C , such as with a colored liquid that provides the desired styling characteristics desired for the particular vehicle. By internally compartmentalizing the interior of the hollow body radiator grille structure 10 with internal walls or baffles, selected portions of the grille structure 10 can be liquid filled, such as the outer band 13 as shown in FIG. 4B , or the interior band 14 as shown on FIG. 4C , instead of the entire grille structure 10 . Since the grille mesh 15 can also be formed as a hollow, watertight body, the grille mesh 15 can also be separately filled with liquid, gas or other media, as is depicted in FIG. 4B .
[0055] Yet another treatment that can be applied to either the exterior 12 or interior 16 surfaces of the grille structure 10 , or embedded within the plastic material, are carbon fiber graphics or fiberglass mesh graphics, as is represented in FIGS. 5A-5C . With applied graphics, many different appearances can be obtained, including fresnel, smoked glass, amber, marble, metallics, chrome, faceted, geometries, etc. As with the other surface treatments, the graphics can be applied to the entire grille, within the material forming the grille or on the surface, or to selected parts, such as the outer band 13 and grille mesh 15 shown in FIG. 5B , or the interior band as shown in FIG. 5C .
[0056] With the radiator grille structure 10 being injection molded, the mold can be configured to incorporate structural alterations into the plastic body of the grille 10 into either the interior 16 or exterior 12 surfaces. Such physical structural alterations, as are represented in FIGS. 6A-6C , can include ribbing, fluting or lamp-like optics. As with the other treatments, the physical structural alterations can be formed into all of the radiator grille structure 10 in a desired configuration, or only to selected portions of the grille 10 , such as the outer band 13 and/or grille mesh 15 shown in FIG. 6B , or the interior band 6 C as shown in FIG. 6C .
[0057] The use of injection molding techniques to manufacture the radiator grille 10 incorporating the principles of the instant invention also provide the opportunity to incorporate the co-injection of light and dark plastic materials into the structure of the grille 10 to establish a specific styling characteristic, as is represented in FIG. 7 .
[0058] A great amount of flexibility in the styling appearance of the radiator grille 10 can come through the use of low visibility lighting techniques. Since the grille 10 is formed from non-opaque plastic material, such as polycarbonate, many lighting technologies, including fiber optics, bulb lighting, LED's, can be utilized. The lighting techniques can be selectively applied internally to the entire grille structure 10 on to specific surfaces or edges, such as around one or more grille pockets 19 , as is depicted in FIG. 8 . One skilled in the art will recognize that the low visibility light techniques can make the radiator grille glow, when the lighting is selectively operated, with substantially any color or colors desired. The lighting can be diffused, and/or the low visibility lighting techniques can incorporate luminescence technology.
[0059] The use of non-opaque plastic materials in the manufacture of radiator grilles 10 make the observance of defects, such as stress risers, knit lines, etc. in the grille structure, as is depicted in FIG. 9 . Accordingly, quality measurements can be improved for radiator grilles. With the non-opaque attributes of the radiator grille 10 , sensors 20 can be built into the grille structure 10 to open the way for sensor technology to be incorporated into radiator grilles 10 , as is represented in FIG. 10 .
[0060] Injection molding the emblems 30 or other supplementary ornamentation placed on a vehicle from non-opaque materials, as is described above with respect to the radiator grilles 10 , enables the same treatments described above in FIGS. 1A-6C to be applied to the emblems 30 , thus providing matching emblem 30 styling characteristics. In FIG. 11 , the outer surface 32 of the emblem 30 is physically treated. In FIG. 12 , the interior surface 36 of the emblem 30 is similarly treated. In FIG. 13 , the internal structure of the emblem 30 is formed with a regular pattern of bubbles. In FIG. 14 , low visibility lighting technologies is applied to the emblem 30 . In FIG. 15 , the emblem 30 is formed as a watertight hollow body which can be liquid filled. Also, as is represented in FIG. 16 , the emblem can be treated with graphics, buried within the emblem material or applied to the surface thereof, such as carbon fiber or fiberglass mesh graphics.
[0061] As is best seen in FIGS. 17-20 , all of the external vehicle grilles 42 associated with parts of the vehicle 40 other than the radiator can also be formed in accordance with the principles of the instant invention, including air intake grilles 44 , 45 . These external and air intake grilles 42 , 44 , 45 can be color coded or treated to correspond to the part of the vehicle on which the grille 42 , 44 , 45 is deployed.
[0062] The formation of the grilles for an automotive vehicle according to the principles of the instant invention can easily provide an in-series or model differentiation. The grilles provide a unique look and present a lightweight and low cost alternative to conventional opaque chromed or painted grilles. The grilles can be manufactured in one piece or in multiple piece configurations. With no chrome or paint surface on the exterior of the grille, there is no opportunity for stone impingement to cause a degradation of the surface appearance of the grille. Furthermore, without the extra chrome or paint surface to be added to the grille, the manufacturing process for the grille is much simpler, and the recycling of the grille is easier without the need to strip the chrome or paint surface. Of course, if the chroming or painting of the exterior surface is still desired, the formation of the grille 10 from non-opaque plastic materials will not prevent this added processing step from being accomplished.
[0063] One skilled in the art will understand that each of the treatments described above are not mutually exclusive. In fact, two or more of the described treatments may be used simultaneously on the grille. For example, either the interior or exterior surfaces could be physically altered by sandblasting to achieve a frosted appearance for the grille, while low visibility lighting techniques are applied to provide a desired color effect for the grille. Other combinations of treatments will be equally combinable to provide the aesthetic appearance desired for the grille, and/or to provide in-series differentiation.
[0064] It will be understood that changes in the details, materials, steps, processes and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention. | A non-opaque radiator grille is deployed on an automotive vehicle. The use of non-opaque materials enables the radiator grille to incorporate a variety of different features for styling distinctions, including low visibility illumination, frosting, graphics, ribbing, fluting or other texturing. The grille can be treated or textured on an interior surface of the material to provide the desired textured look, instead of on the exterior surface. The non-opaque grille can be liquid filled, sand blasted and/or incorporate luminescence or diffused lighting. A single grille configuration can be treated internally to provide different styling looks for model or series differentiations. The non-opaque nature of the grille material opens the grille for sensing technology to be incorporated directly into the grille. If secondary external treatment processes are still desired, the use of the non-opaque materials would not prevent the chroming or painting of the radiator grilles. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from provisional patent application Ser. No. 60/629,664 filed Nov. 19, 2004 and provisional patent application Ser. No. 60/724,173 filed Oct. 6, 2005 pursuant to one or more of 35 U.S.C. §119, §120, §365. The entire contents of both cited provisional patent applications is incorporated herein by reference for all purposes.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
(none)
BACKGROUND OF THE INVENTION
1. Field of Invention
This invention relates generally to the field of fastening devices and methods of use, more particularly, to threaded fasteners and thread clamping devices, and most particularly to thread clamping devices typically in combination with a bearing plate and other components as a self-adjusting shrinkage compensation device.
2. Description of the Prior Art
Wood is a major construction material in many places throughout the world. Wooden structures frequently use “tie-downs” to secure the wooden structure to its foundation, typically a concrete foundation. The function of tie-downs is thus to secure the wooden structure to its foundation in the presence of forces (perhaps substantial forces) tending to separate the structure from its foundation, such as high winds, seismic events or general shifting and settling of the surrounding earth. However, the wood typically used for construction often has considerable water content when initially installed and with time, the water evaporates and the wood dries out. In the process of drying out, the wood dimensionally shrinks. Approximately 4% shrinkage in the first year following construction of a wooden structure is not uncommon. This shrinkage commonly causes tie-downs to loosen, thereby making the structure more susceptible to damaging displacements in the presence of high winds, earthquakes among other external forces. Catastrophic damage may result.
A common method for implementing a tie-down is by imbedding a vertical threaded rod into the concrete of the foundation at the location where the wooden structure is to be joined to the foundation. The threaded rod generally resides within the walls of a single or multilevel structure as it passes from the concrete foundation up through each floor of the structure. Each floor is typically attached to the threaded rod by a separate tie-down. The primary fastener presently used to implement a tie-down is a standard “hex” nut.
If a standard nut is used, a space will typically develop under the standard nut and above the wood as the wood shrinks in dimension due to loss of water as described above. This space allows the tie-down (and structure) to move vertically when an overturning moment is applied to the structure as might occur, for example, during a seismic event, wind loading, among other circumstances. This motion of the structure with respect to the foundation, in turn, allows for deformation of the structural walls and may produce substantial damage that the tie-down is designed to prevent when functioning properly, that is when holding the structure securely in place on the foundation. Thus, a need exists in the art for a tie-down that is self-compensating, that is, a tie-down that maintains secure attachment of the structure to the foundation despite shrinkage of the wood.
As described in detail below, various embodiments of the present invention relate to thread clamping devices that include movable segments or “nut segments.” Some distinguishing characteristics of some embodiments of the present invention relate to flat (or planar) surfaces on the nut segments contacting flat surfaces on the top and/or end housings of the thread clamping device. Other shrinkage compensation devices having moveable segments include those of Sasaki (U.S. Pat. No. 5,081,811) and Taneichi (U.S. Pat. No. 6,007,284). Related art includes the following U.S. Pat. Nos. 3,695,139; 4,378,187; 4,974,888; 5,324,150; 5,427,488; 5,733,084; 5,988,965; 6,361,260; 6,406,240. However, these devices use frustoconical surfaces to support the nut segments. That is, the surfaces of the nut segment and the surface(s) of the housing that the nut segment is matched against are both conical. This is a disadvantageous structure since (among other reasons) two conical surfaces only match exactly at a single position and at any other position the two surfaces contact only at lines and points. This typically causes high stress concentrations along the lines and points of contact. Also, as the two non-planar surfaces slide relative to one another in a radial direction, the two surfaces are forced apart. This causes non-linear motion of the segments and can cause the segments to jam within the supporting top and bottom structures if insufficient clearance is not allowed. The flat surfaces employed on various embodiments of the present invention reduce or avoid these problems by employing flat surfaces and a structure such that no conical surfaces engage one another. These flat surfaces allow linear segment motion and are easily guided as they move between minimum and maximum radial positions. Also, the use of flat surfaces causes the stress loads to be distributed over the entire flat surface area and thus the local stresses remain relatively low within the thread clamping device pursuant to various embodiments of the present invention. This is true even when sufficient forces are applied so as to force the rod engaged by the thread clamping device to fail in tension.
In addition, a major construction cost is often the cost of labor. Therefore, installation of tie-downs in a manner that reduces labor costs is advantageous. For example, one common requirement when installing tie-downs is that threaded rods be connected together end to end. This is generally accomplished with a machined component having internal threads matching the threaded rod. Often, the threaded rod that comes out of the foundation of the structure is of very short length and another threaded rod is connected to this short rod using a connector. The connector is first turned and threaded onto the projecting end of rod protruding from the foundation and a second rod joined to the first by means of the connector. This requirement to connect two threaded rods is fairly common worldwide, and not specific to the construction industry. This process of connecting two rods, most often performed manually, is time consuming and labor intensive. Thus, a need exists in the art for devices and procedures for the efficient and rapid connection of threaded rods.
SUMMARY OF THE INVENTION
Accordingly and advantageously the present invention relates to thread clamping devices including as a component thereof nut segments having flat surfaces that engage corresponding surfaces of the devices end housing and top housing. This flat-against-flat structure provides advantages in strength, stability and durability among other advantages. Such thread clamping devices can be combined with other structures to provide a self-adjusting shrinkage compensation device, couplers for threaded rods, among other devices. Methods of employing such thread clamping devices are also described.
In view of the foregoing, in accordance with the various embodiments of the present invention, there is provided a Thread Clamping Device (“TCD”) which may be advantageously configured pursuant to some embodiments of the present invention to move axially along a threaded rod in one direction without rotation, and further, will not move axially in the opposite direction without rotation. Indeed, in one embodiment, the TCD when combined with a bracket or bearing plate may become a “tie-down” for use in construction or for other purposes.
A bearing plate to distribute the load and to prevent medium crushing is typically attached to the shrinking medium (such as wood) using any convenient attaching means such as traditional screws, nails, rivets, adhesives, among others. The bearing plate is typically sandwiched between the TCD and the shrinking medium. That is, the bearing plate is located between the TCD and the shrinking medium. For typical wooden construction, a threaded rod protrudes vertically from a concrete foundation and upwards through components of the wooden structure such as a wooden wall top plate for single level construction or floor plate for the above floors in multilevel construction. Thus, the TCD is “on” the rod above the bearing plate (where “on” denotes having the rod passing through the TCD and engaging therewith substantially as depicted in FIG. 1 ). In this manner, as shrinkage of the wood occurs, the screws typically attaching the TCD to the top plate or floor plate would pull the TCD downward with respect to the threaded rod. Each time the TCD moves at least one half (½) thread downward, the TCD pursuant to some embodiments of the present invention has a structure that permits the TCD to internally ratchet and lock in place, thus preventing the TCD from moving upward with respect to the threaded rod (where the threaded rod itself cannot move as one end is buried in concrete during the construction process). Thus, the TCD maintains a tight tie-down despite shrinkage.
Additionally, in some embodiments of the present invention, a coupler comprising two TCDs is incorporated into a single package, back to back, to couple ends of two opposing threaded rods. Moreover, in yet other embodiments of the present invention, a quick release mechanism is included within the TCD which allows for fast and convenient release of TCD engagement from the threaded rod. Additionally, further embodiments of the present invention relate to methods of attachment of a TCD to commercially available “hold-downs”. Hold-downs attach to the shrinking medium (such as wood) and provide substantially the same load distribution function as a bearing plate. Mechanical and magnetic attachment methods of TCD to hold-downs are described.
Additionally, another advantage of the TCD over a traditional hex nut is that the TCD is capable of successfully engaging a damaged threaded rod, even when a substantial portion of the threads of the rod have been deformed or contaminated with material (such as concrete) to the point where the standard hex nut will jam.
These and other features and advantages of the present invention will be understood upon consideration of the following detailed description of the invention and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The drawings herein are schematic, not to scale and the relative dimensions of various elements in the drawings are not to scale.
Some of the drawings depict threaded structures having internal threads, external threads or both. An artifact in the drawing program produces threads whose depiction in the figures may appear as lacking the true spiral structure of actual threads, although the thread profile is properly depicted. However, the threads are depicted herein for purposes of explaining various structures, embodiments and/or other features or uses in connection with the present invention, and the possible apparent absence of spirals in the depiction does not affect the description of the invention.
The techniques of the present invention can readily be understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a typical threaded clamping device (TCD) and threaded rod.
FIG. 2 is a top view of a typical TCD.
FIG. 3 is a first side view of a typical TCD.
FIG. 4 is a second side view of a typical TCD.
FIG. 5 is a top perspective three dimensional view of a typical TCD disassembled.
FIG. 6 is a top view of a typical end housing.
FIG. 7 is a vertical sectional view of the end housing taken substantially along line 7 - 7 of FIG. 6 .
FIG. 8 is a three dimensional top perspective view of a typical end housing depicting segments in different positions.
FIG. 9 is a three dimensional top perspective view of a typical end housing and four segments in the engaged position.
FIG. 10 is a three dimensional top perspective view of a typical end housing and four segments in the disengaged position.
FIG. 11 is a three dimensional top perspective view of a typical end housing and four segments.
FIG. 12 is a three dimensional top perspective view of a typical end housing and four segments of identical threaded phase.
FIG. 13 is a bottom perspective view of a typical TCD with top housing partially removed to reveal internal components.
FIG. 14 is a top perspective view of a typical TCD with top housing partially removed substantially along line 14 , 18 - 14 , 18 of FIG. 2 to reveal internal components.
FIG. 15 is a three dimensional top perspective view of four nut segments, coil springs and a threaded rod.
FIG. 16 is an expanded outer perspective view of a single nut segment.
FIG. 17 is an expanded inner perspective view of a single nut segment.
FIG. 18 is a vertical cross sectional view of a typical TCD taken substantially along line 14 , 18 - 14 , 18 of FIG. 2 , and threaded rod depicting motion direction.
FIG. 19 is a perspective view of a typical assembly of TCD, screws and bearing plate.
FIG. 20 is a top perspective view of a typical TCD and bearing plate installed on a structure.
FIG. 21 depicts a partial stud structure and foundation with TCD, bearing plate installed onto a threaded rod.
FIG. 22 is a top three dimensional perspective view of a coupler assembly and two threaded rods disengaged.
FIG. 23 is a top three dimensional perspective view of a coupler assembly engaged with two threaded rods in the installed position.
FIG. 23A is a top view of a typical coupler.
FIG. 24 is a cut-away cross sectional top perspective view taken substantially along line 24 , 25 - 24 , 25 of FIG. 23A , of a coupler assembly and internal components.
FIG. 25 is a cross sectional view taken substantially along line 24 , 25 - 24 , 25 of FIG. 23A , of a coupler and engaged threaded rods. Also motion directions are shown.
FIG. 26 is a three dimensional exploded top perspective view of a TCD and components.
FIG. 27 is an outside perspective side view of a single nut segment.
FIG. 28 is an inside perspective side view of a single nut segment.
FIG. 29 is a three dimensional top perspective view of a typical multi-nut segment TCD.
FIG. 30 is a three dimensional exploded top perspective view of a multi-nut segment TCD and components.
FIG. 30A is a top view of a typical multi-nut segment TCD.
FIG. 31 is a three dimensional top perspective view of a multi-nut segment TCD with housing partially removed substantially along line 31 , 32 - 31 , 32 of FIG. 30A to reveal internal components.
FIG. 32 is a cross sectional view taken substantially along line 31 , 32 - 31 , 32 of FIG. 30A , of a typical multi-nut segment TCD also showing motion directions.
FIG. 33 is a three dimensional top perspective view of a typical TCD with quick release mechanism in the unreleased position.
FIG. 34 is a three dimensional top perspective view of a typical TCD with quick release mechanism in the released position.
FIG. 35 is a three dimensional exploded perspective view of a typical TCD and internal components.
FIG. 36 is a top view of a TCD with release mechanism showing the wire posts in the unreleased position.
FIG. 37 is a top view of a TCD with release mechanism showing the wire posts in the released position.
FIG. 38 is a bottom perspective view of TCD release mechanism where the housing and segments have been removed and the end housing is depicted in cross section.
FIG. 39 is a top three dimensional perspective view of TCD, connector clip, coupler, threaded rod, sheet metal hold-down and the wood structure before assembly.
FIG. 40 is a top three dimensional expanded perspective view of a typical TCD attached to a sheet metal hold-down.
FIG. 41 is a top perspective view of a TCD, wire clip, and cross sectional depiction of a magnetic bracket assembly.
FIG. 42 is a top three dimensional expanded perspective view of a typical TCD, wire clip, and magnetic bracket attached to a sheet metal hold-down.
FIG. 43 is a top three dimensional perspective view of a typical TCD, wire clip, magnetic bracket, studs, and tube connector with a portion thereof removed to show cross bolts and threaded rod.
FIG. 44 is a perspective view of another TCD embodiment and threaded rod.
FIG. 45 is a top view of a typical TCD.
FIG. 46 is a first side view of a typical TCD.
FIG. 47 is a second side view of a TCD.
FIG. 48 is a top perspective three dimensional view of a TCD disassembled.
FIG. 49 is a top view of an end housing.
FIG. 50 is a vertical sectioned view of the end housing taken substantially along line 50 - 50 of FIG. 49 .
FIG. 51 is a three dimensional top perspective view of a typical end housing depicting segments in different positions.
FIG. 52 is a three dimensional top perspective view of a typical end housing and four segments having identical threaded phase.
FIG. 53 is a bottom perspective view of a typical TCD with top housing partially removed to reveal internal components.
FIG. 54 is a top perspective view of four nut segments, coil springs and a threaded rod.
FIG. 55 is an expanded outer perspective view of a single nut segment.
FIG. 56 is an expanded inner perspective view of a single nut segment.
FIG. 57 is a vertical cross sectional view taken substantially along line 57 - 57 of FIG. 45 , of a typical TCD and threaded rod depicting motion direction.
FIG. 58 is a perspective view of a typical assembly of TCD, fasteners and bearing plate.
FIG. 59 is an expanded perspective view of a typical TCD and bearing plate installed on a structure.
DETAILED DESCRIPTION
After considering the following description, those skilled in the art will clearly realize that the teachings of the invention can be readily utilized in the construction of fasteners, thread clamping devices, self-adjusting shrinkage compensation devices, among other structures and devices.
FIG. 1 depicts, in perspective view, a typical thread clamping device (“TCD”) 10 engaged with a threaded rod 11 in accordance with some embodiments of the present invention. FIGS. 2 , 3 and 4 show top view, first side view and second side view respectively of TCD 10 . FIG. 5 depicts a typical TCD 10 including a bottom end housing 12 (in short, “end housing”), nut segments 16 A, 16 B, 16 C and 16 D supported by end housing 12 , and a top end housing 14 (in short, “top housing”) engaging end housing 12 with one or more fasteners 22 . For economy of language, “nut segments” are also referred to as “segments.” Nut segments 16 A, 16 B, 16 C and 16 D are contained within top housing 14 .
To be concrete in our descriptions, we describe herein the typical case in which four nut segments are used. However, this is not an essential limitation of the present invention as a different number of segments can be used. At least two segments are needed to enable the segments to move radially with respect to the threaded rod. An even number of segments is advantageous in that segments are thus positioned diametrically opposed across the threaded rod, loading the rod symmetrically with the opposing segments tending to be loaded equally. This is advantageous from the standpoint of stress distribution. But odd numbers of segments are not inherently excluded. Using a larger number of segments is disadvantageous in that the manufacturing cost of the TCD is likely to be increased, but also included within the scope of the present invention. Four segments are considered to be most advantageous from considerations of functionality, manufacturability and assembly.
Two coil springs 18 and 20 are shown surrounding nut segments 16 A, 16 B, 16 C and 16 D. At least one spring (or equivalent means) is needed for compressing the nut segments against the threaded rod. While one or two is an advantageous number pursuant to some embodiments of the present invention, it is not an essential limitation and more can be used.
Fastener holes 24 are shown in the top view of FIG. 2 . Mounting fasteners 26 are shown in FIG. 19 . Mounting fastener 26 passing through fastener hole 24 and plate fastener hole 30 attaches TCD 10 to the shrinking medium 32 (typically wood) shown in FIG. 20 . Upon installation of mounting fastener 26 , bearing plate 28 is also attached in that bearing plate 28 is sandwiched between TCD 10 and the shrinking medium 32 .
While the top housing 14 is typically shown with substantially cylindrical side surfaces, within the scope of the present invention, the top housing 14 of the TCD 10 also includes hexagonal, cubic, square or other substantially tubular configurations capable of accommodating threaded rod 11 , and which is capable of including the components and features of the TCD 10 as described herein.
FIG. 5 illustrates a complete TCD 10 with various parts depicted in exploded view. While FIG. 5 shows two housing fasteners 22 (typically screws) to be mounted to end housing 12 so as to couple end housing 12 to top housing 14 , a larger or smaller number of fasteners 22 can also be used (depending in part upon the shape of TCD 10 ), within the scope of the present invention. Above end housing 12 is shown the lower coil spring 18 and above spring 18 is upper coil spring 20 .
Referring to FIG. 5 , directly above spring 20 are shown nut segments 16 A, 16 B, 16 C and 16 D. Above segments 16 A, 16 B, 16 C and 16 D is shown top housing 14 . The parts depicted in FIG. 5 , when assembled, comprise a complete TCD 10 pursuant to some embodiments of the present invention.
Also shown in FIG. 5 are slots 38 , right inner bearing surfaces 40 and left inner bearing surfaces 41 in end housing 12 . There are, in this example, four slots 38 , four right inner bearing surfaces 40 and four left inner bearing surfaces 41 arranged in a substantially equidistant polar array relative to central axis 8 (see FIG. 7 ). In TCD 10 , central axis 8 is substantially coincident with the axis of threaded rod 11 .
Inner bearing surfaces 40 , 41 and slot 38 are defined as a “feature set”. Also slot 38 , right inner bearing surface 40 and left inner bearing surface 41 typically have an orientation of substantially 30 degrees relative to central axis 8 . FIG. 5 also shows nut segment ribs 46 , segment upper spring groove 42 , segment lower spring groove 44 , left outer segment surface 48 and right outer segment surface 50 . There is generally one nut segment rib 46 , one segment upper spring groove 42 , one segment lower spring groove 44 , one inner sloping surface 36 , one left outer segment surface 48 and one right outer segment surface 50 for each segment 16 A, 16 B, 16 C and 16 D. In the following descriptions various configurations of nut segment assemblies will be described. For economy of language, we define segments 16 A, 16 B, 16 C and 16 D as shown in FIG. 5 as Nut Segment Assembly I or “NSA-I.”
FIG. 6 is a top view of end housing 12 . Shown in top view are right inner bearing surface 40 , left inner bearing surface 41 and slot 38 .
FIG. 7 shows slot 38 and surfaces 40 and 41 as substantially parallel and at substantially a 30 degree angle relative to central axis 8 . In an assembled configuration (as depicted, for example, in FIG. 5 ), segment surfaces 48 and 50 bear against end housing surfaces 40 and end housing surface 41 respectively for each of the four segments 16 A, 16 B, 16 C, 16 D.
In an assembled configuration as depicted in FIG. 5 for example, left and right outer segment surfaces 48 and 50 respectively bear against right and left inner bearing surfaces 40 and 41 respectively for each of the four nut segments 16 A, 16 B, 16 C and 16 D.
To be precise in our language we intend “outer segment surface” to denote the outermost surface (s) on the lower portion of each segment (in the orientation of FIG. 5 ), e.g., 48 and 50 in FIG. 5 . The phrase “outer segment surface” does not include any surface of any raised portion or “segment rib” such as denoted by 46 in FIG. 5 .
Further, we intend “inner bearing surface” to denote the innermost surface (s) on the tapering, inner portion of the end housing 12 , e.g., 40 and 41 in FIG. 5 . The phrase “inner bearing surface” does not include any surface of any depressed portion or “slot” such as denoted by 38 in FIG. 5 .
As discussed in detail elsewhere herein, an important feature of some embodiments of the present invention relates to the use of planar surfaces as both outer segment surfaces and inner bearing surfaces, in contrast to the prior art in which frusto-conical surfaces are used in comparable locations. Thus, comparisons of the present invention with prior art should focus on the inner bearing surfaces and the outer segment surfaces. Structure of any segment rib(s) and slot(s) are not relevant to this comparison.
For economy of language, we refer to nut segments 16 A- 16 D as “segments,” inner bearing surfaces 40 and 41 as “end housing surfaces,” and left and right outer segment surfaces 48 and 50 as “segment surfaces.”
The end housing surfaces 40 and 41 lie in a single plane separated into two (left and right) surfaces by slot 38 . Similarly, segment surfaces 48 and 50 lie in a single plane separated by nut segment rib 46 .
FIG. 8 is a three dimensional top perspective view of end housing 12 depicting only two nut segments 16 B and 16 C. Segment 16 C is shown in an engaged position and segment 16 B is shown in an extreme disengaged position. It can also be observed that nut segment rib 46 resides substantially within slot 38 . All nut segment ribs 46 reside in their respective slots 38 .
FIG. 9 is a three dimensional top perspective view of end housing 12 with all four nut segments 16 A, 16 B, 16 C and 16 D in the engaged position. In some embodiments of the present invention, nut segments 16 A, 16 B, 16 C and 16 D are comprised of four individual, substantially equal sized segments (defined as Nut Segment Assembly I, or NSA-I) held by one or more springs 20 and 18 such that each of the four individual segments engage to substantially the same axial position on threaded rod 11 . In this embodiment, the segments are not geometrically identical. The segments in this assembly are physically different in that different segments have different thread phase. Since a thread advances axially one thread pitch for each revolution of the thread, (that is, the thread follows a spiral path), each segment must have its respective thread at a different axial position than any of the other three segments. Each of the four segments has its thread phase one quarter of a thread pitch in difference than an adjoining segment. In these embodiments, segments 16 A, 16 B, 16 C and 16 D ratchet approximately at the same moment each time the rod 11 moves one thread pitch in the ratcheting direction with respect to TCD 10 . It should also be noted that by changing the sequence of the segments radially around threaded rod 11 the motion of the segments change relative to one another whereas the ratcheting of the segments will not occur at the same moment each time the rod 11 moves one thread pitch.
The effect of thread phase can most easily be understood by considering a standard hex nut cut along the central (thread) axis into 4 substantially equal pieces. Each piece contains a quarter a full revolution and, hence, a quarter of a thread phase different from the adjoining pieces. If the pieces were to be rejoined, they would screw down a threaded rod just as they did before the hex nut was cut so long as they are rejoined in the same sequence as before separation. However if you exchange any two of the pieces before rejoining (that is, alter the circumferential sequence, “scrambling” the sequence) the resulting assembly will jam when an attempt is made to screw this scrambled assembly down a threaded rod because the scrambled pieces are out of correct thread phase position. If one examines the inside thread spiral it will not be a uniform continuous thread spiral but will have discontinuous jumps at the rejoined boundaries.
However, in contrast interchanging the position of nut segments in a TCD allows different ratcheting options and, because the TCD segments move independently, the TCD will successfully screw and unscrew correctly when engaging a threaded rod of matching pitch diameter and thread pitch.
FIG. 10 is a three dimensional top perspective view of end housing 12 with all four nut segments 16 A, 16 B, 16 C and 16 D in the disengaged position.
FIG. 11 is a three dimensional top perspective view of end housing 12 and all four nut segments 16 A, 16 B, 16 C and 16 D with the positions of segments 16 B and 16 D exchanged from that depicted in FIG. 10 . When viewed from the top (see FIG. 2 ) and counting in a counter clockwise polar direction starting with segment 16 A, the sequence of FIG. 11 is thus is 16 A, 16 D, 16 C and 16 B. This is identified as “Nut Segment Assembly II” or “NSA-II”. Unless otherwise noted, when describing any nut segment assembly, the sequence is presumed to be viewed from the top and enumerated in a counter clockwise direction. NSA-II is distinct from that depicted in FIG. 9 (for example) which is 16 A, 16 B, 16 C, 16 D and denoted herein as “Nut Segment Assembly I” or “NSA-I.”
FIG. 12 is a three dimensional top perspective view of end housing 12 . Four nut segments are shown. In this configuration all segments are the same and denoted as 16 A. When viewed from top and counting in a counter clockwise polar direction starting with segment 16 A the sequence is 16 A, 16 A, 16 A and 16 A or NSA-III. This is different from nut segment assembly NSA-I where the sequence is 16 A, 16 B, 16 C and 16 D. NSA-III denotes an assembly of segments that are geometrically identical ( 16 A for example, but any of the other segments suffice for NSA-III), and also have the same thread phase. In the NSA-III configuration, the segments do not move in and out (towards and away from threaded rod 11 ) in unison. Thus, while the segments of NSA-I move in and out in unison, those of NSA-III do not, but both function as a TCD within the scope of the present invention.
FIG. 13 is a three dimensional bottom perspective view of a TCD with a portion of end housing 12 removed and portions of top housing 14 removed. Also nut segments 16 A and 16 C are depicted as having been sliced in half and one half removed for clarity. Also nut segment 16 D has been removed to reveal internal ramps 34 (“ramps”). Eight ramps are typically present in top housing 14 although not all are depicted in FIG. 13 . However there could be more or less ramps depending on the size of the TCD among other factors. The ramps 34 are part of top housing 14 and are substantially parallel to end housing surfaces 40 and 41 shown in FIG. 6 respectively. The ramps 34 are advantageously configured in pairs. Each ramp pair engages the inner sloping surface 36 of a single nut segment. There are typically four slots 38 in end housing 12 . Each ramp pair is typically arranged in a quadrature polar array about central axis 8 (that is, every 90 deg. about central axis 8 ).
FIG. 14 is a three dimensional top perspective view of a typical TCD with half of top housing 14 removed to reveal the internal components (except for segment 16 D which has also been removed). As can be seen, nut segments 16 A, 16 B, 16 C with upper coil spring 20 and lower coil spring 18 are located substantially within top housing 14 and end housing 12 of TCD 10 . Also shown in FIG. 14 are inner sloping surfaces 36 bearing against ramps 34 . The surfaces of ramps 34 are in edge view in FIG. 14 .
FIG. 15 is a three dimensional perspective view of nut segments encircled by lower and upper coil springs 18 and 20 respectively (referred to collectively as “coil springs”) and engaged to threaded rod 11 . As shown, coil springs 18 and 20 reside in grooves 44 and 42 respectively in each segment 16 A, 16 B, 16 C and 16 D in the assembled configuration. The segments are shown in FIG. 9 in the same position with respect to threaded rod 11 as they are in FIG. 15 .
FIG. 16 is an expanded three dimensional outer perspective view of one nut segment of TCD 10 in accordance with one embodiment of the present invention. FIG. 16 depicts segment upper spring groove 42 , segment lower spring groove 44 , left outer segment surface 48 , right outer segment surface 50 and nut segment rib 46 .
FIG. 17 is an expanded three dimensional inner perspective view of one segment, such as 16 A, 16 B, 16 C or 16 D, of nut assembly NSA-I of TCD 10 . Also depicted in FIG. 17 are inner sloping surface 36 , segment upper spring groove 42 , segment lower spring groove 44 and segment thread 52 .
FIG. 18 is a cross sectional view of a TCD engaged with threaded rod 11 in accordance with one embodiment of the present invention. Also shown in cross section in FIG. 18 are any two opposing nut segments (such as 16 A and 16 C), lower coil spring 18 , upper coil spring 20 , end housing 12 and top housing 14 . Also shown are directions of motion 56 and 58 .
FIG. 19 is a top perspective exploded view of a typical assembly of TCD 10 , mounting fasteners 26 , fastener holes 24 and bearing plate 28 . Also shown is plate fastener hole 30 in bearing plate 28 .
FIG. 20 is a top perspective view of TCD 10 , mounting fasteners 26 and bearing plate 28 shown installed to the shrinking medium 32 and engaged to threaded rod 11 . This combination of TCD 10 , mounting fasteners 26 and bearing plate 28 comprise one embodiment of a self-adjusting shrinkage compensation device.
FIG. 21 depicts a partial stud structure including TCD 10 in the installed configuration. FIG. 21 depicts a typical configuration of foundation 54 , threaded rod 11 , TCD 10 and bearing plate 28 shown installed to the shrinking medium 32 with screws or other mounting fasteners (not visible in FIG. 21 ) and engaged to threaded rod 11 .
FIG. 44 is a perspective view of another embodiment of TCD 222 engaged to a threaded rod 11 in accordance with other embodiments of the present invention. FIGS. 45 , 46 and 47 show top view, first side view and second side view respectively of TCD 222 . FIG. 48 depicts a disassembled view of TCD 222 including an end housing 210 , nut segments 214 supported by end housing 210 , and a top housing 212 engaging end housing 210 with one or more tabs 218 . Nut segments 214 are contained within top housing 212 . Surrounding nut segments 214 is a coil spring 20 . For embodiments only having a single coil spring such as that depicted in FIG. 48 , we omit the distinction of upper coil spring and lower coil spring. TCD 222 is depicted as having four identical nut segments 24 and therefore has the ratcheting properties described above for NSA-III.
FIG. 45 also shows fastener holes 220 . FIG. 58 shows mounting fasteners 224 . Mounting fastener 224 passing through fastener holes 220 and plate fastener holes 228 attaches TCD 222 to the shrinking medium 230 (typically wood) as shown in a typical configuration in FIG. 59 .
Upon installation of mounting fastener 224 , bearing plate 226 is also attached in that bearing plate 226 is sandwiched between TCD 222 and the shrinking medium 230 .
To be concrete in our depictions, top housing 212 is shown with substantially cylindrical side surfaces, but this is not an essential limitation of the present invention. Within the scope of the present invention, top housing 212 of the TCD 222 can include hexagonal, cubic, square or any other substantially tubular configuration capable of accommodating threaded rod 11 , and which is capable of including the components and features of the TCD 222 or other embodiments.
FIG. 48 depicts TCD 222 with all parts shown in exploded view. To be concrete in our depiction, but not restrictive, four tabs 218 are shown on end housing 210 and four tab holes 216 are shown in top housing 212 that are used to couple top housing 212 to end housing 210 . There is generally one tab hole 216 for each tab 218 . However, within the scope of the present invention, depending upon the shape of TCD 222 , less or more tabs 218 and tab hole 216 pairs may be used.
Above end housing 210 is shown a coil spring 20 . FIG. 48 shows nut segments 214 directly above coil spring 20 . Top housing 212 is shown above nut segments 214 . The parts depicted in FIG. 48 , when assembled, comprise a complete TCD 222 .
Also shown in FIG. 48 are slots 244 , right inner bearing surfaces 246 and left inner bearing surfaces 248 in end housing 210 . There are, in this example, four slots 244 , four right inner bearing surfaces 246 and four left inner bearing surfaces 248 arranged in an equidistant polar array relative to central axis 8 (see FIG. 50 ) in TCD 222 in end housing 210 . TCD 222 has central axis 8 substantially coincident with the axis of threaded rod 11 . Inner bearing surfaces 246 , 248 and slots 244 are defined as a feature set. Also slot 244 , right inner bearing surface 246 and left inner bearing surface 248 have an orientation of substantially 30 degrees relative to central axis 8 .
FIG. 48 also shows nut segment ribs 240 , segment spring groove 242 , left outer segment surface 238 and right outer segment surface 236 . There is one nut segment rib 240 , one segment spring groove 242 , one left outer segment surface 238 and one right outer segment surface 236 for each nut segment 214 . Various configurations of nut segment assemblies can be used within the scope of various embodiments of the present invention.
FIG. 49 is a top view of end housing 210 . Shown in top view are right and left inner bearing surfaces 246 and 248 and slot 244 .
FIG. 50 shows slot 244 and inner bearing surfaces 246 and 248 as substantially parallel and at substantially a 30 degree angle to central axis 8 . As depicted in FIG. 48 , right and left outer segment surfaces 236 and 238 bear against right inner bearing surface 246 and left inner bearing surface 248 respectively for each of the four nut segments 214 . Inner bearing surfaces 246 and 248 lie in a single plane separated into two surfaces by slot 244 . Similarly, outer segment surfaces 236 and 238 lie in a single plane separated by nut segment rib 240 .
FIG. 51 is an upper perspective view of end housing 210 in which only two nut segments are shown, 214 A and 241 B. Segment 214 A is shown in an engaged position and segment 214 B is shown in an extreme disengaged position. It can also be observed that nut segment rib 240 resides substantially within slot 244 . All nut segment ribs 240 reside in their respective slots 244 .
FIG. 53 is a three dimensional bottom perspective view of a TCD with a portion of end housing 210 removed and portions of top housing 212 removed. Also one nut segment 214 has been removed for clarity revealing internal ramps 252 (right ramp), 253 (left ramp), and center rib 254 . Four right ramps 252 , four left ramps 253 and four center ribs 254 are depicted. However, this number is not an essential limitation of the present invention and there could be more or less depending on the size of the TCD and other factors.
The ramps 252 and 253 and center ribs 254 are part of top housing 212 and are parallel to respective end housing 210 , inner bearing surfaces 246 and 248 . The ramps 252 and 253 are typically configured in pairs. Each ramp pair engages a single nut segment top surface 234 (left top surface) and 235 (right top surface). Each ramp pair is arranged in a quadrature polar array about axis 8 . Also shown are four tabs 218 extending outwardly from end housing 210 .
FIG. 54 is a three dimensional perspective view of four nut segments 214 encircled by coil spring 20 comprising NSA-IV and engaged to threaded rod 11 . It is shown that spring 20 resides in groove 242 in each segment 214 respectively in the assembled configuration. The segments are shown in FIG. 52 in the same position with respect to threaded rod 11 as in FIG. 54 .
FIG. 55 is a three dimensional outer perspective view of one nut segment 214 in accordance with some embodiments of the present invention. FIG. 55 depicts spring groove 242 , left outer segment surface 238 , right outer segment surface 236 and rib 240 . FIG. 56 is a three dimensional inner perspective view of segment 214 of NSA-IV of TCD 222 . Also shown are nut segment top surfaces 234 and 235 , groove 242 , segment slot (or slot) 232 and segment thread 258 .
FIG. 57 is a cross sectional view of TCD 222 engaged with threaded rod 11 in accordance with some embodiments of the present invention. Also shown in cross section are any two opposing nut segments 214 , coil spring 20 , end housing 210 and top housing 212 . Also shown are motion directions 260 and 262 . Other features shown are tabs 218 and tab holes 216 .
FIG. 58 is a top perspective exploded view of TCD 222 , mounting fasteners 224 and bearing plate 226 . Also shown is plate fastener hole 228 in bearing plate 226 above shrinking medium 230 .
FIG. 59 is a top perspective view of TCD 222 , mounting fasteners 224 and bearing plate 226 shown installed to the shrinking medium 230 and engaged to threaded rod 11 . This combination of TCD 222 , fasteners 224 and bearing plate 226 comprise a self-adjusting shrinkage compensation device.
Referring to FIG. 44 TCD 222 may be configured to move along threaded rod 11 in one direction without rotation of TCD 222 , and to not move in the opposite direction without rotation. The direction of motion whereby the TCD moves along threaded rod 11 without rotation shall be defined as the “ratcheting direction” and the opposite direction of motion as the “non-ratcheting direction”. In particular, in accordance with some embodiments of the present invention, the TCD may be configured to be engaged to threaded rod 11 such that a single downward hand movement of the TCD down the length of threaded rod 11 will correspondingly move TCD 222 in the ratcheting direction to a predetermined position on threaded rod 11 . Once in place, an upward hand movement of the TCD along the length of threaded rod 11 will be met with an opposing force such that the TCD will not move in the non-ratcheting direction. Rather, in order to move the TCD in the non-ratcheting direction of threaded rod 11 (typically the upward direction when used in wooden structures), the TCD is rotated along the threads of threaded rod 11 . The most common configuration with respect to a TCD engaged to a vertical threaded rod 11 is where (when viewed from above) a clockwise rotation of the TCD will advance the TCD downward with respect to threaded rod 11 and a counter-clock wise rotation of the TCD will advance the TCD upward with respect to threaded rod 11 .
It should be noted that while the above description is discussed with respect to upward and downward movements of the TCD along the length of threaded rod 11 , the direction of the movements of the TCD may be arbitrary depending upon, for example, the position of threaded rod 11 to which the TCD is engaged. However, if the TCD is only to be used in a vertical position, the weight of the segments, as directed along the surfaces of the housing, is typically sufficient to maintain adequate contact with the threaded rod. That is, for vertical operation the springs holding the nut segments against the threaded rod can become optional and can be omitted in some embodiments of the present invention.
In one embodiment, the TCD will ratchet whenever the TCD is moved along threaded rod 11 a minimum of one quarter (¼) of a thread pitch in the ratcheting direction. That is, when the TCD moves one quarter of a thread pitch one of the segment pairs will ratchet such that if forces try to move the nut assembly in the opposite non-ratcheting direction, a minimum of one nut segment will lock up and prevent motion in the opposite direction with respect to threaded rod 11 . To implement ¼ thread ratcheting four identical nut segments are arranged in all four positions (for example, nut segments 214 in NSA-III shown in FIG. 52 ).
We describe detailed functioning of a TCD by reference to FIG. 53 , FIG. 54 , FIG. 55 , FIG. 56 and FIG. 57 . However, this is by way of illustration and not limitation as other TCD embodiments function in a similar manner. Differences in mode of operation for different TCD embodiments will be noted when present.
Referring to FIGS. 52-57 , each of the four nut segments are driven upwards and outward at a 30 degree angle relative to central axis 8 as a result of nut segment top right and left surfaces 234 and 235 contacting ramps 252 and 253 as threaded rod 11 is pushed upward, for example, by seismic movement or wind that cause building overturning moments. Overturning moments typically cause a structure to move up and down with respect to its foundation. In this case with enough linear segment movement in directions 260 and/or movement 262 ( FIG. 57 ) nut segments 214 will completely disengage threaded rod 11 threads, and re-engage when the next rod thread moves into position to allow the four segments 214 to move toward rod 11 center and re-engage the threads of threaded rod 11 .
On the other hand, if the forces reverse in direction and threaded rod 11 is driven down (or TCD 222 driven up), nut segments 214 will be driven toward threaded rod 11 , and the threads will stay engaged as long as the downward force exists because of the inward radial force pushing segments 214 toward threaded rod 11 . The inward radial force is generated by (see FIGS. 48 , 49 and 50 ) the inner bearing surfaces 246 and 248 of end housing 210 contacting outer segment surfaces 238 and 236 respectively of a segment. Also to be considered is the outward radial force caused by the interaction of thread flanks of rod 11 against the flanks of segment thread 258 , the upper thread flank 258 A and lower thread flank 258 B, as depicted in FIG. 56 for example. The inward radial force relative to axis 8 on segments 214 overcomes the outward radial force on segments 214 as long as the thread flanks 258 A and 258 B included angle remains 60 degrees (the standard flank angle for American Standard and Metric threads) and the angle of surfaces 246 , 248 , 238 and 236 remain substantially 30 degrees relative to axis 8 and the forces pulling rod 11 downward relative to TCD 222 (“reversing forces”) are in effect. The resultant inward forward force keeps the segments 214 engaged with threaded rod 11 .
Moreover, in one embodiment of the present invention, the material for nut segments 214 is advantageously chosen so as to have a yield point greater than or equal to that of the material of threaded rod 11 . Even when the yield points are similar for the materials of threaded rod 11 and segments 214 , and one segment 214 begins plastic deformation, as soon as threaded rod 11 moves, other segments 214 engage threaded rod 11 to overcome the strength of threaded rod 11 .
Alternatively, the material for nut segments 214 , may have a yield point substantially lower than that for threaded rod 11 , in which case threaded rod 11 will still fail (i.e., give way or break) before TCD 222 is compromised if there is sufficient length of thread engagement.
Moreover, coil spring 20 in some embodiments of the present invention is chosen so as to have sufficient tension to cause nut segments 214 to close around threaded rod 11 even in the case where the gravitational force is pulling nut segments 214 away from threaded rod 11 (for example, in the case where TCD 222 is inverted).
Referring to FIG. 57 , the directional arrows 260 and 262 illustrate the manner in which nut segments 214 are configured to move when the TCD moves in the ratcheting direction with respect to threaded rod 11 .
Referring to FIG. 48 , FIG. 49 , and FIG. 51 , segments 214 , the engagement of ribs 240 and slots 244 provide linear guidance and transfer torque to nut segments 214 . The ribs 240 and slots 244 are advantageously configured to engage one another. Ribs 240 are on segments 214 . The matching slots 244 are on end housing 210 . When torque is applied to end housing 210 this torque is transmitted to segments 214 through slot 244 engaging rib 240 . Additionally, the ribs and slots also guide the radial motion engagement of TCD 222 to threaded rod 11 . Torque may be applied to end housing 210 through top housing 212 .
Referring to FIGS. 46-53 and FIG. 57 torque is transmitted from the top housing 212 to end housing 210 through tab holes 216 on top housing 212 engaging tabs 218 on end housing 210 . Torque is also transmitted directly from top housing to segments by center rib 254 ( FIG. 53 ) engaging segment slot 232 . The tab holes 216 and tabs 218 also perform a fastening function and facilitate automatic assembly of the top housing 212 to the end housing 210 . During final assembly the top housing tab holes 216 are aligned over the end housing tabs 218 and then the top housing 212 is pushed down over the end housing 210 . The tabs 218 force the top housing 210 wall outward over the tabs 218 until the downward motion of the top housing 210 allows the tabs 218 to snap into the tab holes 216 . The top housing 212 now cannot be removed from the end housing 210 without damage to the top housing 212 . This accomplishes the final assembly of the TCD 222 without the use of other fasteners.
Referring to FIGS. 50 and 53 a conical lead-in 256 is advantageously used to guide the TCD 222 over the threaded rod 11 upon initial engagement of TCD 222 to the end of threaded rod 11 . The conical lead-in 256 causes the installation of TCD 222 to be quick and easy as the conical lead-in 256 guides the end of threaded rod 11 to the center of TCD 222 and to the bottom of nut segments 214 . The nut segments 214 then move as depicted FIG. 57 as previously described.
With respect to top housing 212 , it should be noted that some embodiments of this invention call for torque to be applied to housing 212 to tighten or loosen TCD 222 with respect to threaded rod 11 . Application of torque is typically applied with a wrench engaging exterior surfaces of a housing equivalent to top housing 212 , optionally with the addition of exterior “flats” to facilitate gripping by a wrench or other device. The use of exterior flats is included within the scope of some embodiments of the present invention.
While the previous description related chiefly to TCD 222 , a similar description applies to TCD 10 .
Referring to FIG. 1 TCD 10 may be configured to move along threaded rod 11 in one direction without rotation of TCD 10 (the ratcheting direction), and to not move in the opposite direction without rotation (the non-ratcheting direction). In particular, in accordance with some embodiments of the present invention, TCD 10 is configured to be engaged to threaded rod 11 such that a single downward hand movement of TCD 10 down the length of threaded rod 11 will correspondingly move TCD 10 in the ratcheting direction, to a predetermined position on threaded rod 11 . Once in place, an upward hand movement of TCD 10 along the length of threaded rod 11 will be met with an equal and opposite force such that TCD 10 will not move in the non-ratcheting direction. Rather, in order to move TCD 10 in the upward direction of threaded rod 11 , TCD 10 is rotated along the threads of threaded rod 11 . The most common configuration with respect to TCD 10 engaged to a vertical threaded rod 11 is where a clockwise rotation of TCD 10 will advance TCD 10 downward with respect to threaded rod 11 and a counter-clock wise rotation of TCD will advance TCD upward with respect to threaded rod 11 .
It should be noted that while the above description is discussed with respect to upward and downward hand movements of TCD 10 along the length of threaded rod 11 , the direction of the movements of TCD 10 may be arbitrary depending upon, for example, the position of threaded rod 11 to which TCD is engaged.
In one embodiment, TCD 10 will ratchet whenever TCD 10 is moved along threaded rod 11 a minimum of one half (½) of a thread pitch in the ratcheting direction. That is, when TCD 10 moves one half of a thread pitch one of the segment pairs will ratchet such that if forces try to move the nut assembly in the opposite non-ratcheting direction, one nut segment pair will lock up and prevent motion in the opposite direction with respect to threaded rod 11 . To implement ½ thread ratcheting segments 16 A, 16 B, 16 C and 16 D are arranged so that two opposing nut segments have threads that are 180 degrees out of thread phase from the remaining two opposing nut segments. Referring to FIG. 11 it is shown this is accomplished by exchanging the position in nut segment assembly of any two non-adjoining nut segments, but two and only two can be exchanged in any one 4 segment assembly. (Thus 16 A and 16 C could be exchanged or 16 B and 16 D could be exchanged). In this configuration one or the other of the nut segment pairs 16 A and 16 C or 16 B and 16 D will ratchet each time the rod 11 moves one half a thread pitch in the ratcheting direction with respect to TCD 10 .
In particular, with respect to FIG. 13 through FIG. 18 , each of the four segments 16 A, 16 B, 16 C and 16 D are driven upwards and outward at a 30 degree angle relative to central axis 8 as a result of surface 36 ( FIGS. 13 and 14 show the edge of ramp 34 ) contacting ramp 34 as threaded rod 11 is pushed upward (for example, by seismic movement or wind that cause building overturning moments. Overturning moments cause a structure to move up and down with respect to its foundation.) In this case with enough linear segment movement 56 and/or movement 58 ( FIG. 18 ) segments 16 A, 16 B, 16 C and 16 D will completely disengage threaded rod 11 threads, and re-engage when the next rod thread moves into position to allow the four segments 16 A, 16 B, 16 C and 16 D to move toward rod 11 center and re-engage the threads of threaded rod 11 .
On the other hand, if the forces reverse in direction and threaded rod 11 is driven down (or TCD 10 driven up), nut segments 16 A, 16 B, 16 C and 16 D will be driven toward threaded rod 11 , and the threads will stay engaged as long as the downward force exists because of the inward radial force pushing segment 16 A, 16 B, 16 C and 16 D toward threaded rod 11 . The inward radial force is generated by (see FIGS. 5 , 6 and 7 ) surfaces 40 and 41 contacting surfaces 48 and 50 of end housing 12 . Also to be considered is the outward radial force caused by the interaction of thread flanks of rod 11 against segment thread 52 flank. The inward radial force relative to axis 8 on segments 16 A, 16 B, 16 C and 16 D overcomes the outward radial force on segments 16 A, 16 B, 16 C and 16 D as long as the thread flank included angle remains 60 degrees (the standard flank angle for American Standard and Metric threads) and the angle of surfaces 40 , 41 , 48 and 50 remain substantially 30 degrees relative to axis 8 and the reversing forces are in effect. The resultant inward forward force keeps the segments 16 A, 16 B, 16 C and 16 D engaged with threaded rod 11 .
Moreover, in some embodiments of the present invention, the material for nut segments 16 A, 16 B, 16 C and 16 D is chosen so as to have a yield point greater than or equal to the material for threaded rod 11 . Even when the yield points are similar between the materials for threaded rod 11 and segments 16 A, 16 B, 16 C and 16 D, and one of segment 16 A, 16 B, 16 C and 16 D start plastic deformation, as soon as threaded rod 11 moves, other segments 16 A, 16 B, 16 C and 16 D will start to engage to overcome the strength of threaded rod 11 .
Alternatively, the material for nut segments 16 A, 16 B, 16 C and 16 D, may have a yield point substantially lower than that for threaded rod 11 , in which case threaded rod 11 will still fail (i.e., give way or break off) before TCD 10 is compromised if there is sufficient length of thread engagement.
Moreover, coil springs 20 and 18 in one embodiment are configured to have sufficient tension to cause nut segments 16 A, 16 B, 16 C and 16 D to close around threaded rod 11 even in the case where the gravitational force is pulling nut segments 16 A, 16 B, 16 C and 16 D away from threaded rod 11 (for example, in the case where TCD 10 is inverted). Indeed, if nut segments 16 A, 16 B, 16 C and 16 D are not driven to threaded rod 11 center by coil springs 20 and 18 force, nut segments 16 A, 16 B, 16 C and 16 D, may move to the outside top housing 14 wall and remain in that position resulting in TCD 10 not engaging with threaded rod 11 .
The example shown in FIG. 9 depicts that nut segments 16 A, 16 B, 16 C and 16 D are comprised of four individual, substantially equal sized segments (defined as nut segment assembly NSA-I) held together by coil spring 20 and 18 such that each of the four individual segments engage to substantially the same axial position on threaded rod 11 . In this embodiment each segment is not geometrically equal to the other. All four segments in this assembly are physically different in thread phase. Since a thread advances axially one thread pitch for each revolution of the thread, each segment must have its respective thread at a different axial position than any of the other three segments. Each segment has its thread phase one quarter of a thread pitch in difference than an adjoining segment. In this embodiment segments 16 A, 16 B, 16 C and 16 D will ratchet approximately at the same moment each time the rod 11 moves one thread pitch in the ratcheting direction with respect to TCD 10 .
Referring to the FIG. 11 , the directional arrows 56 and 58 shown in FIG. 18 illustrate the manner in which nut segments 16 A, 16 B, 16 C and 16 D are configured to move when TCD 10 moves in the ratcheting direction with respect to threaded rod 11 .
Referring to FIG. 5 through FIG. 10 , FIG. 15 and FIG. 16 segments 16 A, 16 B, 16 C and 16 D, the engagement of ribs 46 and slots 38 provide linear guidance and torque to nut segments 16 A, 16 B, 16 C and 16 D. The ribs 46 and slots 38 are configured to engage each other. Ribs 46 are on segments 16 A, 16 B, 16 C and 16 D. The matching slots 38 are on end housing 12 . When torque is applied to end housing 12 , this torque is transmitted to segments 16 A, 16 B, 16 C and 16 D through slot 38 engaging rib 46 . Additionally, the ribs and slots also guide the radial motion engagement of TCD 10 to threaded rod 11 . Torque may be applied to end housing 12 through top housing 14 and fasteners 22 .
With respect to top housing 14 , it should be noted that some embodiments of this invention call for torque to be applied to housing 14 to tighten or loosen TCD 10 with respect to threaded rod 11 . Application of torque is typically applied with a wrench or other tool engaging exterior surfaces of a housing equivalent to top housing 14 , optionally with the addition of exterior flats.
The TCDs pursuant to some embodiments of the present invention can be used as the basis for a coupler, multi nut TCD, quick release TCD, TCD with mechanical clip attachment, TCD with magnetic attachment as described in the following. To be concrete in our description, we describe these structures and uses in connection chiefly with TCD 10 . But this is by way of illustration and not limitation as other embodiments of TCDs as described herein can also be used in connection with such devices.
Coupler.
FIGS. 22-28 depict embodiments of the present invention including an optional coupler or coupler assembly.
FIG. 22 is a top perspective view of coupler 60 with top threaded rod 76 and bottom threaded rod 74 depicted without the rods inserted into coupler 60 .
FIG. 23 is a top perspective view of coupler 60 with top threaded rod 76 and bottom threaded rod 74 depicted with rods 76 and 74 inserted into coupler 60 .
FIG. 24 is a sliced cross section view of the coupler assembly in accordance with some embodiments of the present invention. A housing body (or housing) 62 is engaged at each end portion to a respective end housing 64 . Each of the two end housings 64 are engaged to the respective ends of the housing body 62 by attachment fasteners 68 such as those described above. Additionally, also shown in the FIG. 24 is pin 66 mounted through the housing body 62 and center plug 86 of the coupler 60 . Also shown are segments 72 A, 72 B and 72 C resting against the surfaces of end housing 64 and under surfaces of center plug 86 . A full complement of nut segments 72 A, 72 B, 72 C and 72 D plus springs 18 and 20 are defined as segment assembly NSA-V. Coil springs 18 and 20 are shown residing in segments 72 A, 72 B and 73 C. The coupler assembly is symmetrical about a plane that is perpendicular to the axis of threaded rods 74 and 76 ( FIG. 23 ) and bisects pin 66 . That is, if the rod axis is the y-axis of a normal right-handed coordinate system, the symmetry plane is the (x,z) plane. Segments 88 A, 88 B, 88 C and 88 D plus springs 18 and 20 are defined as assembly NSA-VI and are mirror images of segment assembly NSA-V in the coupler assembly 60 . See also FIG. 26 . Segments 88 are physically the same as segments 72 . All features described above in the lower half of coupler 60 appear in the upper half as mirror images in coupler 60 . Also shown in FIG. 24 is a center plug 86 which is configured to receive threaded rod 74 and rod 76 into hole 120 . Holes 120 in center plug 86 are advantageously slightly smaller in diameter than the outer diameter of the threaded rods.
FIG. 25 is a cross sectional view of the coupler assembly engaged with two threaded rods depicting movements of segments 72 A, 72 B, 72 C and 72 D and segments 88 A, 88 B, 88 C and 88 D and threaded rod movements pursuant to some embodiments of the present invention. Referring to the Figure, the directional arrows as shown illustrate the directional movements of the various components of the coupler 60 .
FIG. 26 is a three dimensional perspective view of the components of the coupler assembly and pin 66 exploded or disassembled. This illustration shows that the coupler is comprised of two sets of nut segments 72 A, 72 B, 72 C and 72 D and segments 88 A, 88 B, 88 C and 88 D, assembled back to back in housing 62 . Nut segments 72 A, 72 B, 72 C and 72 D comprise Nut Segment Assembly V (NSA-V) and are shown also exploded radially. Nut segments 88 A, 88 B, 88 C and 88 D comprise Nut Segment Assembly VI (NSA-VI) and are shown in their operating configuration. Nut segment assemblies V and VI are separated by center plug 86 . Center plug 86 is retained in housing body 62 by pin 66 which passes through hole 96 and hole 97 . At each end of plug 86 are bearing surfaces 104 and 106 separated by rib 80 . Surfaces 104 , 106 and rib 80 comprise a feature set. There are eight sets of surfaces 104 and 106 and rib 80 . Four sets are at one end and four sets at the opposite end of plug 86 . The feature sets are geometrically arranged similarly as slot 38 , surface 40 and 41 shown in FIG. 6 if viewed from the end of plug 86 . At each end of housing 62 end housings 64 are shown attachment fasteners 68 , clearance holes 94 and threaded hole 98 in housing 62 .
FIG. 27 is a three dimensional outer perspective view of one segment of segments 72 A, 72 B, 72 C and 72 D (NSA-V) and segments 88 A, 88 B, 88 C and 88 D (NSA-VI) shown in coupler 60 , quick release TCD 122 and multi nut TCD 100 . The “quick release” TCD and the “multi nut” “multi-nut segment” TCD are described in detail elsewhere herein. Shown in this illustration are upper spring groove 114 , lower spring groove 116 , left bearing surface 108 , right bearing surface 110 , rib 112 and slot 102 .
FIG. 28 is a three dimensional inner perspective view of one of the segments 72 A, 72 B, 72 C or 72 D or segments 88 A, 88 B, 88 C or 88 D as in coupler 60 , quick release TCD 122 or multi nut TCD 100 . Also shown are surface 90 , surface 92 , slot 102 , upper spring groove 114 , lower spring groove 116 , optional spring groove 118 and segment thread 52 .
Referring to FIG. 23 and FIG. 24 , coupler 60 can have a configuration so as to engage one or two threaded rods 74 and/or 76 . As with TCD 10 , coupler 60 may move along threaded rod 74 and/or 76 in one direction without rotation of coupler 60 , and not move in the opposite direction without rotation. For the purposes of describing coupler 60 and other embodiments the direction of motion whereby coupler moves along threaded rods 74 and/or 76 without rotation shall be defined as the ratcheting direction and the opposite direction of motion as the non-ratcheting direction. Threaded rod 74 and/or 76 may be inserted into opening 126 at either end of coupler 60 . The insertion may continue until rod 74 and/or 76 fills hole 120 in center plug 86 . Verification of sufficient insertion of rod 74 and/or 76 may be observed through inspections holes 140 and 141 see FIGS. 22 , 23 , 24 and 26 ). Inspection holes 140 and 141 are aligned to allow viewing through housing body 62 and center plug 86 . Now referring to FIG. 24 , hole 120 is advantageously taken to be slightly smaller than rod 74 and/or 76 in outside diameter to provide locking friction between center plug 86 and rods 74 and/or 76 . The housing body (or body) 62 is typically constructed of steel as is rod 74 and/or 76 . The center plug 86 is typically constructed of a polymer such as nylon so as to deform under the force of rod insertion and provide a locking friction to rod 74 and/or 76 .
In these embodiments, coupler 60 will typically ratchet whenever rod 74 and/or 76 is moved along a minimum of one (1) thread pitch in the ratcheting direction until rod 74 and/or 76 bottoms in hole 120 . More specifically referring to FIG. 25 , the vertical arrows 78 and 84 illustrate the movement of threaded rod 74 and rod 76 , while the angled arrows 82 illustrate the movement of nut segments 72 A, 72 B, 72 C and 72 D and segments 88 A, 88 B, 88 C and 88 D inward and outward, respectively relative to the movement of the threaded rod 74 and rod 76 .
Comparing FIG. 27 and FIG. 16 , the similarities between segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C and 88 D and segments 16 A, 16 B, 16 C and 16 D are shown as follows: In FIG. 16 left outer segment surface 48 , right outer segment surface 50 , nut segment rib 46 , segment lower spring groove 44 and segment upper spring groove 42 are equivalent and identical in function to (now refer to FIG. 27 ) surface 108 , surface 110 , rib 112 , lower spring groove 116 and upper spring groove 114 .
Comparing FIG. 28 and to FIG. 17 , the similarities between segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C and 88 D and segments 16 A, 16 B, 16 C and 16 D are shown as follows: In FIG. 17 inner sloping surface 36 is equivalent and identical in function to (now refer to FIG. 28 ) surface 90 and surface 92 . Surfaces 90 and 92 are in the same plane separated by slot 102 .
The difference between segments 16 A, 16 B, 16 C and 16 D and segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D is that there is no slot 102 on surface 36 (see FIG. 15 ). Segments 16 A, 16 B, 16 C and 16 D are not stackable (stackable means one can nest on top of the other), segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D are stackable.
In particular with respect to FIGS. 24 , 25 and 26 , each of the segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D are driven towards coupler 60 midpoint and outward at a 30 degree angle relative to central axis 8 as a result of surface 90 and 92 ( FIGS. 26 and 28 ) contacting surface 106 and 104 ( FIG. 26 ) as threaded rod 74 and/or 76 is pushed inward as shown in FIG. 25 by arrows 78 and 84 . In this case with enough linear segment movement 82 ( FIG. 25 ) segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D will completely disengage threaded rod 74 and/or 76 threads, and re-engage when the next rod thread moves into position to allow segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D to move toward rod 74 and/or 76 center and re-engage the threads of threaded rod 74 and/or 76 .
On the other hand, if the forces reverse in direction and threaded rod 74 and/or 76 is axially pulled outward with respect to coupler 60 , segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D will be driven toward threaded rod 74 and/or 76 axis 8 , and the threads will stay engaged as long as the axial outward force exists because of the inward radial force pushing segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D toward threaded rod 74 and/or 76 . The inward radial force is generated by (see FIGS. 26 and 27 ) surfaces 108 and 110 contacting surfaces 130 and 128 of end housing 64 . Also present is the outward radial force caused by the interaction of thread flanks of rod 74 and/or 76 against segment thread flank 52 ( FIG. 28 ). The inward radial force relative to axis 8 segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D overcomes the outward radial force on segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D as long as the thread-included flank angle remains approximately 60 degrees (the standard flank angle for American Standard and Metric threads) and the angle of surfaces 90 , 92 , 104 , 106 , 108 , 110 , 128 and 130 remain substantially 30 degrees relative to axis 8 and the reversing forces are in effect. The resultant inward forward force keeps segments 72 A, 72 B, 72 C, 72 D, segments 88 A, 88 B, 88 C, 88 D engaged against threaded rod 74 and/or 76 . Referring to FIG. 26 when torque is applied to end housing 64 this torque is transmitted to segments 72 A, 72 B, 72 C, 72 D and 88 A, 88 B, 88 C, 88 D through slot 132 engaging rib 112 ( FIG. 28 ) Additionally, the ribs and slots also guide the radial motion engagement of segments contained within coupler 60 to threaded rod 74 and/or 76 .
Multi Nut TCD.
FIG. 29 illustrates a perspective view of a multi-nut TCD 100 engaged to threaded rod 11 in accordance with some embodiments of the present invention. There is a housing body 136 , engaged at the upper end to top housing 138 and at the lower end to an end housing 134 . Each of the two housings 134 and 136 are attached to the respective ends of the housing body 136 by attachment fasteners 68 typically of the type as previously described.
FIG. 30 is a three dimensional perspective view of the components of TCD 100 assembly exploded or disassembled. This illustration shows TCD 100 comprised of two sets of nut segments 72 A, 72 B, 72 C and 72 D one on top (nested) of the other in housing 136 . The bottom nut segment assembly is defined as assembly 73 and the upper nut segment assembly is defined as assembly 75 . (Also referred to herein as “segment assemblies,” “nut assemblies” or “assemblies.”) Both nut segment assemblies 73 and 75 are supported at the bottom by end housing 134 . Each nut segment assembly 73 and 75 is encircled by springs 18 and 20 (not shown in FIG. 30 ). Also a retaining ring 142 resides in a groove 148 (see FIG. 32 ) in end housing 134 .
FIG. 31 is a sliced cross section view of TCD 100 in accordance with some embodiments of the present invention. Housing body 136 (depicted as sliced in half) is engaged at each end portion to end housing 134 (depicted as sliced in half) and at the other end a top housing 138 (depicted as sliced in half). End housing 134 and top housing 138 are attached to housing body 136 by attachment fasteners 68 such as those described above. Also shown are segment assemblies 73 and 75 . The segment assemblies are nested one on top of the other. The lower segment assembly 73 is supported by end housing 134 and the upper segment assembly 75 is supported by the upper surfaces of assembly 73 . Coil spring 20 is shown residing in segments 72 A, 72 B and 73 C. Coil spring 18 is also present as shown in FIG. 15 , but cannot be seen in this FIG. 31 .
FIG. 32 is a cross sectional view of TCD 100 engaged with threaded rod 11 illustrating movements of segments 72 A, 72 B, 72 C and 72 D, upper assembly 75 and lower assembly 73 , and threaded rod movements, in accordance with some embodiments of the present invention. Directional arrows 144 and 146 illustrate the directional movements of the various segments of TCD 100 . More specifically, the vertical arrow 146 illustrates the movement of the threaded rod 11 , while the angled arrows illustrate the movement of nut segments 72 A, 72 B, 72 C and 72 D and segments 88 A, 88 B, 88 C and 88 D inward and outward, respectively relative to the movement of the threaded rod 11 .
TCD 100 typically has a configuration so as to move along threaded rod 11 in one direction without rotation of TCD 100 , and to not move in the opposite direction without rotation. For the purposes of describing TCD 100 and related embodiments, the direction of motion whereby TCD moves along threaded rod 11 without rotation shall be defined as the ratcheting direction and the opposite direction of motion as the non-ratcheting direction. In particular, in accordance with some embodiments of the present invention, TCD 100 may be configured to be engaged to threaded rod 11 such that a single downward hand movement of TCD 100 down the length of threaded rod 11 will correspondingly move TCD 100 in the ratcheting direction to a predetermined position on threaded rod 11 . Once in place, an upward hand movement of TCD 100 along the length of threaded rod 11 will be met with an equal and opposite force such that TCD 100 will not move in the non-ratcheting direction. Rather, in order to move TCD 100 in the upward direction of threaded rod 11 , TCD 100 is rotated along the threads of threaded rod 11 . The most common configuration with respect to TCD 100 engaged to a vertical threaded rod 11 is that in which a clockwise rotation of TCD 100 will advance TCD 100 downward with respect to threaded rod 11 and a counter-clock wise rotation of TCD will advance TCD upward with respect to threaded rod 11 .
The segment assemblies 73 and 75 within TCD 100 operate with rod 11 in the same manner as NSA-II in TCD 10 described previously. TCD 10 is a single nut segment assembly NSA-II ( FIG. 15 ) where TCD 100 has two segment assemblies 73 and 75 ( FIG. 30 ) stacked or nested one on top of the other. Because assemblies 73 and 75 are stacked the top surfaces of each segment has a slot 102 ( FIGS. 27 and 28 ) in the top surfaces 90 and 92 to interface with rib 112 . The ability to stack the segment assemblies offers the ability to strengthen thread engagement and to offer more thread phasing options with respect to rod 11 engagement. By altering the thread phasing within a segment assembly and between segment assemblies in a stack one can cause the TCD to ratchet with less motion along the rod 11 . Although only two nut segment assemblies are shown stacked ( FIGS. 30 and 31 ), this is by way of illustration and not limitation as several such assemblies can be stacked within the scope of the present invention.
Quick Release TCD.
FIGS. 33-35 depict a typical TCD with quick release mechanism in accordance with some embodiments of the present invention. A TCD with release mechanism, denoted by 122 , includes a top cap (or cap) 162 mounted to the modified top housing (or top housing) 156 and secured by a crescent ring 160 . The top housing 156 is attached to housing body (or housing) 154 with fasteners 68 . Also shown is end housing 152 attached to the opposite end of housing body 154 with fasteners 68 . TCD 122 is similar to TCD 100 with the following modifications. Wire posts 164 A, 164 B, 164 C, 164 D have been added. The top cap 162 has been added above the top housing 156 and top housing 156 has been modified with a post, or top housing post, 124 such that cap 162 can rotate about the top housing post 124 and cause the wire posts 164 A, 164 B, 164 C, 164 D to rotate 90 degrees upon a rotation of the cap 162 by approximately 25 degrees.
FIG. 34 is a three dimensional perspective view of TCD 122 with release mechanism in the released position. FIG. 35 is a three dimensional perspective view of the components of TCD 122 assembly exploded or disassembled. This illustration shows that TCD 122 is typically comprised of two sets of nut segments, one on top (nested) of the other in housing 154 . Both nut segment assemblies 73 and 75 are supported at the bottom by end housing 152 . Each segment assembly 73 , 75 is encircled by springs 18 and 20 (not shown). Also a retaining ring 158 resides in groove 168 in top housing 156 . More specifically, in the unreleased (i.e., normal) position, the wavy portion of the wire posts 164 A, 164 B, 164 C, 164 D reside between nut segments 72 A, 72 B, 72 C and 72 D as shown in FIG. 36 . FIG. 36 is a top view of TCD with release mechanism in normal (unreleased) position. FIG. 37 is a top view of TCD 122 with release mechanism in the release position. Referring to FIGS. 36 and 37 , the four wire posts 164 A-D are positioned relatively equidistant around upper nut assembly 75 .
In the manner described above, in accordance with some embodiments of the present invention, by incorporating wire posts between upper and lower nut segment assemblies 73 and 75 of TCD 122 , TCD 122 may be configured for quick release from its engaged position. More specifically, pursuant to some embodiments, upper and lower nut segments 72 A, 72 B, 72 C and 72 D segment assemblies 73 , 75 of TCD 122 are configured so that the space between the individual nut segments making up the nut segment assemblies, 72 A- 72 D in FIG. 36 , is wide enough to accommodate the wire posts. Further, a top housing post 124 is included in top housing 156 , while holes are present in top housing 156 to accommodate wire posts. Similarly, in some embodiments, holes are also present in end housing 152 to provide a bearing for the other end of the wire posts 164 A- 164 D.
FIG. 38 illustrates how wire posts 164 A, 164 B, 164 C and 164 D are typically retained by top cap 162 and end housing 152 . FIG. 38 is a bottom perspective view of TCD 122 with top housing 156 , housing 154 and nut segment assemblies 75 and 73 removed to clearly show the under side of cap 162 and specifically pocket 172 A, 172 B, 172 C and 172 D and pocket hole 174 B. Only pocket hole 174 B is visible in the figure along with wire post 164 B entering pocket hole 174 B. However each pocket has a corresponding pocket hole. Also shown is end housing. 152 sliced in half revealing post end bearings (“bearings”) 176 A, 176 C, and 176 D. In the fully assembled TCD 122 bearings 176 A, 176 B, 176 C and 176 D reside in holes 170 A, 170 B, 170 C and 170 D respectively.
Referring to FIGS. 36 , 37 , 38 , as nut segments 72 A, 72 B, 72 C and 72 D move in and out due to the ratcheting operation described previously, the space between nut segments 72 A, 72 B, 72 C and 72 D gets larger and smaller. With the rotation of top cap 162 by approximately 25 degrees, the wire posts 164 A, 164 B, 164 C, 164 D in turn are configured to rotate through a rotation angle of approximately 90 degrees. In this case, the wavy portion of the wire posts 164 A, 164 B, 164 C, 164 D occupy approximately twice the space and prevent nut segments 72 A, 72 B, 72 C and 72 D from closing (i.e., returning to the center position and engaging rod 11 ) after they open during the normal TCD operation described above. Once open, the nut segments remain open and TCD 122 (with the release mechanism) may be readily removed from threaded rod 11 .
In the manner described above, in accordance with some embodiments of the present invention, by incorporating wire posts between upper and lower nut segment assemblies 73 and 75 of TCD 122 , TCD 122 may be configured for quick release from its engaged position. More specifically, in some embodiments, upper and lower nut segments 72 A, 72 B, 72 C and 72 D of TCD 122 have a configuration so that the space between nut segments becomes wide slot 178 shown in FIG. 37 to accommodate the wire posts 164 A, 164 B, 164 C, 164 D, and further, a post 124 is present in top housing 156 , while holes 166 A, 166 B, 166 C, 166 D are present in top housing 156 to accommodate wire posts 164 A, 164 B, 164 C, 164 D. Similarly referring to FIG. 38 , in some embodiments, holes 170 A, 170 B, 170 C, 170 D are present in end housing 152 to provide a support for post end bearing 176 A, 176 B, 176 C, 176 D.
TCD with Mechanical Clip Attachment.
FIG. 39 is a top perspective view of TCD 100 and coupler 60 in the pre-installed configuration (that is, the components are in the act of being installed). Shown in this illustration is a shrinking medium (typically a wood structure) 32 , a typical sheet metal commercial hold-down 186 , hold-down bolts (“bolts”) 188 , connector clip (“clip”) 184 and bottom and top threaded rods 74 and 76 .
FIG. 40 is a top perspective close up view of TCD 100 , clip 184 and hold-down 186 in the installed configuration. Also shown is end housing groove 190 .
FIG. 39 shows the installation of TCD 100 , connector clip 184 and coupler 60 . In this configuration coupler 60 engages rod 74 and rod 76 providing a solid connection between the rods. Hold-down 186 has already been installed to wood 32 with bolts 188 . Rod 76 is fed through hold-down hole 208 as it is installed in coupler 60 . TCD 100 is then slid down rod 76 until TCD 100 engages hold-down 186 .
Now referring to FIG. 40 , clip 184 is then installed into end housing groove (“groove”) 190 in TCD end housing 134 shown in FIG. 29 and under hold-down 186 . TCD 100 is now coupled to wood 32 through hold-down 186 . This combination of TCD 100 , hold-down 186 , clip 184 and threaded rods 74 and 76 comprise a self-adjusting shrinkage compensation device.
TCD with Magnetic Attachment.
FIG. 41 is a top perspective close up view of TCD 100 , wire clip 196 , groove 190 , and sliced one half view of magnet bracket (“bracket”) 194 and ring magnet 192 . Also shown is bracket slot (“slot”) 198 . Bracket assembly 200 is comprised of bracket 194 and ring magnet 192 bonded to the internal diameter of bracket 194 .
FIG. 42 is a top perspective close up view of TCD 100 , wire clip 196 , slot 198 , bracket assembly (or “magnetic bracket assembly”) 200 , hold-down 186 and threaded rod 76 . FIG. 43 is a top perspective view of TCD 60 , 100 , magnetic bracket assembly 200 and attaching wire clip 196 , steel tube (or other magnetic material) hold-down 206 , end plate 204 , cross bolts (“bolts”) 202 through wood 32 . Also shown is threaded rod 76 .
FIG. 43 is similar to the functionally shown in FIG. 42 , except the sheet metal hold-down 186 shown in FIG. 42 is changed to a commercially available steel tube 206 with welded end plate 204 . Tube 206 and end plate 204 are shown with a pie shaped slice removed to reveal attaching cross bolts 202 .
FIG. 41 shows TCD 100 and a sliced magnetic bracket assembly 200 . Bracket 194 also has a slot 198 through which wire clip 196 will pass when attaching assembly 200 to TCD 100 .
FIG. 42 shows TCD 100 after it has been installed to hold-down 186 by clip 196 passing through slot 198 except, instead of a clip 184 making the connection, there is a magnetic assembly 200 attached to TCD 100 . This combination of TCD 100 , hold-down 186 , clip 196 , bracket assembly 200 and threaded rods 74 and 76 comprise a self-adjusting shrinkage compensation device.
FIG. 43 shows TCD 100 after it has been installed to steel tube hold-down 204 / 206 by clip 196 passing through slot 198 except, instead of a clip 184 making the connection, there is a magnetic assembly 200 attached to TCD 100 . FIG. 43 is similar to FIG. 42 except that in FIG. 42 the commercial hold-down is a steel tube with a welded end plate attached to wood 32 with bolts 202 . This combination of TCD 100 , hold-down 204 / 206 , clip 196 , bracket assembly 200 and threaded rods 74 and 76 comprise a self-adjusting shrinkage compensation device.
Various other modifications and alterations in the structure and method of operation of this invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific embodiments, it should be understood that the invention should not be unduly limited to such specific embodiments.
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. | The present invention relates to a thread clamping device including a plurality of movable nut segments around a threaded rod, and spring members flexibly holding the segments against the rod. The thread clamping device has a structure adapted to accommodate substantially planar outer surfaces of the segments engaging planar surfaces of the end housing of the device, leading to a more robust device and improved performance. Such a thread clamping device can advantageously be used as a component of a self-adjusting shrinkage compensation device, a coupler for threaded rods, hold-downs, among other uses. Various embodiments of the thread clamping device include a multi nut configuration, a quick release, and including mechanical or magnetic clip attachments. | 5 |
PRIORITY
[0001] This application claims the benefit of priority under 35 U.S.C. §119 to U.S. provisional application No. 61/228,661 filed on Jul. 27, 2009 and Indian provisional application No. 902/MUM/2009 filed on Apr. 2, 2009, and Indian provisional application No. 1398/MUM/2009 filed on Jun. 10, 2009, the contents of which, are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to processes for the preparation of bosentan, novel compounds which can be useful intermediates for the synthesis thereof, and a pharmaceutical composition comprising the same.
[0004] 2. Description of the Prior Art
[0005] Bosentan is an orally active dual endothelin ETA/ETB receptor antagonist and is used in the pulmonary arterial hypertension and systemic sclerosis. Bosentan is chemically described as 4-tert-butyl-N-[6-(2-hydroxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzenesulphonamide monohydrate and has the structural formula, as shown
[0000]
[0006] U.S. Pat. No. 5,292,740 (the '740 patent) describes pyrimidine sulfonamide derivatives including bosentan or a stereoisomer or salt thereof, a pharmaceutical composition and method of treatment.
[0007] The '740 patent discloses a process for the preparation of bosentan, which is illustrated by the scheme, which follows:
[0000]
[0008] U.S. Pat. No. 6,136,971 describes a process for preparing ethylene glycol sulfonamide derivatives, including bosentan, using via formyl bosentan and pyrimidine monohalide intermediate, as illustrated by the scheme that follows:
[0000]
[0009] PCT Publication WO2009/004374 describes an improved process for the preparation of bosentan using sodium hydroxide for hydrolysis and via bosentan tartaric acid salt which is illustrated by the scheme, which follows:
[0000]
[0010] The present invention provides simple, ecofriendly, inexpensive, reproducible, robust processes for the preparation of bosentan and compounds useful as intermediates for the synthesis thereof, which are well suited on a commercial scale.
SUMMARY OF THE INVENTION
[0011] The present invention relates to processes for the preparation of bosentan and compounds that can be used as novel intermediates for the synthesis thereof.
[0012] In one aspect, the present invention provides a process for preparing bosentan or a pharmaceutically acceptable salt thereof, comprising:
[0013] reacting 4-tertiarybutyl-N-[6-chloro-5-(O-methoxyphenoxy)[2,2′-bipyrimidin]-4-yl]benzenesulfonamide compound of formula I or a salt thereof
[0000]
[0000] with ethylene glycol in the presence of alkoxide or hydride and an organic solvent to form bosentan.
[0014] The present invention provides a process for preparing bosentan comprising: reacting 4-tertiary butyl-N-[6-(2-alkoxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzenesulfonamide compound of formula III or a salt thereof with a reducing agent in the presence of an organic solvent;
[0000]
[0015] where R is methyl, ethyl, benzyl, hydrogen.
[0016] In yet another aspect, the present invention provides a process for preparing the compound of formula III or a salt thereof comprising: reacting 4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula IV
[0000]
[0017] where R is same as defined previously for compound of formula III with 4-tertiarybutylphenylsulfonamide compound of formula V in the presence of a base and an organic solvent.
[0000]
[0018] The present invention provides a process for preparing 4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula IV: comprising a) subjecting 4,6-dichloro-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VI
[0000]
[0000] to basic hydrolysis to form 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VII
[0000]
[0000] b) reacting the compound of formula VII with a compound of formula VIII in the presence of a base and an organic solvent under phase transfer conditions
[0000]
[0000] where R is benzyl, benzyloxy carbonyl, methyloxymethyl, hydrogen and X is halogen, OH.
[0019] In another aspect, the present invention provides a compound 4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine of structural formula IV
[0000]
[0020] In yet another aspect, the present invention provides a compound 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine of structural formula VII
[0000]
[0021] The present invention provides a process for the preparation of bosentan comprising reacting 4-tertiarybutyl-N-[6-(2-alkynoyloxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzenesulfonamide compound of formula IX or a salt thereof
[0000]
[0022] where R is H, methoxy, ethoxy
[0000] with a reducing agent in the presence of an organic solvent.
[0023] In still another aspect, the present invention provides a process for preparing a compound of formula IX comprising:
a) reacting 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VII
[0000]
[0025] with a compound of formula X
[0000]
[0026] where R is same as defined for compound of formula IX and X is halogen atom. to form 4-chloro-6-alkanoyloxy ethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula
[0000]
b) reacting the compound of formula XI with 4-tertiarybutylphenylsulfonamide compound of formula V or a salt thereof
[0000]
[0000] in the presence of a base and an organic solvent.
[0028] The present invention provides a compound 4-tertiarybutyl-N-[6-(2-alkynoyloxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide compound of formula IX or a salt thereof.
[0000]
[0029] The present invention provides a compound 4-chloro-6-alkanoyloxy ethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of structural formula XI
[0000]
[0030] In yet still another aspect, the present invention provides a process for the purification of bosentan or pharmaceutically acceptable salt thereof comprising:
a) providing a solution of bosentan or salt thereof, prepared by the processes herein described, in a solvent or a mixture of solvents; and b) optionally filtering the solution on celite; and c) adding an anti-solvent to the filtrate to precipitate the solid; d) recovering the solid to obtain bosentan in pure form.
[0035] The present invention provides bosentan or a pharmaceutically acceptable salt thereof, prepared by the processes herein described above, having less than about 0.5 area % of total impurities as measured by high performance liquid chromatography (HPLC).
[0036] The present invention provides bosentan or a pharmaceutically acceptable salt thereof, prepared by the processes herein described above, having less than about 0.15 area % of any individual impurity as measured by HPLC.
[0037] In another aspect, the present invention encompasses a pharmaceutical composition comprising bosentan or its pharmaceutically acceptable salts, prepared by processes herein described, and at least a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The present invention provides a process for preparing bosentan or a pharmaceutically acceptable salt thereof comprising: reacting 4-tertiarybutyl-N-[6-chloro-5-(O-methoxyphenoxy)[2,2′-bipyrimidin]-4-yl]benzenesulfonamide compound of formula I or a salt thereof
[0000]
[0000] with ethylene glycol in the presence of an alkoxide or hydride and an organic solvent to form bosentan.
[0039] The alkoxide is selected from alkali metal alkoxide including sodium methoxide, sodium ethoxide, sodium isopropoxide, sodium tertiary butoxide, potassium methoxide, potassium ethoxide, potassium tertiary butoxide or alkaline earth metal alkoxide, as for example magnesium methoxide, magnesium ethoxide, magnesium tertiary butoxide and the like. Preferably the alkoxide is selected from sodium methoxide, sodium ethoxide, potassium methoxide. Most preferably the alkoxide is sodium methoxide.
[0040] The hydride is selected from alkali metal hydrides and alkaline earth metal hydrides include but are not limited to sodium hydride, potassium hydride, lithium hydride, magnesium hydride, calcium hydride and the like. Preferably, sodium hydride.
[0041] The molar equivalents of alkali or alkaline earth metal alkoxide or hydride employed is from about an equimolar amount to about 5 times the equimolar amount with respect to the compound of formula I.
[0042] The reaction is normally and preferably effected in the presence of an inert solvent. The solvents that can be used include but are not limited to haloalkanes such as dichloromethane, chloroform, carbon tetrachloride, dichloroethane and the like; ethers such as tetrahydrofuran, 1,4-dioxane, diisopropyl ether, methyl tertiary butyl ether and the like and mixtures thereof. Preferably tetrahydrofuran (THF).
[0043] The reaction can take place over a wide range of temperatures, from about 30° C. to about 100° C. Preferably from about 50° C. to about 55° C. More preferably from about 70° to about 80° C.
[0044] The time required for the reaction of preparing bosentan or a pharmaceutically acceptable salt thereof may also vary widely, depending on many factors, notably the reaction temperature and the nature of the reagents and solvents employed and volume of ethylene glycol. The reaction period may transpire from about 1 hour to about 20 hours. Preferably from about 5 hours to about 10 hours.
[0045] The dimer impurity depends on the volume of ethylene glycol in the reaction. Preferably the volume of ethylene glycol is from about 100 mole to about 110 mole of Formula I.
[0046] The reaction optionally can be carried out in neat conditions, i.e. in the absence of solvents.
[0047] The present invention provides a process for the preparation of 4-tertiary butyl-N-[6-hydroxy-5-(O-methoxyphenoxy)[2,2′-bipyrimidin]-4-yl]benzenesulfonamide compound of formula II or a salt thereof comprising: subjecting 4-tertiary butyl-N-[6-chloro-5-(O-methoxyphenoxy)[2,2′-bipyrimidin]-4-yl]benzenesulfonamide compound of formula I or a salt thereof
[0000]
[0000] to aqueous basic hydrolysis.
[0048] The reaction is effected by using aqueous base and an inert solvent.
[0049] The bases that can be used include, but are not limited to, inorganic bases such as alkali metal alkoxides like sodium methoxide, sodium ethoxide, potassium t-butoxide and the like; alkali metal carbonates, such as sodium carbonate or potassium carbonate and the like; alkali metal hydroxides, such as sodium hydroxide, potassium hydroxide and the like. Of these, the alkali metal hydroxides are preferred. The amount of base employed is not critical, but good practice recommends an amount of base from about an equimolar amount to about 5 times the equimolar amount with respect to the compound of formula II.
[0050] The reaction is effected in the presence of a solvent. The solvents that can be used include, but are not limited to, halogenated solvent such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably aqueous alcohols and polar aprotic solvents.
[0051] The reaction is carried out at a temperature from about 30° C. to about 100° C. or reflux temperatures of the solvents used. Preferably from about 30° C. to about 75° C.
[0052] The time required for the reaction may also vary widely, depending on many factors, notably the reaction temperature and the nature of the reagents and solvent employed. However, provided that the reaction is effected under the preferred conditions outlined above, a period from about 30 minutes to about 10 hours, preferably from about 30 minutes to about 5 hours, is sufficient. The molar ratio of the amounts of the compound of formula II and the base may be about 1:0.5 to about 1:5.
[0053] The present invention provides a process for preparing bosentan comprising reacting 4-tertiary butyl-N-[6-(2-alkoxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide compound of formula III or a salt thereof
[0000]
[0000] where R is benzyl, acetyl,
with a suitable reducing agent in the presence of an organic solvent.
[0054] The process of reduction is carried out by either using organic or inorganic acids, or using hydrogenation.
[0055] The inorganic acids that can be used include, but not limited to, sulfuric acid, hydrochloric acid, hydrobromic acid and the like; organic acids such as acetic acid, formic acid, trifluoroacetic acid and the like, preferably hydrochloric acid & sulfuric acid.
[0056] Alternatively, the process of reduction when carried out using hydrogenation, occurs with the use of hydrogenation catalysts in the presence hydrogen. The hydrogenation catalysts include but are not limited to palladium-carbon, Raney nickel and the like, preferably palladium-carbon.
[0057] The solvent that can be used is selected from alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; halogenated solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably alcohols, more preferably, methanol.
[0058] The reaction can take place over a wide range of temperatures from about 0° C. to about 100° C. Preferably from about 0° C. to about 50° C.
[0059] The time required for the reaction can range from about 1 hour to about 20 hours. Preferably from about 1 hour to about 5 hours.
[0060] The present invention provides a process for preparing the compound of formula III or a salt thereof comprising: reacting4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula IV
[0000]
[0061] where R is benzyl, alkyl and hydrogen atom, as defined previously for compound of formula III
[0000] with 4-tertiarybutylphenylsulfonamide compound of formula V
[0000]
[0000] in the presence of a base and an inert organic solvent.
[0062] The reaction is carried out in the presence of a base and an inert solvent.
[0063] The bases that can be used include but are not limited to organic amines, such as triethylamine, tributylamine, N-methylmorpholine, pyridine, 4-dimethylamino-pyridine, lutidine, collidine and the like; alkali metal alkoxides, such as sodium methoxide, sodium ethoxide or potassium t-butoxide; alkali metal carbonates, such as sodium carbonate or potassium carbonate; and alkali metal hydroxides, such as sodium hydroxide or potassium hydroxide and mixtures thereof or metal hydrides. Preferably, sodium hydride.
[0064] The mole ratios of the compounds of formula IV and V would generally be from about an equimolar amount to about 5 times. Preferably, equimolar amounts.
[0065] The solvent that can be used is selected from alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; halogenated solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably, aprotic polar solvents like DMF.
[0066] The reaction can take place over a wide range of temperatures from about 25° C. to about 150° C. Preferably from about 25° C. to about 75° C.
[0067] The time required for the reaction can range from about 1 hour to about 10 hours. Preferably from about 1 hour to about 5 hours.
[0068] The reaction of compound of formula IV with the compound of formula V can also be carried out in neat conditions in the absence of solvents.
[0069] The present invention provides a process for preparing 4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula IV comprising:
a) subjecting 4,6-dichloro-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VI
[0000]
[0000] to basic hydrolysis to form 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VII
[0000]
b) reacting the compound of formula VII with a compound of formula VIII in the presence of a base and an organic solvent under phase transfer conditions.
[0000]
[0000] where R is benzyl, benzyloxy carbonyl, methyloxymethyl, H, and X is halogen, OH.
[0072] The bases that can be used include but are not limited to organic amines, such as triethylamine, tributylamine, N-methylmorpholine, pyridine, 4-dimethylamino pyridine, lutidine, collidine and the like; alkali metal alkoxides, such as sodium methoxide, sodium ethoxide or potassium t-butoxide; alkali metal carbonates, such as sodium carbonate or potassium carbonate; and alkali metal hydroxides, such as sodium hydroxide or potassium hydroxide and mixtures thereof or alkali metal hydride preferably alkali metal hydroxide.
[0073] The mole ratio of the compounds of formula VII and VIII would generally be from about an equimolar amount to about 5 times. Preferably, about 2 molars to about 3 molars.
[0074] The solvent that can be used is selected from alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; halogenated solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably, alcohols.
[0075] The reaction can take place over a wide range of temperatures from about 25° C. to about 150° C. Preferably from about 25° C. to about 75° C.
[0076] The time required for the reaction can range from about 1 hour to about 10 hours. Preferably from about 1 hour to about 5 hours.
[0077] Optionally the compound of formula VI is reacted with the compound of formula VIII to give the compound of formula IV.
[0078] The present invention provides a compound: 4-chloro-6-alkoxyethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine of structural formula IV with R as hydrogen.
[0000]
[0079] The present invention provides a process for the preparation of the compound IV with R as hydrogen comprising the reaction of 4,6-dichloro-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VI with ethylene glycol in the presence of base such as hydroxide ion bases and hydride ion bases. Preferably, sodium hydride.
[0080] The solvent that can be used is selected from alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; halogenated solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), tetrahydrofuran (THF), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably, THF.
[0081] The present invention provides a compound: 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine of structural formula VII.
[0000]
[0082] The present invention provides a process for the preparation of bosentan comprising: reacting 4-tertiarybutyl-N-[6-(2-alkynoyloxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide compound of formula IX or a salt thereof
[0000]
[0000] with a reducing agent in the presence of an organic solvent; where R is H, methoxy, ethoxy.
[0083] The process of reduction is carried out by hydrogenation.
[0084] The process of reduction is carried out using hydrogenation catalysts in the presence of hydrogen. The hydrogenation catalysts include but are not limited to palladium-carbon, Raney nickel and the like, preferably palladium-carbon.
[0085] The solvent that can be used is selected from the group alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; halogenated solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably alcohols.
[0086] The reaction can take place over a wide range of temperatures from about 0° C. to about 100° C. Preferably, from about 0° C. to about 50° C.
[0087] The time required for the reaction can range from about 1 hour to about 20 hours. Preferably, from about 1 hour to about 5 hours.
[0088] The present invention provides a process for preparing a compound of formula IX comprising
a) reacting 4-chloro-6-hydroxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula VII
[0000]
[0090] with a compound of formula X
[0000]
[0091] where R is same as defined for compound of formula IX and X is halogen atom, to form 4-chloro-6-alkanoyloxy ethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of formula XI
[0000]
b) reacting the compound of formula XI with 4-tertiarybutylphenylsulfonamide compound of formula V or a salt thereof
[0000]
[0000] in the presence of a base and an organic solvent.
[0093] The reaction, previously described above, is carried out in the presence of a base and an inert solvent. The bases that can be used include but are not limited to organic amines, such as triethylamine, tributylamine, N-methylmorpholine, pyridine, 4-dimethylaminopyridine, lutidine, collidine and the like; alkali metal alkoxides, such as sodium methoxide, sodium ethoxide or potassium t-butoxide; alkali metal carbonates, such as sodium carbonate or potassium carbonate; and alkali metal hydroxides, such as sodium hydroxide or potassium hydroxide and mixtures thereof alkali metal hydride. Preferably sodium hydride.
[0094] The solvent that can be used is selected from alcohols such as methanol, ethanol, isopropyl alcohol and the like; esters such as ethyl acetate, isopropyl acetate and the like; solvents such as dichloromethane, ethylene dichloride, chloroform and the like; aprotic polar solvents such as N,N-dimethylformamide (DMF), dimethylsulfoxide (DMSO), dimethylacetamide (DMA), tetrahydrofuran (THF), acetonitrile and the like; hydrocarbon solvents such as n-hexane, n-heptane, cyclohexane, toluene and the like and mixtures thereof. Preferably, THF.
[0095] The reaction can take place over a wide range of temperatures from about 25° C. to about 150° C. Preferably, from about 25° C. to about 75° C.
[0096] The time required for the reaction can range from about 1 hour to about 24 hours. Preferably, from about 1 hour to about 5 hours.
[0097] The reactions, previously described, of a) a compound of formula VII with the compound of formula X; b) compound of formula XI with the compound of formula V can also be carried out in neat conditions.
[0098] The mole ratio of the compounds of formula VII and X employed would generally be from about an equimolar amount to about 5 times. Preferably, from about 2 molars to about 3 molars.
[0099] The present invention provides a compound 4-tertiarybutyl N-[6-(2-alkynoyloxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzenesulfon amide compound of formula IX or a salt thereof.
[0000]
[0100] The present invention provides a compound 4-chloro-6-alkanoyloxy ethoxy-5-(O-methoxyphenoxy)-2,2′-bipyrimidine compound of structural formula XI
[0000]
[0101] The isolation of the desired target compounds from the reaction mixtures in all of the above previously described processes can be carried out by methods known in the art Said methods take into consideration the physical properties of the desired compound, whereupon crystallization, extraction, washing, column chromatography, etc. may be combined. Preferably, extraction and crystallization.
[0102] The present invention provides that in the processes previously described, the intermediate compounds are optionally isolated and can be obtained by the so-called one pot reaction.
[0103] The target compound, bosentan, is optionally purified by recrystallisation using a solvent or mixture of solvents or alternatively, by converting into a pharmaceutically acceptable salt, which is subjected to purification then reverted back to bosentan.
[0104] In another aspect, the present invention provides a process for the purification of bosentan or pharmaceutically acceptable salt thereof comprising:
a) providing a solution of bosentan or pharmaceutically acceptable salt thereof in a solvent or a mixture of solvent; b) optionally filtering the solution; c) adding an anti-solvent to the filtrate to precipitate the bosentan or pharmaceutically acceptable salt thereof; d) recovering the solid to obtain bosentan or pharmaceutically acceptable salt thereof in pure form.
[0109] The solvent that can be used is selected from the group consisting of ketones such as acetone, ethyl methyl ketone, methyl isobutyl ketone and the like; ethers such as tetrahydrofuran, 1,4-dioxane, diethyl ether, methyl tertiary butyl ether, diisopropyl ether, and the like and mixtures thereof. Preferably, acetone.
[0110] The temperatures for dissolution are from about 30 to about 75° C. or reflux temperatures of the solvents used. Preferably, from about 55° C. to about 60° C.
[0111] The solution obtained is optionally filtered on celite to remove the unwanted solids and particles.
[0112] The antisolvents that can be used include but are not limited to water, hydrocarbons such as n-pentane, n-hexane, n-heptane, cyclohexane and mixtures thereof. Preferably, water.
[0113] The temperature for precipitation of solid is from about 10° C. to about 35° C. Preferably from about 25° C. to about 30° C.
[0114] The obtained bosentan may be recovered by the conventional technique known in the art, preferably by filtration. The purification steps described above are optionally repeated.
[0115] Bosentan obtained is optionally dried at temperatures from about 35° C. to about 55° C. Preferably from about 50 to about 55° C. under vacuum of about 600 mmHg to about 710 mmHg.
[0116] In one embodiment, the present invention provides bosentan or a pharmaceutically acceptable salt thereof obtained by the processes described above having each one or none of the following impurities, at amounts determined by HPLC, namely:
[0000] Formula A 6-chloro-5-(2-methoxyphenoxy)-2,2′-bipyrimidin-4-ol.
Formula B 2-{[6-chloro-5-(2-methoxyphenoxy)-2,2′-bipyrimidin-4-yl]oxy}ethanol.
Formula C 6-hydroxy 2-sulfonamide impurity.
Formula D Bosentan-dimer impurity.
Formula E 6,6′-ethoxy-2-chloro impurity.
Formula F 6,6′-ethoxy-2-sulfonamide impurity
Formula G Desmethyl bosentan Impurity
Formula H Hydroxy desmethyl bosentan impurity
Formula I 6-Hydroxy bosentan Impurity
Formula J 6-Methoxy bosentan Impurity
[0000]
[0117] The present invention provides bosentan or a pharmaceutically acceptable salt thereof obtained by the above described processes, having any or each one the above described impurities in an amount less than about 0.15%.
[0118] The present invention provides bosentan or a pharmaceutically acceptable salt thereof obtained by the above described processes having a purity, as measured by HPLC, of at least about 98%, more preferably, at least about 99% and most preferably at least about 99.5%.
[0119] Preferably, the chemical purity of the bosentan or a pharmaceutically acceptable salt thereof is about 99% or more, more preferably about 99.5% or more, more preferably about 99.8% or more, more preferably about 99.9% or more, as measured by area under HPLC.
[0120] In one embodiment, the present invention encompasses bosentan or a pharmaceutically acceptable salt thereof having less than about 0.20% of any single impurity as measured by area under HPLC peaks. Preferably, the bosentan or a pharmaceutically acceptable salt thereof has less than about 0.15% of any single chemical impurity as measured by area under HPLC peaks.
[0121] The present invention provides a bosentan or a pharmaceutically acceptable salt thereof, obtained by the above process, as analyzed chemical purity using high performance liquid chromatography (“HPLC”) with the conditions described below:
Column: Zorbax SB-C 8 , 250×4.6 mm, 5μ [Part No. 880975-906] Column Temperature: 25° C. Mobile phase: Mobile phase A=Buffer [Buffer: Dissolve 1 gm of Octane-1-sulfonic acid sodium salt in 1000 ml of water and mix. Add 1 ml of Triethylamine to it and mix. Adjust pH to 2.5 with diluted perchloric acid (10% in water)]. Mobile Phase B=Methanol
[0000]
Time(min.)
% Mobile Phase A
Mobile Phase B
0.0
55
45
22
33
67
42
33
67
48
20
80
65
20
80
67
55
45
75
55
45
Diluent A: Water:Methanol:Methylene chloride (20:80:0.05, v/v/v)
Diluent B: Water: Methanol (20:80, v/v)
Flow Rate: 1.0 mL/minute
Detection: UV 220 nm
Injection Volume: 20 μL
[0131] In yet another embodiment, bosentan or its pharmaceutically acceptable salts obtained by the processes described above has residual organic solvents or organic volatile impurities less than the amount recommended for pharmaceutical products, as set forth for example in ICH guidelines and U.S. pharmacopoeia, which are less than about 600 ppm of dichloromethane, less than about 800 ppm of N,N-dimethylformamide (DMF), less than about 3000 ppm of methanol, 5000 ppm of acetone, ethyl acetate, isopropyl alcohol, and tetrahydrofuran (THF), less than about 890 ppm of toluene, Isopropyl acetate and acetic acid.
[0132] In one embodiment, bosentan or its pharmaceutically acceptable salts obtained by the process of the present invention can have a D 50 and D 90 particle size of less than about 400 microns, preferably less than about 200 microns, more preferably less than about 150 microns, still more preferably less than about 50 microns and most preferably less than about 15 microns. The particle size can be determined by such techniques as, for example, Malvern light scattering, a laser light scattering technique, etc., using, e.g., a Malvern® Mastersizer 2000. It is noted the notation D x means that X % of the particles have a diameter less than a specified diameter D. Thus, a D 50 of about 250 μm means that 50% of the particles composition comprising of bosentan or its pharmaceutically acceptable salts have a diameter less than about 250 μm.
[0133] The particle sizes of the bosentan or its pharmaceutically acceptable salts obtained by, for example, milling, grinding, micronizing or other particle size reduction method known in the art to bring the solid state bosentan or its pharmaceutically acceptable salts to the desired the foregoing desired particle size range.
[0134] The present invention also provides pharmaceutical compositions comprising bosentan or its pharmaceutically acceptable salts obtained by the processes of present invention. Such pharmaceutical compositions may be administered to a mammalian patient in any dosage form, e.g., liquid, powder, elixir, injectable solution, etc. Dosage forms may be adapted for administration to the patient by oral, buccal, parenteral, ophthalmic, rectal and transdermal routes. Oral dosage forms include, but are not limited to, tablets, pills, capsules, troches, sachets, suspensions, powders, lozenges, elixirs and the like.
[0135] The simple, eco-friendly processes for the preparation of bosentan or its pharmaceutically acceptable salts thereof of the present invention are easily scalable.
[0136] The following examples are provided to enable one skilled in the art to practice the invention and are merely illustrative of the invention. The examples should not be read as limiting the scope of the invention as defined in the features and advantages.
EXAMPLES
Example 1
PREPARATION OF 4,6-DIHYDROXY-5-(2-METHOXYPHENOXY)-2,2′-BIPYRIMIDINE
[0137] 330.7 g (1.1811 mole) of 2-pyrimidine carboximidamide benzene sulphonate and 250 g (0.9842 mole) of 2,2-methoxy phenoxy melonate dimethyl ester were added to the clear solution of sodium methoxide at 40-45° C. (3 L of methanol and 132.87 g (2.4606 mole) of sodium methoxide). The reaction mixture was heated to reflux and maintained for about 5 hrs. Reaction was monitored by HPLC. Cooled the reaction mass up to about 40-45° C., then methanol was distilled off completely. The residue was taken into 2.5 L of purified water to get a clear solution and then added 212.5 ml of hydrochloric acid (Conc.) [pH of the mass ˜1.0] and stirred the reaction mass for about 4-5 hrs or until complete precipitation. The reaction mass was filtered and sucked dry. Washed with 1 L of purified water and finally washed with 125 ml of Acetone. The wet cake was charged in a clean flask and added 625 ml of acetone. The mass was stirred for about 3-4 hrs and the title compound, 4,6-Dihydroxy-5-(2-methoxyphenoxy)-2,2′-bipyrimidine, was filtered off and washed with 125 ml of acetone and dried in hot oven at about 50-55° C. until the LOD is below 10.0%.
[0000] Dry weight: 210 grms; Purity by HPLC: 98.8%.
Example-2
PREPARATION OF 4,6-DICHLORO-5-(2-METHOXYPHENOXY)-2,2′-BIPYRIMIDINE
[0138] 120 g (0.3840 moles) of 6-Dihydroxy-5-(2-methoxyphenoxy)-2,2′-bipyridine was added to 235.38 g (1.5384 moles) of phosphorus oxychloride (POCl 3 ) under nitrogen and slowly added 75.96 g (0.9615 moles) of pyridine under nitrogen. The reaction mass was maintained for 30 minutes at the same temperature. The reaction mass was heated to about 95-100° C. for about 5 hrs. Reaction was monitored by HPLC. Cooled the reaction mass to about 10-15° C. and charged about 990 ml of methylene chloride to get a clear solution. Transferred the methylene chloride solution in another clean flask and added 990 ml of purified water and the mixture was cooled to about 5-10° C. The reaction mass was quenched in the mixture. Raised the temperature to about 25-30°. Stirred the mass for about 30 minutes and separated the product containing methylene chloride layer, extracted the aqueous layer with another 990 ml of Methylene chloride. The total methylene chloride layer was collected and washed with two portions of 990 ml each of purified water. Methylene chloride layer was washed with about 750 ml of 10% Sodium carbonate solution. Methylene chloride layer was washed with about 750 ml of 10% sodium chloride solution. The organic phase was dried using by sodium sulphate. The solvent was evaporated and the residue was treated with 990 ml of diisopropyl ether. The target compound, 4,6-Dichloro-5-(2-methoxyphenoxy)-2,2′-bipyrimidine was filtered off and washed with about 396 ml of Diisopropyl ether. Dried in hot air oven at about 50-55° C. for about 12-16 hrs until the LOD is about below 1.0%.
[0000] Dry weight 180 grms; Purity by HPLC: 99%.
Example-3
PREPARATION OF P-T-BUTYL-N-[6-CHLORO-5-(O-METHOXYPHENOXY)-4-PYRIMIDINYL]BENZENESULPHONAMIDE
[0139] 66.0 g (0.3094 moles) of 4-t-butyl benzenesulphonamide, 53.38 g (0.3868 moles) of potassium carbonate, and 90 g (0.2578 moles) of 4,6-dichloro-5-(2-methoxyphenoxy)-2,2′-bipyrimidine were added to about 900 ml of toluene at about 25-30° C. Heat the reaction mass to reflux and maintain for about 3 hrs. Reaction was monitored by HPLC. Cooled the reaction mass to about 25-30° C. and charged about 900 ml of purified water into the reaction mass and stirred for about 60 min at about 25-30° C. Filtered the reaction mass and washed with about 450 ml of purified water. Unload the wet material and charged into the same flask. Charged about 900 ml of methylene chloride and about 900 ml of purified water and stirred the mass for about 60 minutes at about 25-30° C. Filtered the reaction mass and washed with about 450 ml of purified water. Unload the wet cake and charged in same flask. Charged about 900 ml of purified water and charged about 10 ml of 50% solution of HCl in to mass. Stirred the mass for about 60 minutes. Filtered the mass and washed with about 450 ml of purified water. Sucked dry completely. Charged the wet material into a flask and charged about 450 ml of acetone and 450 ml of purified water at about 25-30° C. Raised the temperature to about 60-65° C. and maintained the temperature for about 30 mins. Cooled the reaction mass to about 25-30° C. and maintained for about 30 minutes. Filtered and washed with a solvent mixture of about 90 ml each of acetone and purified water. Sucked dry completely. Unloaded the wet cake and dried under vacuum at about 50-55° C. for about 12-16 hrs until the water content was about below 3.5% % to give 112 gms of the title compound.
Purity by HPLC: 98.5%.
Example-4
PREPARATION OF 4-TERT-BUTYL-N-[6-(2-HYDROXYETHOXY)-5-(2-METHOXYPHENOXY)-2-(2-PYRIMIDINYL) PYRIMIDIN-4-YL]BENZENESULFONAMIDE USING SODIUM METHOXIDE
[0140] 630.0 g 1296.55 g (10.1711 moles 20.91 moles) of ethylene glycol and 51.33 g (0.9506 moles) of sodium methoxide were added to 1000 ml of tetrahydrofuran in a reaction vessel. The reaction mass was heated to about 50-55° C. to get a clear solution. 100 g (0.19011 moles) of p-t-butyl-N-[6-chloro-5-(o-methoxyphenoxy)-4-pyrimidinyl]benzenesulphonamide, prepared as in Example 3, was added in the reaction mass at about 50-55° C. The reaction mass was stirred for about 5-6 hrs for about 15-20 hrs at about 80-85° C. Reaction was monitored by TLC using 10% methanol and chloroform as mobile phase or alternatively, by HPLC. Cooled the reaction mass to about 40-45° C. The tetrahydrofuran was distilled off under vacuum at about 35-40° C. The resulting solution was cooled to 10-15° C. About 1000 ml each of dichloromethane and purified water were added into the resulting mass. The mass was stirred for about 30 min at about 10-15° C. The pH was adjusted to about 4.0-5.0 using 50% of hydrochloric acid. Stirred, settled, and separated the dichloromethane layer. Again extracted the aqueous layer using about 900 ml of dichloromethane. The total dichloromethane layers were combined and washed with three portions of 1000 ml each of purified water three times. The organic phase was dried by passing through sodium sulphate. Filtered the dried organic phase and then the solvent was evaporated to yield of 107 g of a foamy solid 4-tert-butyl-N-[6-(2-hydroxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide. Then the solid was added to a solvent mixture of about 360 ml each of methanol and isopropyl acetate. Heated the reaction mass to about 60-65° C. and cooled to about 25-30° C. and stirred for about 2 hrs at about the same temperature. The solid was filtered and washed with a solvent mixture of 90 ml each of methanol and isopropyl acetate to yield 80 g of the target compound, crude 4-tert-Butyl-N-[6-(2-hydroxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzenesulfonamide.
Yield: 87%; Purity by HPLC: 97.8%.
Example-5
PREPARATION OF 4-TERT-BUTYL-N-[6-(2-HYDROXYETHOXY)-5-(2-METHOXYPHENOXY)-2-(2-PYRIMIDINYL) PYRIMIDIN-4-YL]BENZENESULFONAMIDE USING SODIUM HYDRIDE
[0141] 1166.9 g (18.821 moles) of Ethylene glycol, 34.2 g (1.425 moles) of Sodium hydride (60%) were added to 2100 ml of tetrahydrofuran. The reaction mass was heated to about 50-55° C. and stirred for about 2 hrs. 90.0 g (0.1710 moles) of p-t-butyl-N-[6-chloro-5-(o-methoxyphenoxy)-4-pyrimidinyl]benzenesulphonamide was added to the reaction mass. Heated the reaction mass to reflux and maintained for about 15-17 hrs at about 70-75° C. Reaction was monitored by HPLC. Cooled the reaction mass to about 25-30° C. and added about 2300 ml of methanol and the mixture was stirred for about 15 minutes. Charged 900 ml each of methylene chloride and of purified water into the reaction mass. The reaction mass was cooled to about 10-15° C. Added 196 ml of 50% of HCl solution and adjusted the pH to about 4.0-5.0 The solvent was distilled out under vacuum at about 40-45° C. The resulting solution was cooled to about 5-10° C. 2100 ml each of dichloromethane and of purified water were added into the resulting mass. The mass was stirred for about 30 minutes at about 5-10° C. pH was adjusted to about 3.5-4.5 using 50% of hydrochloric acid. Temperature was raised to about 25-30° C. and then separated the methylene chloride layer. Extracted the aqueous layer with about 2100 ml of methylene chloride. Combined total methylene chloride layers and washed with three portions of 2100 ml each of purified water. Methylene chloride layer was taken and washed with mixture of 1100 ml of methanol and 100 ml of purified water and was dried on sodium sulphate. Methylene chloride was distilled and degassed completely under vacuum. Charged 350 ml of methanol and 350 ml of isopropyl acetate and heated the reaction mass at 65° C. to get clear solution an stirred at same temp. for 15-30 mins. Cooled the reaction mass to 25-30° C. and maintained for 2 hrs at 25-30° C. Filtered the product and washed with mixture of 175 ml of methanol and 175 ml of Isopropyl acetate. Suck dried completely. Bosentan wet wt: 145 grms; Dry wt: 78 grms; Purity by HPLC: 98.8%.
[0142] The resulting mother liquor was cooled to about 5-10° C. 10 V each of dichloromethane and of purified water were added into the resulting mass. The mass was stirred for about 30 minutes at about 5-10° C. The solution's pH was adjusted to about 3.5-4.5 using 50% of hydrochloric acid. Stirred, settled, and separated the dichloromethane layer. Again, extracted the aqueous layer with the use of another 10 V of dichloromethane. The total dichloromethane layers were combined and washed with three portions about 5 V of each purified water. The organic phase was dried using sodium sulphate. Filtered and evaporated the solvent to yield of 10.5 g of foamy solid 4-tert-butyl-N-[6-(2-hydroxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide. 10 V of diisopropyl ether was added and then stirred for about 4-6 hrs. The solid was filtered and washed with diisopropyl ether to yield 10 g of crude 4-tert-Butyl-N-[6-(2-hydroxyethoxy)-5-(2-methoxyphenoxy)-2-(2-pyrimidinyl)pyrimidin-4-yl]benzene sulfonamide; Purity by HPLC: 97.8%.
Example-6
Purification of Bosentan Using Acetone and Water
[0143] 10 g of bosentan was added to 30 ml of acetone and refluxed to get a clear solution. 20 ml of water was added dropwise at reflux temperature. The suspension was slowly cooled to about 25-30° C. Filtered the mass and dried at about 25-30° C. under vacuum. Dry weight 8.9 grms; Purity by HPLC: 99.6%.
Example-7
Purification of Bosentan Using Ethanol and Water
[0144] 10 g of bosentan was added to 30 ml of ethanol and refluxed to get a clear solution. 30 ml of Water was added dropwise at reflux temperature. The suspension was slowly cooled to about 25-30° C. Filtered the mass and dried at about 25-30° C. under vacuum. Dry weight: 9 grms, Purity by HPLC: 99.6%.
Example-8
Purification of Bosentan Using Methanol
[0145] 10 g of bosentan was added to 100 ml of methanol and refluxed to obtain a clear solution. The clear mass was stirred and slowly cooled to about 25-30° C. and filtered. The solid product was dried at about 25-30° C. under vacuum for about 10-12 hrs. Dry weight: 9 grms; Purity by HPLC: 98.9%.
Example-9
Purification of Bosentan Using Acetonitrile and Water
[0146] 10 g of bosentan was added to 40 ml of acetonitrile and refluxed to obtain a clear solution. 30 ml of Water was added dropwise at reflux temperature. The suspension was slowly cooled to 25-30° C. Filtered the mass and dried at about 25-30° C. under vacuum. Dry weight: 8.9 grms; Purity by HPLC: 99.5%.
Example-10
Purification of Bosentan Using Acetonitrile
[0147] 10 g of bosentan was added to 30 ml of acetonitrile and refluxed to obtain a clear solution. The clear mass was stirred and slowly cooled to about 25-30° C. and filtered. The solid product was dried at about 25-30° C. under vacuum for about 10-12 hrs. Dry weight: 8.7 grms; Purity by HPLC: 98.9%
Example-11
Purification of Bosentan Using THF and Water
[0148] 10 g of Bosentan was added to 20 ml of tetrahydrofuran and refluxed to get a clear solution. 30 ml of water was added dropwise at reflux temperature. The suspension was slowly cooled to about 25-30° C. Filtered the mass and dried at about 25-30° C. under vacuum.
[0000] Dry weight: 9 grms; Purity by HPLC: 98.9%. | The present invention relates to processes for the preparation of bosentan and compounds that can be used as structurally novel intermediates for the synthesis thereof, and a pharmaceutical composition of the same. | 2 |
The present application is the national phase of International Application No. PCT/CN2012/087142, titled “MOVEMENT INHIBITING APPARATUS FOR FLOATING OFFSHORE WIND TURBINE AND FLOATING BASE USED FOR OFFSHORE WIND TURBINE”, filed on Dec. 21, 2012, which claims the benefit of priority to Chinese Patent Application No. 201110440041.9, entitled “MOVEMENT INHIBITING APPARATUS FOR FLOATING OFFSHORE WIND TURBINE AND FLOATING BASE USED FOR OFFSHORE WIND TURBINE”, filed with the Chinese State Intellectual Property Office on Dec. 23, 2011, both of which applications are incorporated herein in their entireties by this reference.
BACKGROUND
1. Field of the Disclosure
The present application relates to an offshore wind turbine, and particularly to a motion suppression device for a floating offshore wind turbine configured to suppress the swinging motion of the offshore wind turbine around a vertical axis, and a floating foundation for the offshore wind turbine having the motion suppression device for the offshore wind turbine.
2. Discussion of the Background Art
An offshore wind turbine generally employs a gravity foundation, a monopile foundation, a jacket foundation, a tripod foundation, a suction caisson foundation, or a floating foundation according to a depth of seawater and seabed geological conditions. Among all these foundation types, the floating foundation is not restricted by the seabed conditions and is applicable to an offshore wind farm having a water depth greater than 50 meters, thus the floating foundation is a promising technique which has a bright prospect for wide application.
Floating platforms in the marine industry and the offshore oil industry are similar to the floating foundation for the offshore wind turbine.
At present, an anti-roll device in the marine industry mainly includes a fin stabilizer, a bilge keel, an anti-roll tank, an anti-roll rudder, and so on, and the fin stabilizer, the bilge keel, and the anti-roll rudder may keep the ship stable by using the lift force of fluid acting on these structures during the navigation. The faster the ship travels the more stable the ship is. The anti-roll tank may keep the ship stable by using a pressure difference between ballast water in side tanks of larboard and starboard to offset an overturning moment of the ship.
A motion suppression device for the floating platform of the offshore oil projects mainly includes a damping plate for truss-spar and a stabilizing plate for floating bodies such as an FPSO.
However, the foundation for the floating offshore wind turbine bears loads quite different from the floating platforms in the traditional marine industry and offshore oil industry. In addition to combined loads from wind and wave, the foundation for the floating offshore wind turbine is also subject to a gyro revolving effect resulting from the operation of the wind turbine of a high-rise structure. The gyro revolving effect may generate overturning moments Mx and My and a torque Mz about a vertical axis on the foundation, and cause violent motions of the whole wind turbine in six degrees of freedom, including axial motions along axes X, Y, and Z and swinging motions about these axes, which may bring a tremendous challenge for a pitch and yaw control system of the wind turbine, and adversely affect the normal operation of the wind turbine, reduce the generated energy, or even endanger the structural safety of the whole system.
The foundation for the floating wind turbine is structurally different from the floating platform in the marine industry, and the loads, produced in the operation of machines carried on the foundation for the floating wind turbine is also different from that of the floating platform in the marine industry. At present, there is no effective motion suppression device specifically designed for overall motion of the floating offshore wind turbine. Therefore, it is necessary to provide a device for suppressing the motion of the floating wind turbine in six degrees of freedom.
SUMMARY
The present application intends to provide a motion suppression device for suppressing the motion of a floating offshore wind turbine, and a floating foundation for the offshore wind turbine having the motion suppression device.
A motion suppression device for a floating offshore wind turbine is provided, wherein the floating offshore wind turbine has a floating foundation, and the motion suppression device includes at least one annular stabilizing plate arranged horizontally surrounding the floating foundation.
The stabilizing plate is provided with a plurality of fin stabilizers including a first group of fin stabilizers arranged on one side of the stabilizing plate, and the first group of fin stabilizers are arranged vertically surrounding the floating foundation and spaced apart from each other.
The plurality of fin stabilizers further include a second group of fin stabilizers arranged on the other side of the stabilizing plate, and the second group of fin stabilizers are arranged vertically surrounding the floating foundation and spaced apart from each other.
Each fin stabilizer in the first group is deflected by a first angle in a width direction with respect to a straight line passing through a center of the floating foundation and an inner endpoint of the fin stabilizer.
Each fin stabilizer in the first group is deflected by a first angle in a width direction with respect to a straight line passing through a center of the floating foundation and an inner endpoint of the fin stabilizer, and each fin stabilizer in the second group is deflected by a second angle in a width direction with respect to the straight line passing through the center of the floating foundation and the inner endpoint of the fin stabilizer.
The first angle and the second angle may be equal.
A deflection direction of the first group of fin stabilizers may be opposite to a deflection direction of the second group of fin stabilizers.
The first angle may be greater than 0 degree and less than 45 degree, preferably range from 5 degree to 10 degree.
The first angle may be greater than 0 degree and less than 45 degree, and the second angle may range from 1 degree to 15 degree.
The first angle may range from 5 degree to 10 degree and the second angle may range from 5 degree to 10 degree.
The fin stabilizers may each have an L-shaped cross section.
The fin stabilizers may each be provided with a stiffener.
The fin stabilizers may have a flat surface or a curved surface.
The stiffener of the fin stabilizer may include at least one of a horizontal stiffener, an inclined stiffener, or a vertical stiffener.
A stiffener may be provided on a surface of the stabilizing plate.
The stabilizing plate may have a flat surface or a curved surface.
The stabilizing plate may be provided with evenly distributed spoiler holes.
A permeability, caused by the spoiler holes, of the stabilizing plate may range from 5% to 30%.
A permeability, caused by the spoiler holes, of the stabilizing plate may range from 8% to 12%.
The fin stabilizers in the first group are connected by an annular member.
The fin stabilizers in the first group and the fin stabilizers in the second group may be both connected by an annular member.
The annular member may have a polygonal or circular shape.
The annular member may be formed by a square tube, a circular tube or a steel sheet.
The annular member may be provided to connect outer sides of ends, far away from the stabilizing plate, of the fin stabilizers and/or the annular member may pass through the fin stabilizers.
Inner sides of the fin stabilizers may be secured to the floating foundation.
A floating foundation for an offshore wind turbine is further provided according to the present application, and the floating foundation may be provided with the motion suppression device for the floating offshore wind turbine.
The floating foundation may be of a spar type or a semi-submersible type.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present application will become more clearly based on the following description in conjunction with the accompanying drawings.
FIG. 1 is a stereogram of an offshore wind turbine with a spar type floating foundation using a motion suppression device according to a first embodiment of the present application;
FIG. 2 is a stereogram of the motion suppression device according to the first embodiment of the present application;
FIG. 3 and FIG. 4 are, respectively, a plan view and a stereogram of a stabilizing plate of the motion suppression device in FIG. 2 ;
FIG. 5 is a stereogram of a fin stabilizer of the motion suppression device in FIG. 2 ;
FIG. 6 is a stereogram of an offshore wind turbine with a semi-submersible floating foundation using a motion suppression device according to a second embodiment of the present application; and
FIG. 7 is a stereogram of the motion suppression device according to the second embodiment of the present application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of the present application will be described in detail below in conjunction with the accompanying drawings.
FIG. 1 is a stereogram of an offshore wind turbine with a spar type floating foundation using a motion suppression device according to a first embodiment of the present application. FIG. 2 is a stereogram of the motion suppression device according to the first embodiment of the present application. FIG. 3 and FIG. 4 are, respectively, a plan view and a stereogram of a stabilizing plate of the motion suppression device in FIG. 2 . FIG. 5 is a stereogram of a fin stabilizer of the motion suppression device in FIG. 2 .
An offshore wind turbine with a spar-type floating foundation is taken as an example to describe the motion suppression device according to the first embodiment of the present application.
As shown in FIG. 1 , an offshore wind turbine 100 with a spar type floating foundation mainly includes a spar type floating foundation 10 , a motion suppression device 20 , a mooring device 30 , a blade 40 , a nacelle 50 and a tower 60 . The motion suppression device 20 is installed surrounding the floating foundation 10 and configured to reduce an overall motion magnitude of the offshore wind turbine 100 , the mooring device 30 is configured to pull the floating foundation 10 and anchor it to the seabed to avoid substantial movement or overturn of the offshore wind turbine 100 , the blade 40 is configured to receive wind energy and rotate to drive a rotor in the nacelle 50 to rotate so as to generate electrical energy, and the tower 60 is installed on the floating foundation 10 to support the blade 40 and the nacelle 50 .
For simplicity and avoidance of vagueness of the subject matter of the present application, publicly known components will not be described herein. The structure and work principle of the motion suppression device according to the first embodiment of the present application will be described below in conjunction with FIGS. 2 to 5 .
As shown in FIG. 2 , the motion suppression device 20 includes an annular stabilizing plate 21 connected to the floating foundation 10 . As shown in FIG. 1 , the annular stabilizing plate 21 is arranged horizontally surrounding an underwater portion of the floating foundation 10 , and may have a circular ring shape or a polygonal shape with a circular inner hole. The stabilizing plate 21 may be formed as a planar surface or a curved surface. The stabilizing plate is arranged around the floating foundation, which may effectively increase the damping against the rolling, pitching and heaving of the floating foundation, thereby reducing the motion magnitude of the floating wind turbine.
As shown in FIGS. 2 to 4 , a plurality of circular or elliptical spoiler holes 213 may be uniformly arranged on the stabilizing plate 21 . The vertical flow of fluid may be disturbed by the provided spoiler holes 213 , which may effectively increase the damping against the heaving of the floating foundation, and further reduce the motion magnitude of the floating wind turbine. When the stabilizing plate 21 has a permeability of 5% to 30% due to the spoiler holes 213 , the stabilizing plate 21 may increase the damping against the heaving of the floating foundation more effectively. Preferably, a permeability of 8% to 12% may achieve the best effect. In addition, the spoiler hole 213 may be of other shapes, for example triangle, square, diamond, and trapezoid.
As shown in FIG. 3 , multiple turns of reinforcing flat steel may be arranged on the stabilizing plate 21 circumferentially to function as circular stiffeners 211 , for example three turns of reinforcing flat steel may be arranged. Apparently, a radial stiffener 212 may be arranged on the stabilizing plate 21 radially, for example six radial stiffeners may be arranged. In addition to the circular stiffeners 211 , a periphery of the stabilizing plate 21 may be provided with a flanging or a stiffener (not shown) to improve the strength of the stabilizing plate 21 .
In addition, by arranging fin stabilizers 22 around the floating foundation on the stabilizing plate 21 , the yawing damping and added mass of the floating foundation may be effectively increased, which may mitigate the motion of the floating wind turbine. A plurality of fin stabilizers 22 may be arranged vertically around the floating foundation on the horizontal stabilizing plate 21 and spaced apart from each other. Two groups of the fin stabilizers 22 may be respectively arranged on and below the horizontal stabilizing plate 21 . However, the present application is not limited to this. The fin stabilizers 22 may be arranged only on the horizontal stabilizing plate 21 or only below the horizontal stabilizing plate 21 . Preferably, the fin stabilizers 22 are uniformly spaced apart from each other.
For instance, a plurality of fin stabilizers 22 may be evenly arranged both on and below the stabilizing plate 21 , and the number of the fin stabilizers 22 ranges from 4 to 10 (for example, may be 6 or 8). Preferably, each fin stabilizer 22 on the stabilizing plate and each fin stabilizer 22 below the stabilizing plate are, respectively, deflected by an angle α and an angle β with respect to a radial direction of the floating foundation (or with respect to a straight line passing through a centre of the floating foundation and an inner endpoint of the fin stabilizer). Preferably, the angle α and β may both be greater than 0 degree and less than 45 degree, and more preferably, the angle α and β may both in a range of 5 degree to 10 degree. Preferably, the angle α and the angle β are equal. Of course, the angel α and the angle β may be unequal. It has been proven in practice that, when six fin stabilizers 22 are provided in one group, the fin stabilizers with a deflection angle of 10 degree may produce a good stabilizing result. More preferably, the upper fin stabilizers 22 arranged on the stabilizing plate and the lower fin stabilizers 22 arranged below the stabilizing plate are deflected in opposite directions. Due to the deflection of the fin stabilizers 22 , the fluid flow about an axis Z is subject to a higher damping effect, which effectively increases the yawing damping and added mass of the floating foundation. Additionally, since the upper fin stabilizers and the lower fin stabilizers are deflected in different directions, the yawing magnitude of the floating foundation may be significantly reduced both clockwise and anticlockwise. To adapt to the deflection angle of the fin stabilizers 22 , the radial stiffeners 212 may also be deflected by an angle identical or substantially identical to that of the fin stabilizers 22 .
As shown in FIGS. 2, 3 and 5 , each fin stabilizer 22 extends vertically and has an L-shaped cross section. As shown in FIG. 5 , outer edges of the fin stabilizer 22 are folded to form an L-shaped edgefold 223 to increase the structural stiffness and make the structure of the whole motion suppression device 20 more secure and reliable. However, the present application is not limited to this. The outer edges of the fin stabilizer 22 may also be reinforced by flat steel instead of forming the L-shaped cross section, and in this way, the structure of the whole motion suppression device 22 may also be more secure and reliable.
To improve the overall performance and reliability of the motion suppression device 20 , outer sides of the fin stabilizers 22 on and below the horizontal stabilizing plate 21 may be connected, and inner sides of all the fin stabilizers 22 may be connected to the floating foundation 10 (for example, by welding or bolting). Preferably, as shown in FIGS. 2 and 3 , an annular member 23 may be provided to connect the outer sides of ends, far from the horizontal stabilizing plate 21 (i.e. upper ends), of the upper fin stabilizers 22 , and an annular member 24 may be provided to connect the outer sides of ends, far from the horizontal stabilizing plate 21 (i.e. bottom ends), of the lower fin stabilizers. However, the present application is not limited to this. For instance, the annular members 23 and 24 may connect the fin stabilizers 22 at their inner sides or pass through the fin stabilizers 22 to connect them. The present application may install more annular members in various manners and arrange different annular members at different locations on the fin stabilizers (for example, one annular member may be provided to connect the fin stabilizers at the inner sides or the outer sides, and another annular member may be provided to pass through the fin stabilizers to connect them). The annular members 23 and 24 may be composed of circular tubes, square tubes or steel sheets, and may have a circular or polygonal shape.
To further improve the stiffness of the motion suppression device, as shown in FIG. 5 , a side surface of each fin stabilizer 22 may be provided with horizontal stiffeners 221 , vertical stiffeners 222 , or inclined or bent stiffeners (not shown) to enhance the structural stiffness of the fin stabilizer 22 .
Although the fin stabilizer 22 in the embodiment shown in FIG. 5 is rectangular, the present application is not limited to this, and the fin stabilizer 22 may also in other flat shapes, such as triangle or trapezoid, or have a curved surface. If the floating foundation with the motion suppression device 20 has a uniform diameter, a radial width of the stabilizing plate 21 may be equal to a width of the fin stabilizer 22 . If the floating foundation with the motion suppression device 20 has a non-uniform diameter, the width of the fin stabilizer 22 may vary with the diameter of the floating foundation 10 . Preferably, the outer edges of the fin stabilizers 22 are flush with an outer edge of the stabilizing plate 21 . Obviously, it is allowed that the outer edges of the fin stabilizers 22 are not flush with the outer edge of the stabilizing plate 21 . In addition, the inner edges of the fin stabilizers 22 are preferably flush with an inner edge of the stabilizing plate 21 .
The motion suppression device with two layers of fin stabilizers arranged on and below the stabilizing plate is described above in conjunction with FIGS. 1 to 6 . However, the present application is not limited to this, for example one or more stabilizing plates may be provided, and one or more layers of fin stabilizers may be provided.
In the above embodiment, the whole motion suppression device is made of steel. For the wind turbine with a spar type floating foundation shown in FIG. 1 , routine maintenance is not required since the wind turbine is secured to the floating foundation when the wind turbine is built.
The motion suppression device according to a second embodiment of the present application is described below in conjunction with FIGS. 6 and 7 .
FIG. 6 illustrates a wind turbine 200 with a large floating foundation 10 ′. Due to its large size, the floating foundation may be partially submerged in the seawater, thus being referred to as a semi-submersible foundation.
Except the floating foundation 10 ′ and a motion suppression device 20 ′, the wind turbine 200 has basically the same structure as the wind turbine 100 , thus other parts of the wind turbine will not be described in detail herein.
As shown in FIGS. 6 and 7 , the floating foundation 10 ′ is octagonal, and correspondingly, the motion suppression device 20 ′ surrounding the floating foundation 10 ′ includes an annular stabilizing plate 21 ′ arranged octagonally and two layers of fin stabilizers, respectively, arranged on and below the stabilizing plate 21 ′. Similar to the first embodiment, in the second embodiment, circular spoiler holes may be provided on the stabilizing plate 21 ′. In addition, like the first embodiment, in the second embodiment, the stabilizing plate 21 ′ may be provided with flat steel functioning as circular stiffeners 211 ′ and radial stiffeners 212 ′, and the fin stabilizer 22 ′ may be provided with flat steel or a flanging functioning as stiffeners, so as to enhance the structural strength of the motion suppression device 20 ′ and improve the shake-reducing effect thereof.
Although the floating foundation shown in FIGS. 6 and 7 is octagonal, the motion suppression device in the present application is also applicable to semi-submersible floating foundations in other shapes, for example circular, square, pentagon, hexagon or other polygonal shapes.
Based on the above description, it is clear that, the embodiments of the present application may increase the damping against rolling, pitching, and heaving of the floating wind turbine foundation by arranging the stabilizing plate along the periphery of the floating foundation, and increase the yawing damping and added mass of the floating foundation by arranging fin stabilizers on the stabilizing plate. Additionally, spoiler holes may be provided on the stabilizing plate to disturb the vertical flow of fluid, so as to increase the heaving damping of the floating foundation. In summary, the motion suppression device of the present application may reduce the motion magnitude of the floating foundation in any direction.
Moreover, the yawing magnitude of the floating foundation may be effectively reduced by setting the two layers of fin stabilizers which deflect in opposite directions.
The motion suppression device according to the embodiments of the present application is made of conventional steel and has a simple structure, and is effective for mitigating the motion of the whole floating offshore wind turbine.
Further, the motion suppression device according to the embodiments of the present application is featured by low cost, easy fabrication and availability, which may be used for various types of floating wind turbine foundations.
Although the present application is described by exemplary embodiments, it will be readily apparent that, for the person skilled in the art, variations and modifications may be made without departing from the scope and essence of the present application defined by the Claims. | A movement inhibiting apparatus for a floating offshore wind turbine and a floating base with the apparatus. The movement inhibiting apparatus for the floating offshore wind turbine comprises at least one layer of an annular shake-reducing panel placed horizontally and surrounding the floating base. A plurality of shake-reducing fins is further arranged on the shake-reducing panel. The plurality of shake-reducing fins comprises a first set of shake-reducing fins arranged on one side of the shake-reducing panel and the shake-reducing fins of the first set are spaced apart vertically around the floating base. The movement inhibiting apparatus for the floating offshore wind turbine can effectively inhibit the movement of the floating wind turbine and is of low cost. | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to the field of bacterial vaccine characterized to raise adequate immune responses in infants, children and adults against typhoid fever. Particularly, the present invention relates to conjugate vaccines and processes of manufacture thereof, wherein the native polysaccharides of Salmonella typhi are conjugated to carrier proteins and formulated as a prophylactic conjugate vaccine. Furthermore, this invention also relates to the field of combined vaccine formulations for protection against Salmonella typhi and measles virus.
BACKGROUND OF THE INVENTION
[0002] Salmonella typhi , the causative bacterium for typhoid fever in human beings is a major endemic disease in Africa, Asia, and Middle East. Food and water contaminated with S. typhi bacterium was identified as major source in transmission of the disease. Various studies have shown that the global burden of typhoid fever varies in different parts of the world. More than 100 cases in 100,000 populations per year reported in South Central Asia and South-East Asia; Asia, Africa, Latin America and the Caribbean are estimated to have medium incidence of typhoid fever, i.e., 10 to 100 cases in 100,000 populations per year; New Zealand, Australia and Europe have low to very low incidence (Crump et al., 2004). This suggests that Typhoid fever is strongly endemic in the regions of the World particularly in the developing nations and countries with low resource settings.
[0003] Salmonella belongs to the family of Enterobacteriaceae that includes the genera Shigella, Escherichia , and Vibrio . The genus of Salmonella contains two different species, S. enterica and S. bongori. S. enterica is further divided into six subspecies ( enterica, salamae, arizonae, diarizonae, houtenae and indica) containing 2443 serovars. The agents that cause enteric fever are therefore Salmonella enterica subspecies enterica serovar typhi (commonly referred to as S. enterica serovar typhi ) and serovars Paratyphi A, B and C. A serovar or serotype can be defined as a strain that has a unique surface molecule which is responsible for the production of specific antibody. Each serotype has subtle chemical differences in their antigenic region (Brenner et al., 2000).
[0004] Salmonella typhi has a combination of characteristics that make it an effective pathogen. This species contains an endotoxin typical of gram negative organisms, as well as the Vi polysaccharide antigen which is thought to increase virulence. It also produces and excretes a protein known as “invasin” that allows non-phagocytic cells to take up the bacterium, allowing it to live intracellularly. It is also able to inhibit the oxidative burst of leukocytes, making innate immune response ineffective. During the last decade, Salmonella species have been found to acquire more and more antibiotic resistance. The cause appears to be the increased and indiscriminate use of antibiotics in the treatment of Salmonellosis of humans and animals, and the addition of growth-promoting antibiotics to the food of breeding animals. Plasmid-borne antibiotic resistance is very frequent among Salmonella strains involved in pediatric epidemics. Resistance to ampicillin, streptomycin, kanamycin, chloramphenicol, tetracycline, ceftriaxone, cefotaxine, cefoperazone and sulfonamides is commonly observed; Colistin-resistance has not yet been observed. Salmonella strains should be systematically checked for antibiotic resistance to aid in the choice of an efficient drug when needed and to detect any change in antibiotic susceptibility of strains (either from animal or human source). Until 1972, Salmonella typhi strains had remained susceptible to antibiotics, including chloramphenicol (the antibiotic most commonly used against typhoid); but in 1972 a widespread epidemic in Mexico was caused by a chloramphenicol resistant strain of Salmonella typhi . Other chloramphenicol-resistant strains have since been isolated in India, Thailand and Vietnam.
[0005] Vaccination against typhoid fever caused due to Salmonella Typhi is essential for protection against these life-threatening disease due to increasing antibiotic resistance. It is also an important protective tool for people travelling into areas where typhoid fever is endemic. As the bacterium has the ability to acquire multi-drug resistance ability, antibiotics may not offer complete protection. Three types of typhoid vaccines have been made currently available for use till now: (1) Parenteral killed whole cell vaccine; (2) Oral live-attenuated vaccine; and (3) Typhoid-Vi capsular polysaccharide vaccine for parenteral use. Vaccines against typhoid fever were designed in early ages when the organism's cellular and molecular complexity was studied clearly. Initially parenterally administered whole cell S. typhi killed by heat-phenol-inactivation method was used as a vaccine, to be administered in two doses. Since the whole cell inactivated vaccines contain the ‘O’ antigen (endotoxin), they tend to produce local and general reactions in vaccinated individuals and these types of vaccines required a booster dose for every two years. Oral live-attenuated Ty21a vaccine are considered as second generation vaccines prepared with mutant S. typhi strain lacking adenylate-cyclase and AMP receptor protein and mutants auxotrophic for p-amino benzoate and adenine. These live attenuated vaccines reported poor efficacy and was found to be not suitable for administration of children's below 6 years of age. Additionally, a booster dose is also required for every 5 years. Subsequently, capsular Vi-polysaccharide of S. typhi was identified as a protective immunogen capable for eliciting adequate immune responses in humans and hence used as a potential vaccine candidate in routine immunization schedule. A dose of 25 μg/0.5 mL injection of purified capsular Vi-polysaccharide (ViPs) can produce maximum seroconversion i.e. fourfold rise in antibodies. However, the limitations of the Vi-polysaccharide vaccine has been reported in many clinical trials that native polysaccharide vaccine are incapable or do not produce secondary memory responses. This phenomenon is because of bacterial polysaccharides are T-cell independent in nature and hence are not capable to produce cell mediated immune responses. Therefore to overcome the said problem, polysaccharides of S. typhi and carrier proteins were further conjugated to form polysaccharide-protein molecules to make it T-cell dependent antigens. There are various factors that influence the coupling of polysaccharides and proteins which depend upon molecular weight of the ViPs and carrier proteins selected and activation of the functional groups. Low molecular weight polysaccharides can result in efficient coupling to carrier proteins. Different carrier proteins like tetanus toxoid, diphtheria CRM 197, the B subunit of the heat-labile toxin (LT-B) of Escherichia coli , the recombinant exoprotein A (rEPA) of Pseudomonas aeruginosa and Horseshoe rab Haemocyanin (HCH) have been mostly used for conjugation.
[0006] WO1996/011709 discloses an O-acetylated oligonucleotide or polygalactouronate pectin which is substantially identical to Vi polysaccharide subunit structure conjugated to a carrier protein tetanus toxoid wherein the carrier protein being derivatized with cystamine. This particular patent teaches to conjugate an identical polysaccharide but not Vi-polysaccharide to carrier protein with a different derivatizer that is cystamine, Subsequently, WO1998/026799 discloses an isolated lipo-polysachharide from Salmonella Paratyphi A, having removed its Lipid A through detoxification and retaining its O-acetyl content between 70% to 80% and then conjugated to a carrier protein tetanus toxoid through adipic acid dihydrazide (ADH). WO2000/033882 discloses a Vi-polysaccharide of the Salmonella typhi covalently bound to a protein pseudomonas aeruginosa (Vi-rEPA) conjugate through adipic acid dihydrazide. WO2007/039917 discloses an exogenous antigen of Salmonella typhi which is covalently/non-covalently bonded to a Heat Shock Protein.
[0007] WO2009/150543 describes a conjugated Vi-polysaccharide to be used as a vaccine composition against Salmonella typhi causing typhoid fever, wherein the Vi-polysaccharide is covalently conjugated to a protein selected from CRM197 or tetanus toxoid. The method of conjugation as disclosed in WO2009/150543 includes first simultaneously adding carrier protein which is preferably CRM197 or tetanus toxoid to a linker such as adipic acid dihydrazide (ADH), and a carbodiimide such as 1-ethyl-3(3-dimethylaminopropyl) carbodiimide (EDAC), to give a derivatized carrier protein in presence of a 2-(N-morpholino) ethane sulphonic acid (MES buffer). The weight ratio of the carbodiimide EDAC to the carrier protein is between 0.1 to 0.15. It also discloses that higher amounts of carbodiimide/protein ratios can cause aggregate formation. Derivatization of the carrier protein is followed by activation of the Vi-polysaccharide (ViPs) as well. The Vi-polysaccharide is also activated with a carbodiimide wherein various ratios of ViPs and carbodiimide (EDAC) are mixed to activate the Vi-polysaccharide. It is mentioned that Vi activation can be performed at room temperature within 2 minutes wherein higher ratios between 1.5:1 to 200:1 can be used. The derivatized carrier protein CRM197 or tetanus toxoid and the activated Vi-polysaccharide of Salmonella typhi is then reacted with each other to get the conjugated ViPs-CRM197 or ViPs-TT conjugate, followed by removal of the excess linker.
[0008] Safety and immunogenicity of ViPs conjugate vaccines in adults, teenagers and 2 to 4 year old children in Vietnam were evaluated by Zuzana Kossaczka et al in 1999. In this study the geometric mean level of anti-Vi-rEPA (conjugate vaccine) in the 2 to 4 year old children was higher than that elicited by Vi capsular polysaccharide vaccine in the 5 to 14 years old children. Re-injection of conjugate vaccine induced rise in antibody titers in 2 to 4 years old children (T-cell dependent). Konadu et al. (2000) prepared S. paratyphi A O-specific polysaccharide (O-SP) and coupled to tetanus toxoid. These conjugates elicited IgG antibodies in mice and the safety and immunogenicity of the conjugates was evaluated in Vietnamese adults, teenagers and 2-4 years old children. The study concluded that these experimental conjugates were safer and proven to elicit IgG antibodies in adults, teenagers and 2-4 years old children. The efficacy of Salmonella typhi ViPs conjugate vaccine in two to five year old children was evaluated by Feng Ying C et al. In this study the conjugate typhoid vaccine was found to be safe and immunogenic and had more than 90% efficacy in children two to five years old. Serum IgG Vi antibodies after six weeks of second dose levels increased 10 fold in 36 evaluated children. These cases were followed for a period of 27 months. No serious adverse reactions were observed in the study due to the vaccination. Effect of dosage on immunogenicity of ViPs conjugate vaccine injected twice in to 2 to 5 years old Vietnamese children was studied by Do Gia Canh et al. In this study dosage immunogenicity study of 5 μg, 12.5 μg and 25 μg of conjugate vaccine injected twice, six weeks apart was evaluated. This study also confirmed the safety and consistent immunogenicity of four lots of conjugate vaccine in this and previous trials. Novartis vaccine institute for global health carried-out three different dose-related formulations of ViPs-CRM197. They carried out different doses were 25 μg, 12.5 μg, 5 μg and 1.25 μg/dose. The GMT for these concentration at day 28 was 304 U (units), 192 U, 111 U and 63 U respectively. At day 28 GMT with 25 μg/dose elicited the highest antibody level (304 U) after single injection.
[0009] Although, the present state of the art includes conjugate vaccines with Vi-polysaccharide and a carrier protein, however, the existing native Vi-polysaccharide conjugate vaccines when tested in many human clinical trials revealed that these vaccines are safe and immunogenic in adults but failed to induce any protective immune response in children below 2 years of age. Therefore, this native S. typhi polysaccharide vaccine did not prove to find any particular solution against deadly S. typhi infections in children's less than 2 years of age which demands a new vaccine which could immunize children of age below 2 years against S. typhi infections responsible for causing typhoid. The age group of below 2 years of age is the most prone to infections by Salmonella typhi but there seems to be presently not available to the mankind any protective vaccine against S. typhi for infants below 2 years of age still now. As discussed above, various carrier proteins such as CRM-197, r-EPA, have been conjugated to Vi-polysaccharide, wherein the Vi-polysaccharide might not have been isolated from S. typhi , or being depicted from any other sources. Producing typhoid conjugate vaccines is therefore, specific to the particular carrier protein involved and the native polysaccharide involved in the conjugation process and the resulting conjugate vaccine. Each carrier protein-polysaccharide conjugation makes itself a different identity of conjugate vaccine. The prior arts disclosed in the area of typhoid conjugate vaccine, methodology and as well as those currently used, have their own drawbacks, which might be a possible reason behind not having any conjugate vaccine presently available which can protect children below 2 years of age.
[0010] It is also very much evident and well known in the current state of the art that, the present typhoid conjugate vaccines requires at least 2 or more injections with a time interval of 6-8 weeks to comprise a complete vaccination schedule A typhoid Vi capsular polysaccharide-tetanus toxoid (ViPs-TT) conjugate vaccine was made available to the public by BioMed, which required 2 injections of 5 μg each with a time interval of 6-8 weeks to complete a single vaccination schedule. However, this ViPs-TT vaccine also was not capable to immunize children below 2 years of age against Salmonella Typhii.
[0011] Hence, there exists a need of alternating conjugation methodologies, which would reduce costs, and the number of injections to only one injection capable of eliciting sufficient immune response and other associated technical concerns in the field of conjugation chemistry which would be more simpler, less time consuming, cost-effective and safe. An efficient vaccine must be capable of triggering a good immune response and must be applicable for use in infants especially below 2 years of age. The disclosure as set forth in this invention attributes to novel alternative methods of conjugating the Vi-polysaccharide along with the specific carrier protein tetanus toxoid (TT) in an inventive manner put-forth in this application which potentially overcomes the drawbacks of native polysaccharide vaccines and also current conjugation methodologies including other ViPs vaccines conjugated to carrier proteins. The Vi-polysaccharide-protein conjugate vaccine produced by this particular methodology as set forth in this patent application makes it more suitable for immunization in children and infants including less than 2 years of age with secondary memory responses producing high affinity antibodies against S. typhi infections, including humans of any age group. It is also another advantage of the invention put forth in this application that, the number of injections of typhoid conjugate vaccine to complete a vaccination schedule has also been reduced to only ONCE, which at the same time elicits a better immune response when compared to immune response generated by a vaccination schedule of 2 or 3 injections of typhoid conjugate vaccine being practiced earlier. Single injection of typhoid conjugate vaccine is always preferable for infants and children since it would reduce, additional visits to the clinic, pain suffered by a child or infant for repeated injections for vaccination. It is already reported that, 40% of injections worldwide are administered with un-sterilized, reused syringes and needles, and especially in the targeted developing countries, this proportion is more than 70%, exposing millions of people to infections wherein pathogens enter the tissues of the body during an injection. Furthermore poor collection and disposal of dirty injection equipment, exposes healthcare workers and the community to the risk of needle stick injuries. Unfortunately in some countries, unsafe disposal also lead to re-sale of used equipment on the black market. Open burning of syringes is unsafe under WHO, yet half of the non-industrialized countries in the World, follow this practice. (“Injection safety”, Health Topics A to Z. World Health Organization. Retrieved May 9, 2011). Unsafe injections cause an estimated 1.3 million early deaths each year. (M. A. Miller & E. Pisani. “The cost of unsafe injections”. Bulletin of the World Health Organization 77 (10): 1808-811). Although, to improve injection safety, the WHO recommends certain alternatives to injections subject to availability, or else controlling and regulating the activity of health care workers and patients, vaccinees, by ensuring the availability of equipment and supplies aided with managing waste safely and appropriately; these measures are not always possible to be observed absolutely. In such circumstances, a combination of Typhoid conjugate and measles vaccine in one SINGLE shot will definitely play a substantial role in decrease of worries pertaining to injection safety in national immunization programs. Many countries do have legislation or policies that mandate that healthcare professionals use a safety syringe (safety engineered needle) or alternative methods of administering medicines whenever possible, however reduction in the number of injections for ensuring protection against Typhoid and Measles in one single injection in infants surely indicates high compliance from a public health perspective since where there was at least 3 injections required earlier to inject typhoid (2 injections minimum) and measles (one injection) vaccine, now the same is accomplished by only ONE injection.
OBJECTS OF THE INVENTION
[0012] Primary object of the invention is development of a vaccine formulation for prophylaxis and treatment of Salmonella typhi infections in humans so that the T-independent polysaccharides can be made T-cell dependent thereby facilitating to produce efficient immune responses in children of all age groups especially below 2 years of age and also including adults as well.
[0013] Another object of the invention is to provide a vaccine composition against fever caused due to S. typhi with suitable conjugate polysaccharides as the vaccine antigen that would confer protection to children below 2 years of age.
[0014] One objective of the invention is to provide a fed-batch method of production of Vi capsular polysaccharide.
[0015] One more objective of the invention is to provide methods of conjugation of Vi capsular polysaccharide with or without size reduction to a carrier protein.
[0016] Yet another objective of the invention is to provide alternative methods effective conjugation methodology in a reduced time through size-reduction of ViPs of Salmonella typhi prior to conjugation with carrier protein thereby increasing the percentage of conjugation between the Vi polysaccharide and carrier protein.
[0017] Yet another object of the invention is to provide a method of conjugation for Vi capsular polysaccharide of Salmonella typhi and a carrier protein tetanus toxoid as final polysaccharide conjugated bulk and finished vaccine with or without a linker molecule.
[0018] A further objective of the invention is to provide immunogenic vaccine formulations comprising coupled polysaccharide-protein conjugates of Vi-polysaccharide-proteins in appropriate single dose and multidose vials in infants and adults to be administered at appropriate concentrations effective to confer prophylaxis against S. typhi.
SUMMARY OF THE INVENTION
[0019] According to one embodiment of this invention, cultivation and processing of Salmonella typhi Vi-polysaccharide is disclosed. It is further purified through several downstream processing steps to obtain pure Vi-polysaccharide.
[0020] According to one other embodiment of this invention, method of conjugation of pure Vi-polysaccharide to conjugate with protein tetanus toxoid is disclosed in the presence of a linker molecule Adipic Acid Dihydrazide (ADH). The yield of pure resultant ViPs-TT conjugate is as high as 70%-80%.
[0021] According to one other alternative embodiment of this invention, method of conjugation of Vi-polysaccharide to conjugate with protein tetanus toxoid is disclosed without presence of any linker molecule. The yield of pure resultant ViPs-TT conjugate without linker is as high as 70%-80%.
[0022] A further embodiment of this invention discloses stable formulations of ViPs-TT conjugate vaccine in appropriate concentrations of ViPs-TT with or without 2-phenoxyethanol as preservative with ViPs-TT to ensure, a complete vaccination schedule through one injection only.
[0023] One another embodiment of this invention provides, clinically established experimental data of the stable ViPs-TT conjugate vaccine formulation evidencing strong sero-protection and eliciting the desired immunogenicity against Salmonella typhi infections in humans including infants below 2 years of age (6 months to 2 years), as well as subjects in other age groups through only one injection comprising a complete vaccination schedule.
BRIEF DESCRIPTION OF DRAWINGS
[0024] FIG. 1 : General flow diagram of ViPs production and conjugation with linker ADH (left side) and without linker (right side).
[0025] FIG. 2 : Serological identification test of Vi polysaccharide.
[0026] FIG. 3 : HPLC (RI Detector) for Typhoid native Vi-polysaccharide, the HP-GPC column profile of the purified Vi-polysaccharide was analyzed by RI detector. The peak at 13.185 minutes represents native Vi-polysaccharide, which signifies molecular weight of ˜900 kDa.
[0027] FIG. 4 : Size reduced ViPs using homogenizer for about 45 passes. The HP-GPC column profile of the size reduced Vi-polysaccharide was analyzed by RI detector. The peak at 16.04 minutes represents size reduced Vi-polysaccharide, which signifies molecular weight of ˜200 kDa.
[0028] FIG. 5 : Size reduced ViPs using microwave oven. The HP-GPC column profile of the size reduced Vi-polysaccharide was analyzed by RI detector. The peak at 15.18 minutes represents size reduced. Vi-polysaccharide, which signifies molecular weight of ˜250 kDa.
[0029] FIG. 6 : HPLC (RI) for ViPs-TT conjugate bulk. HPLC Profile of the Vi-polysaccharide-Tetanus toxoid conjugate was detected by RI detector using HP-GPC column. The peak at 12.83 minutes represents conjugate ViPs-TT without linker molecule.
[0030] FIG. 7 : HPLC (UV) for ViPs-TT conjugate bulk. HPLC Profile of the Vi-polysaccharide-Tetanus toxoid conjugate was detected by UV detector using HP-GPC column. The peak at 12.66 minutes represents conjugate ViPs-TT without linker molecule.
[0031] FIG. 8 : HPLC (RI) for ViPs-TT conjugate bulk without linker. HPLC profile of the Vi-vi polysaccharide-Tetanus toxoid conjugate vaccine was detected by RI detector using HP-GPC column. The peak at 12.98 minutes represents conjugate ViPs-TT conjugate without linker.
[0032] FIG. 9 : HPLC (UV) for ViPs-TT conjugate bulk without linker. HPLC profile of the Vi-polysaccharide-Tetanus toxoid conjugate vaccine was detected by UV detector using HP-GPC column. The peak at 12.662 minutes represents conjugate ViPs-TT conjugate without linker.
[0033] FIG. 10 : HPLC (RI) for ViPs-TT conjugate vaccine. HPLC profile of the Vi-polysaccharide-Tetanus toxoid conjugate vaccine was detected by RI detector using HP-GPC column. The peak at 12.82 minutes represents conjugate ViPs-TT conjugate.
[0034] FIG. 11 : HPLC (UV) for ViPs-TT conjugate vaccine. HPLC profile of the Vi-polysaccharide-Tetanus toxoid conjugate vaccine was detected by UV detector using HP-GPC column The peak at 12.72 minutes represents conjugate ViPs-TT conjugate.
[0035] FIG. 12 : Comparison of Geometric Mean Titer of different age groups after single injection of 25 μg single injection of ViPs-TT conjugate vaccine.
[0036] FIG. 13 : Comparison of % age seroconversion of different age groups after single injection of 25 tag single injection of ViPs-TT conjugate vaccine.
DETAILED DESCRIPTION OF THE INVENTION
[0037] Salmonella typhi are grown in suitable medium and the actively grown cells were transferred into the fermenter containing pre-sterilized medium. Initially, batch mode fermentation process is carried out and once the cultures reaches early stationary phases, a feed medium containing high concentration of carbon source was pumped into the fermenter incrementally. Fed-batch mode fermentation process is carried out till the desired optical density was obtained. The cultures are harvested by inactivating with low concentration of formalin and then centrifuged to obtain cell supernatant. Hexadecyltrimethylammonium bromide (Cetavlon) is added to the cell supernatant to precipitate the crude Vi-polysaccharide from host cell components. Sequential purification steps i.e ethanol precipitations, concentration and diafiltration using different molecular weight cut-off membranes and sterile filtration techniques were carried out to isolate purified Vi-polysaccharide from host cell impurities like nucleic acids, proteins and lipo-polysaccharides.
[0038] The factors that influence the coupling of polysaccharides and proteins depend upon molecular weight and activation of the functional groups. Low molecular weight of polysaccharides can result in efficient coupling. Different proteins like tetanus toxoid, diphtheria CRM 197, the B subunit of the heat-labile toxin (LT-B) of Escherichia coli , the recombinant exoprotein A (rEPA) of Pseudomonas aeruginosa and Horseshoe rab Haemocyanin (HCH) have been mostly used for conjugation. Determining molecular sizes of polysaccharides and polysaccharide-protein conjugates of bacterial polysaccharides is an important aspect in designing conjugate vaccines. The assessment of physico-chemical characteristics of polysaccharide-protein conjugate plays important role in eliciting specific immune responses. Determination of the molecular size of the polysaccharide before and after conjugation results in efficient conjugation. The two important critical quality control tests employed after conjugation and purification are the ‘polysaccharide (PS) to protein ratio’ and the ‘percent non-conjugated polysaccharide (Free polysaccharide)’.
[0039] Podda et al. (2010) reported the epidemiology and significance of vaccination in the children below two years of age. The currently available vaccines have some relevant limitations and hence cannot be used in children under two years of age, an age group affected by a significant burden of typhoid disease. Introduction of a conjugate vaccine is expected to be an effective tool for efficient immunization of all age groups yet there is no experimental data available at present which would enable vaccination of typhoid conjugate vaccine below 2 years of age. This invention, relies on its unique conjugation methodology of the ViPs-TT conjugate vaccine having an advantage of making it possible to vaccinate children or infants under two years of age to be prevented from Salmonella typhi infections that causes typhoid fever in this tender age group which is accordingly supported by experimental clinical trial data, and also reduces the number of injections to accomplish a complete vaccination schedule through only one dose of the typhoid conjugate vaccine in infants below 2 years of age.
Example 1
Cultivation and Processing of S. typhi Vi Polysaccharide
[0040] The strain Salmonella typhi (Ty2) was obtained from Dr. John Robbins, National institutes of Child Health and Human Development (NICHD), USA. The culture received form NICHD, USA was confirmed and identified as Salmonella serovar typhi by identification of the following characteristics: gram staining, glucose positive without gas formation, H 2 S positive on a Xylose Lysine Deoxycholate agar (XLD agar), and positive serology with Vi-polysaccharide. The purity of the strain was confirmed on different selective media such as, Bismuth Sulfite Agar (BSA), Triple Sugar Iron (TSI) agar. The purity of the strain was confirmed on different selective media such as Xylose Lysine Deoxycholate agar (XLD agar), Bismuth Sulfite Agar (BSA), Triple Sugar Iron (TSI) agar.
[0041] Salmonella typhi Ty2 was grown on Soyabean Casein Digest (SCDM) medium at 37±1° C., for 12 hours. The bacterial culture was centrifuged and the pellet was re-suspended in sterile glycerol (50%). 0.5 mL aliquots of the glycerol suspension in 1 mL cryovials were prepared and stored at −70° C. Viable cell count of the master seed was also carried out. The contents of cryovial of the Master seed lot was inoculated into SCDM broth and incubated at 37±1° C. for 12 hours. The bacterial culture was centrifuged and the pellet was re-suspended in sterile glycerol (50%). Viable cell count was carried out. Aliquots of the glycerol suspension in cryovials were prepared and stored at −70° C. The Master and Working cell banks were characterized by grams staining, utilization of glucose (Durham's method), oxidase test, agglutination test and viable cell count. This was plated on Tryptone Soya Agar (TSA) and incubated at 37° C. for 48 to 72 hours. Colony count was performed using colony counter.
1.1. Fermentation Process:
[0042] Inoculum Development:
[0043] The contents of one cryovial of the working seed lot was removed from the freezer and thawed at room temperature using a water bath. One cryovial from working cell bank of Salmonella typhi was inoculated into 10 mL Soybean Casein Digest Medium (SCDM) and cultured at 37±1° C. for 12 hours (Stage-I), transferred to two flasks each containing 50 mL SCDM at 37±1° C. for 12 hours (Stage-II) and finally transferred to four flasks each containing 400 mL SCDM and incubated at 37±1° C. for 12 hours (Stage-III). At every stage of culture transfer, purity and morphological characteristics was checked by gram staining. The OD was checked at 600 nm. The OD of the Salmonella typhi culture recorded at different stages of seed growth varied from 1.2 to 3.8.
Batch Mode Fermentation:
[0044]
[0000]
TABLE 1.1
Fermentation parameters and specification limits
Parameters
Ranges
pH
6.9 ± 0.2
Dissolved oxygen
70-90%
Stirrer speed
250 ± 10 rpm
Temperature
37 ± 2° C.
Air flow
0.5 ± 0.1 VVM
(Volume per volume per minute)
[0045] Initially 85 L of SCDM was prepared in 100 L S.S vessel and transferred to the fermentor. This was sterilized in situ at 121° C. for 15 minutes. The medium was cooled to 37° C. At this stage supplement mix was pumped into the fermentor through the addition port. To maintain pH, 50% ammonia solution in a bottle was connected to the addition port as a nitrogen source. The seed inoculum was transferred into the fermentor and the fermentation process was carried out at a pH of 6.9±0.2, temperature of 37±2° C. and the Dissolved Oxygen is maintained at 70-90%. for a period of up to 22 to 24 hours. The growth was checked by taking the OD values at 600 nm initially at 0 hour and at every 2 hours up to 24 hours.
[0046] Fed Batch Mode Fermentation:
[0047] Fed batch fermentation process for S. typhi resulted in increased Vi polysaccharide production. Stage III cultures with an OD 600 of 3.8 was ideal for fermentation. The pH was maintained at 6.90 and dissolved oxygen level was between 40% to 60%. To the early stationary phase culture the feed medium containing carbon source along with inorganic salts and minerals was pumped incrementally into the fermenter throughout the fermentation process. The fed batch fermentation process adopted herein to increase biomass by feeding with a solution containing glucose at a range of 1 to 2 mg/mL concentration. The pH was maintained in the range of 6.90 to 7.20 and dissolved oxygen level was maintained between 40%-60%. Ammonia solution (50%) was supplied as a nitrogen source along with the feed medium. Foaming was controlled by pumping antifoam solution through the addition port aseptically. The optimal pH maintained was 7.2 using 10% NH 4 OH and dissolved oxygen concentration was maintained at 35% air saturation. Glucose level was monitored every 30 minutes, and through the fed-batch process the glucose concentration was maintained at about 1 g/L throughout the process.
[0048] Process was continued up to 24 hours and then the bacterial culture were inactivated with 0.5% formaldehyde and kept under mild stirring in chilled condition (below 15° C.). The growth was checked by taking the OD values at 600 nm for 0 hr and every 2 hours for 24 hours. This feeding strategy resulted in an increase in the biomass in terms of optical density to about 120 to 130. The increased biomass translated into a greater Vi polysaccharide production which achieved a final yield of Vi-polysaccharide obtained in the fed batch culture of approx 1000 mg per liter in the present process from which 400 mg of purified ViPS per liter was finally obtained, after completion of downstream processing. Thus, Fed-Batch mode of cultivation resulted in a final yield of at least 40%.
1.2. Downstream Process of Purified Vi Polysaccharide Bulk (VIPs):
[0049] Fermentation cell supernatant is subjected to different steps of purification to isolate purified Vi-polysaccharide. Vi-polysaccharide consists of partly 3-O-acetylated repeated units of 2-acetylamino-2-deoxy-d-galactopyranuronic acid with α-(1→4) linkages. Hence the determination of O-acetyl content could be correlated to the amount of Vi-polysaccharide. The final pure Vi-polysaccharide fraction should contain 2 mM of O acetyl per gram of Vi-polysaccharide (WHO TRS 840). The supernatant normally contains large amount of proteins, nucleic acid and lipopolysaccharides. Filtration techniques play an important role in downstream processing in purification of bacterial polysaccharides from host cell impurities. Retention of the desired molecule from the dissolved substances is done on the basis of size; higher sized particles will be retained at the surface and those lower than the nominal weight limit (NMWL) of the membrane flow out in the permeate (Jagannathan et al., 2008). 100 kDa cut-off membrane cassettes were used at initial step of cell supernatant concentration and 300 kDa cut-off membrane cassettes at final concentration step and diafiltered using sterile water for injection (WFI).
[0050] Cell Separation:
[0051] The harvested culture was centrifuged in a bowl centrifuge at 9000 rpm (8000 g) for 30 minutes at 4° C. The supernatant was collected in sterile vessels. A sample was taken from the supernatant and assayed for O-acetyl content.
[0052] Concentration and Diafiltration:
[0053] The supernatant was diafiltered by using tangential flow filtration (TFF) system using 100 kDa membrane. The supernatant was concentrated to 1/10 th of the original volume and further diafiltered with water for injection (WFI) till the required concentrate was obtained. O-acetyl content of the concentrate was assayed.
[0054] Cetrimide Precipitation:
[0055] To the concentrate 0.4 M cetrimide was added and incubated at (5°±1° C.) for 3±1 hours. The contents were centrifuged at 9000 rpm for 30 minutes at 4° C. The pellet collected was suspended in the required volume of 1 M NaCl. The O-acetyl content of the pellet suspension was determined.
[0056] Ethanol Precipitation:
[0057] One volume of ethanol and 2% of sodium acetate were added to the resuspended cetrimide precipitate; the contents were stirred for 20±5 minutes using a magnetic stirrer. Contents were centrifuged at 4200 rpm (8000 g) for 30 minutes at 4° C. The supernatant was collected into a sterile bottle and the pellet was discarded. To the supernatant, two volumes of ethanol were added (100%) under continuous stirring for a period of 60±10 minutes. 2% of sodium acetate was added to the above content under continuous stirring. After 1 hour of incubation, the contents were centrifuged at 4200 rpm (8000 g) for 30 minutes at 4° C. The supernatant was discarded; pellet was suspended in sterile cool WFI and transferred to sterile bottle. Sample was checked for O acetyl content. Filtration: The concentrated ViPs bulk was passed through 0.22μ capsule filter (Sartopore, Sartorius). This sterile filtered purified bulk of ViPs was assayed for O-acetyl content. The ViPs bulk thus obtained was re-extracted with cetrimide and precipitated with ethanol. Finally, the bulk was concentrated and diafiltered using a 300 kDa cassette (known as concentrated bulk) as mentioned above. The O-acetyl content was assayed after each process. The following O-acetyl contents at different steps of downstream processing, as given in the table 1.2 below was obtained. The O-acetyl content was analyzed by Hestrin method as described below.
[0058] Assay for O-Acetyl Content:
[0059] Determination of O-acetyl content was performed by the method of Hestrin. (Hestrin, 1949). The amount O-acetyl in the sample was proportional to the amount of Vi-content expressed in mg/mL. 0.5 mL of 3.6 N HCl and 1 mL of alkaline hydroxylamine solution were added to the test samples and mixed thoroughly. The mixture was kept at room temperature for 2 minutes and 0.5 mL of ferric chloride solution added and mixed well. The absorbance was measured at 540 nm. The O-acetyl content was calculated as follows:
[0000]
O
-
acetyl
(
µmoles
/
mL
)
=
Test
OD
×
Standard
concentration
×
dilution
factor
Standard
OD
Factor
for
O
-
acetyl
to
Vi
content
conversion
=
O
-
acetyl
(
µmoles
/
mL
)
×
0.294
(
25
/
0.085
/
1000
)
=
Vi
content
(
mg
/
mL
)
[0060] The final sterile filtered (0.22 Vi-polysaccharide bulk is lyophilized in a low temperature vacuum dryer (Lyophilizer FTS system). The lyophilized powder was tested for serological identification by Ouchterlony method, moisture content, protein content, nucleic acids, molecular size distribution and bacterial endotoxin content. In the present study purified Vi-polysaccharide and corresponding homologous antisera were filled in the wells until the meniscus just disappears. The gel plate was incubated in a humidity chamber. The precipitin lines were observed by naked eye when the plate was seen against a bright light back ground. A photograph of the same is shown in FIG. 2 , showing a clear precipitin are observed.
[0061] The molecular size distribution of Vi-polysaccharide was determined by using gel permeation column with Sepharose CL-4B as stationary phase. Fractions were collected after void volume (Vo) corresponding to kDa 0.25 and pooled together. 75% of poly-saccharide eluted at kDa of 0.25. The molecular size distribution of S. typhi Vi-polysaccharide bulk is given in the Table 4.5 below. Characterization of Vi revealed it to have 1% nucleic acids, 0.3% of proteins and an O-acetylation of level of 86% by H-NMR
[0062] Results of dried ViPs bulk obtained for a single batch are tabulated in the table 1.2 below:
[0000]
TABLE 1.2
Results of dried Vi-polysaccharide bulk
Tests
Results
Serological identification
Clear precipitin arc was observed
(Ouchterlony)
Moisture content
1.80%
Protein
2.5 mg/g of Vi polysaccharide powder
Nucleic acids
5 mg/g of Vi polysaccharide powder
O-acetyl content (Hestrin)
2.1 mmoles/g of Vi polysaccharide powder
Molecular size distribution
75% of polysaccharide eluted at 0.25 kDa
Endotoxins
Less than 150 EU/μg of Vi-polysaccharide
powder
[0063] The above results met all the requirements of WHO TRS 840, British pharmacopeia (2010) and Indian pharmacopeia (2010) standards. The requirements of WHO TRS 840 (1994) were considered as standard specifications in present study. The standard requirements of WHO are proteins 10 mg/g, nucleic acids 20 mg/g, O-acetyl content not less than 2 mmol/g of Vi-polysaccharide, molecular size of 50% polysaccharide should elute before 0.25 kDa, Identity by immune precipitation method and sterility test passing. Accordingly to British and European pharmacopeia (2007), the dried Vi-polysaccharide specifications are: protein 10 mg/g, nucleic acids 10 mg/g, O-acetyl groups 2 mmol/g, Not less than 50 percent of the polysaccharide to be found in the pool containing fractions eluted before kDa 0.25, identification using a immunoprecipitation method, and bacterial endotoxin test. These specifications are similar to the WHO TRS 840, British pharmacopoeia (2010) and Indian pharmacopoeia (2010).
Example 2
Conjugation Methodology
[0064] Efficient methods of conjugation of the purified Vi polysaccharide (VIPs) to a carrier protein selected from any bacterial protein or a viral protein, such as diphtheria toxoid, tetanus toxoid, Pseudomonas aeruginosa toxoid, pertusis toxoid, Clostridium perfringens toxoid, Pseudomonas exoprotein A, CRM197 are disclosed in this present invention. Preferably the purified ViPs is conjugated to tetanus toxoid in this present invention. High yield of conjugation are achieved employing various alternative conjugation methodologies. The purified ViPs may be subjected for size reduction prior to conjugation. In the present invention, efficiency of conjugation using either high molecular size (non size reduced) or low molecular size (size-reduced) ViPs was conducted in both the methodologies to achieve high yields of purified ViPs-TT conjugate. For conjugation with high molecular size ViPs and tetanus toxoid, the concentration of ViPs (non-size reduced) in the final reaction mixture shall lie in the range of 1 mg/ml to 10 mg/ml to obtain the desired yields of ViPs-TT conjugate up to 70%-80%, whereas for conjugation of low molecular size ViPs and tetanus toxoid, the concentration of ViPs (size reduced) in the final reaction mixture shall lie in the range of 5 mg/ml to 10 mg/ml to obtain the desired yields of ViPs-TT up to 70%-80%. Alternative methods of size reduction of the purified ViPs is disclosed in the following sections.
[0065] The novelty of the present invention is modification of the Vi polysaccharide and activating them with a linker or without a linker molecule in presence of cross linking agents. According to the present invention, there lies no requirement to activate conjugate proteins. Conjugation between activated polysaccharides and carrier proteins takes place in presence of cross linking agents such as EDAC. WO2009/150543 teaches derivatizing the proteins for conjugation, in which the Vi-polysaccharide was isolated from C. freundi and further conjugated with CRM197 and/or tetanus toxoid as carrier proteins. In their study Vi and EDAC were mixed at appropriate molar ratio (EDAC/Vi) of 0.9-1.4, alternatively CRM197 and/or TT were derivatized with treatment with ADH and EDAC. Vi was conjugated to CRM197 and TT separately and the conjugation mixture was purified using Sephacryl S-1000; fractions were analysed by SDS-PAGE and those which did not contain free protein were collected (Micoli et al., 2011). However, according to WO2009/150543, the excess linker has been removed by dialysis, whereas in the present invention, Vi-polysaccharide was optionally subjected for size reduction (homogenization or by microwave method) and then conjugation has been achieved optionally coupled to the linker molecule or without any linker molecule at all. Hence, wherein linker molecule has not been used, there is no requirement of additional step of removing excess linker molecule. Additionally, in the process involving conjugation with the linker molecule, excess linker was removed by desalting and diafiltration unlike dialysis as mentioned in WO2009/150543.
2.1. Size Reduction of ViPs Using High Pressure Homogenization:
[0066] ViPs is a very large molecule of nearly 1000 kDa. Therefore, the size of the molecule is preferably reduced to approximately one fourth of the large molecule for enabling conjugation with carrier proteins including Tetanus Toxoid at low concentrations. Therefore, the ViPs at a concentration of 5-7.5 mg/ml was subjected to high pressure homogenization at 1500 bar at 2-8° C. and the same activity was repeated for at least 45 passes. The molecular size of the reduced ViPs was thereafter verified through Size Exclusion-Gel Permeation Chromatography as shown in corresponding figures. The retention time of ViPs before size exclusion was 13.185 minutes ( FIG. 3 ), whereas after size exclusion chromatography the retention time of ViPs was eluted at 16.04 minute ( FIG. 4 ), which signifies that the ViPs has been reduced to a corresponding molecular size of approximately 200 kDa. The O-acetyl content of the size reduced ViPs remains the same after homogenization treatment verified by hestrin method. Thereafter, the size reduced ViPs was subjected further to subsequent conjugation steps as discussed in the following sections.
2.2. Size Reduction of ViPs Using Microwave Oven:
[0067] Another method of size reduction of ViPs prior to conjugation was done using micro-wave oven. The ViPs at a concentration of 5-7.5 mg/ml in a glass bottle was put inside a micro-wave oven at 50%-100% power for 5-10 minutes. The micro waves generated inside the oven is responsible for cleaving the glycosyl bonds of long chains of the Vi polysaccharide to reduce it to shorter molecules required to conjugate them to carrier protein. The molecular size of the reduced ViPs was thereafter verified through Size Exclusion-Gel Permeation Chromatography as shown in the corresponding figures. The retention time of ViPs before size exclusion was 13.185 minutes ( FIG. 3 ) whereas after size exclusion chromatography the retention time of ViPs was eluted at 15.18 minute ( FIG. 5 ), which signifies that the ViPs has been reduced to a corresponding molecular size of approximately 250 kDa. The O-acetyl content of the size reduced ViPs remains the same after microwave treatment verified by hestrin method. Thereafter, the size reduced ViPs was subjected further conjugation techniques as discussed in the following sections.
[0000] 2.3. Conjugation of Vi Polysaccharide and Tetanus Toxoid with a Linker
[0068] The purified Vi polysaccharide (either size reduced or non-size reduced) were partially de-O-acetylated in presence of sodium bicarbonate, and coupled with ADH using EDAC mediated reaction at a range of pH 6.0-7.5. The reaction was maintained at 2-8° C. with mild stirring. After incubation, the reaction mixture was quenched by bringing the pH to 8.0 using phosphate buffer-EDTA buffer and further dialyzed using low molecular cut-off membranes with initially phosphate and then followed by MES buffer. The final mixture is concentrated and tested for O-acetyl content, Vi Ps-ADH ratio, free ADH.
[0069] The tetanus toxoid was concentrated and diafiltered with MES buffer using low molecular weight cut off membrane. The final concentrated Tetanus toxoid is tested for protein content. For conjugation the modified Vi-polysaccharides and proteins are coupled in the presence of carbodiimide condensation using EDAC. The final coupled molecules are concentrated and diafiltered using a 1000 kDa cut-off membrane preferably PES (polyether sulphone) membrane, followed by continuous buffer exchange using 20 diavolumes of phosphate buffered saline. The retentate which contained purified ViPs-TT is checked for polysaccharide-protein ratio which shall be within the ratio of 0.5% to 1.5%, Vi-content, protein content and molecular size distribution. Final conjugate bulk was sterile filtered using 0.22μ membrane and stored at 2-8° C.
[0070] Optionally, the final coupled molecules are concentrated and diafiltered using a 1000 kDa cut-off membrane preferably PES (polyether sulphone) membrane, using phosphate buffered saline and then loaded into a gel permeation column (Sepharose cross linked beads). Fractions collected which are within the ratio of 0.5% to 1.5% were pooled together, concentrated and checked for polysaccharide-protein ratio, Vi-content, protein content and molecular size distribution. Final conjugate bulk was sterile filtered using 0.22μ membrane and stored at 2-8° C.
[0071] The molecular size distribution of the present invention, Vi polysaccharide conjugate bulk is given in the Table 2.1. The molecular size of the ViPs-TT conjugate obtained in the present invention is 0.3 kDa; when compared with the results obtained in earlier studies of the conjugate ViPs-TT the molecular size distribution of the given conjugate was <0.1 kDa. This means, molecular size distribution of 0.3 kDa indicates optimal filterable size which allows proper filtration of the ViPs-TT, at the same time providing better immunogenicity to the conjugate vaccine as compared to other lower molecular size distribution(s) provided in the prior arts. Bigger molecular size signifies better immunogenicity, whereas it is also essential to limit the molecular size, at appropriate size which would allow filtration of the ViPs-TT. Therefore, due to this molecular size distribution of 0.3 kDa only ONE single injection of the typhoid conjugate vaccine as laid down in this present invention, is sufficient to comprise a complete vaccination schedule against typhoid fever caused by Salmonella typhi . Prior art prescribes more than one injection, preferably three doses in case of lower molecular size distribution conjugate vaccines against typhoid fever.
[0072] Determination of total and free (unbound) Vi polysaccharide was measured by HPAEC-PAD analysis. In the present methodology the Vi conjugate has yielded 75% of Vi polysaccharide conjugate as eluted at kDa 0.30 thereby giving better polydispersity, and yielded Vi content 0.56 mg/ml, free ViPs 5%, protein content 0.25 mg/mL, Vi Ps-Protein ratio-1.05, free protein peak not detectable and sterility was found be acceptable (Refer Table 2.1). The present methodology was performed with an initial batch size of 10 gms of ViPs, which yielded 8 liters of ViPs conjugate bulk at a Vi conjugate concentration of 0.9 mg/ml-1.0 mg/ml which yielded 7-8 gms of ViPs-TT conjugate, thereby giving an yield of 70%-80%.
[0000]
TABLE 2.1
Results of the ViPs-TT conjugate bulk with linker
Tests
Results (in ranges)
Molecular size
75.7% of polysaccharide eluted at kDa 0.3
distribution
Conjugate Vi content
0.9 mg/ml-1.0 mg/ml
Free Vi Ps
3%-6%.
Protein content
0.78 mg/ml-0.9 mg/ml
Vi Ps/protein ratio
1.1
Free protein
Peak was not detectable at 17 th -18 th minute in
HPLC UV (280 nm) chromatogram. Free
protein is absent
Sterility
No growth was observed
[0073] FIGS. 6 to 7 represents HPLC Chromatograms of Vi-polysaccharide, and ViPs-TT Conjugate bulk at different stages with linker. All the given HPLC profiles clearly demonstrate the conjugation efficiency of the present methodologies.
[0074] The conjugation methodology with linker molecule ADH to obtain a purified ViPs-TT conjugate vaccine antigen for preparation of a conjugate vaccine formulation against typhoid fever caused by Salmonella typhi as described above can be summarized with the following steps:
a. Fed-batch mode of cultivation to obtain purified ViPs with a feed medium, the said feed medium comprising feeding with a solution containing glucose at a range of 1 to 2 mg/mL concentration at a pH maintained in the range of 6.90 to 7.20 and dissolved oxygen level maintained between 40%-60%, wherein ammonia solution (50%) was supplied as a nitrogen source along with the feed medium; b. optionally size reduction of ViPs, wherein the ViPs at a concentration of 5-7.5 mg/ml is subjected to high pressure homogenization at 1500 bar at 2-8° C. and the same activity repeated for at least 45 passes or by a microwave oven so that to a corresponding molecular size of purified ViPs of approximately 250 kDa is obtained; c. treating the purified ViPs of step (a) or step (b) with a cross linking agent EDAC; d. activating the ViPs of step (c) with a linker molecule ADH in presence of EDAC; e. treating the activated ViPs linked to a linker molecule ADH of step (d) at a concentration of 1 mg/ml to 5 mg/ml of purified ViPs of ˜900 kDa or at a concentration of 5 mg/ml to 7.5 mg/ml of purified ViPs of ˜250 kDa with a carrier protein in presence of EDAC to form the Vi-polysaccharide-carrier protein conjugate; f. diafiltering through continuous buffer exchange with phosphate buffered saline of the Vi-polysaccharide-carrier protein conjugate of step (f) with a 1000 kDa membrane to obtain the purified ViPs-carrier protein vaccine antigen.
2.4. Conjugation of Vi-Polysaccharide and Tetanus Toxoid without a Linker:
[0081] The purified Vi polysaccharide (either size reduced or non-size reduced) were taken in the buffer of MES (2-morpholino ethane sulphonic acid), or PBS, or in physiological saline, at a pH varying from 5.0 to 9.0 (exact pH 6-7.5), the concentration of polysaccharide varies from 1.0 mg to 20 mg/ml (5 mg/ml). The protein were taken in the buffer like, MES, or PBS, or in physiological saline at a pH varying from 6.0 to 9.0 (exact pH 6-7.5), at a different concentration of 2.0 mg/ml to 20 mg/ml (10 mg/ml). Ratio of ViPs to protein should be between 1:1 to 1:3 meaning thereby if a total of 1 gm of ViPs is taken, then equivalent of 1 gm to 3 gm protein shall be subjected for conjugation. Conjugation was performed at 2° C.-8° C., to control the reaction rate effectively as compared to room temperature. At higher temperatures, the rate of conjugation is very fast. It is not preferable to expose polysaccharides to higher temperatures, since, after forming conjugates at higher temperatures, there lies possibilities of aggregation of the conjugated polysaccharides-protein molecules. This will increase the size of the molecules, which will become a difficulty to further purify the conjugate proteins in the subsequent steps. Hence, the conjugation is preferred at 2-8° C. The ViPs and TT were added together at a different concentration in any of the buffers described above at different pH conditions and incubated for conjugation. The time of incubation varies between 15-45 minutes at room temperature (25° C.), and within 1 hour to 2 hours at 2-8° C., whereas while following conjugation methodology using ADH (with linker), the incubation time required for conjugation is minimum 2-4 hrs at 2° C. to 8° C. Therefore, the total reaction time is also reduced following this method of conjugation without linker compared to conjugation with linker.
[0082] The final coupled molecules are concentrated and diafiltered using a 1000 kDa cut-off membrane preferably PES (polyether sulphone) membrane, followed by continuous buffer exchange using 20 diavolumes of phosphate buffered saline. The retentate which contained purified ViPs-TT is checked for polysaccharide-protein ratio which shall be within the ratio of 0.5% to 1.5%, Vi-content, protein content and molecular size distribution. Final conjugate bulk was sterile filtered using 0.22μ membrane and stored at 2-8° C.
[0083] Optionally, the final coupled molecules are concentrated and diafiltered using a 1000 kDa cut-off membrane preferably PES (polyether sulphone) membrane, using phosphate buffered saline and then loaded into a gel permeation column (Sepharose cross linked beads). Fractions collected which are within the ratio of 0.5% to 1.5% were pooled together, concentrated and checked for polysaccharide-protein ratio, Vi-content, protein content and molecular size distribution. Final conjugate bulk was sterile filtered using 0.22 g membrane and stored at 2-8° C.
[0084] The present conjugation methodology without any linker molecule was performed with an initial batch size of 10 gms of ViPs, which yielded 8 liters of ViPs conjugate bulk at a Vi conjugate concentration of 0.9 mg/ml 1.0 mg/ml which yielded 7-8 gms of ViPs-TT conjugate, thereby giving an yield of 70%-80%.
[0000]
TABLE 2.2
Results of the ViPs-TT conjugate bulk without linker
Tests
Results (in ranges)
Molecular size
74.3% of polysaccharide eluted at kDa 0.3
distribution
Conjugate Vi content
0.9 mg/ml-1.0 mg/ml
Free Vi Ps
3%-6%.
Protein content
0.75 mg/ml-0.8 mg/ml
Vi Ps/protein ratio
1.2
Free protein
Peak was not detectable at 17 th -18 th minute in
HPLC UV (280 nm) chromatogram. Free
protein is absent
Sterility
No growth was observed
[0085] The crude conjugate then obtained is purified by GPC, TFF, Ion Exchange or HIC. The conjugate matches all required specifications of pharmacopeia and further sterile filtered. FIGS. 8 to 9 represents HPLC Chromatograms of Vi-polysaccharide, and ViPs-TT Conjugate bulk at different stages without linker. All the given HPLC profiles clearly demonstrate the conjugation efficiency of the present methodologies.
[0086] The conjugation methodology without any linker molecule ADH to obtain a purified ViPs-TT conjugate vaccine antigen for preparation of a conjugate vaccine formulation against typhoid fever caused by Salmonella typhi as described above can be summarized with the following steps:
a. Fed-batch mode of cultivation to obtain purified ViPs with a feed medium, the feed medium comprising feeding a solution containing glucose at a range of 1 to 2 mg/mL concentration at a pH maintained in the range of 6.90 to 7.20 and dissolved oxygen level maintained between 40%-60%, wherein ammonia solution (50%) was supplied as a nitrogen source along with the feed medium; b. optionally size reduction of ViPs, wherein the ViPs at a concentration of 5-7.5 mg/ml is subjected to high pressure homogenization at 1500 bar at 2-8° C. and the same activity repeated for at least 45 passes or by a microwave oven so that to a corresponding molecular size of purified ViPs of approximately 250 kDa is obtained; c. treating the purified ViPs of step (a) or step (b) with a cross linking agent EDAC; d. treating the carrier protein with the ViPs of step (c) at a concentration of 1 mg/ml to 5 mg/ml of purified ViPs of ˜900 kDa or at a concentration of 5 mg/ml to 7.5 mg/ml of purified ViPs of ˜250 kDa in presence of a cross linking agent EDAC to form the Vi-polysaccharide-carrier protein conjugate; e. diafiltering through continuous buffer exchange with phosphate buffered saline of the ViPs-carrier protein conjugate of step (d) with a 1000 kDa membrane to obtain the purified ViPs-carrier protein vaccine antigen.
[0092] A linker molecule for example ADH, contains terminal amine groups at both the ends. The Vi native polysaccharide which is further reduced in its size prior to conjugation, contains abundant functional carboxyl groups (—COOH) naturally. Carrier proteins for example, tetanus toxoid contain both the amine (—NH 2 ) and the carboxyl groups (—COOH). In case of conjugation of the ViPs to the carrier protein with the help of a linker molecule ADH, is effected in presence of cross linking agents such as EDAC, wherein the —COOH group of the ViPs should bind with the one —NH 2 group of the ADH linker through one of its ends. The activated ViPs is coupled with the linker ADH, connected through a —CONH bond at one end of the ADH molecule. The other end of the ADH molecule remains free to be further bond with the —COOH group present in the carrier proteins at appropriate concentrations and temperature ranges. The activated ViPs-ADH is therefore again reacted with the carrier protein in presence of cross linking agent EDAC, which enables the —NH 2 present at the other end of the ADH molecule to bind with the —COOH group of the carrier protein molecule, thereby forming an effective bridge between the Vi-polysaccharide and the carrier protein. Thus in this method, there is a necessity remove excess linkers, after treating ViPs with ADH, and again after treating ViPs-ADH to carrier protein. Further EDAC is required to use twice in this method.
[0093] On the other hand, while following the methodology of conjugating ViPs with the carrier proteins without any linker molecule, since ViPs has free —COOH groups and the carrier proteins have free —NH 2 groups, it is possible to directly bond the —COOH of ViPs to the —NH 2 of the carrier proteins through treatment in presence of cross linking agents such as EDAC. The whole reaction is carried out within one step, which minimizes excessive use of EDAC as well as reduces the time to accomplish conjugation of ViPs to the carrier protein. Since all carrier proteins contain free —NH 2 groups, and ViPs also possesses free —COOH, it is possible to conjugate any carrier protein for example diphtheria toxoid, tetanus toxoid, CRM197 etc with Vi polysaccharide through this method. Thus, there lies no requirement of using any linker molecule (ADH) for conjugating the ViPs to the carrier protein. The advantage of conjugation without linker reflects in the stability of the conjugates, because of absence of any connecting molecular bridges between the ViPs and the carrier protein through ADH. This ensures better stability due to the improved strength of the ViPs-carrier protein conjugate (Vies-TT in this case) molecule in absence of any connecting bridges. Further degradation of the ViPs-TT is also reduced to very high extent. Also in this method, it is fairly easy to handle and carry out the experimentation. The total amount of EDAC required is lesser to about 50%, and handled only once instead of using twice in case of ADH linker method. (EDAC is an irritant potential of causing protein coagulation on prolonged exposure). Additionally, there is no requirement of GPC column or TFF system to remove excessive linkers. As the number of steps are reduced, we can minimize the loss of ViPs meant for conjugation to any carrier protein (for example TT), since the purification steps pertaining to ViPs-ADH linking are omitted. The following table exemplifies the completion of the entire conjugation experiment with reduced steps and the total time taken in comparison with and without linker molecule.
Total Time Taken in the Whole Conjugation Experiment:
[0094]
[0000]
TABLE 2.3
Comparison of time taken to complete the conjugation process.
Experiment with ADH linker
Experiment without ADH linker
Activity
Time taken
Activity
Time Taken
Reaction of ViPs with
4 hrs
Not required
Not applicable
ADH
Removal of free ADH
12-15 hrs
Not required
Not applicable
Analysis of % age ADH
2 hrs
Not required
Not applicable
linked to ViPs
Reaction of ViPs with TT
2-4 hrs at 2° C. to 8° C.
Reaction of ViPs with TT
1-2 hrs at 2° C. to 8° C.
Purification of ViPs-TT
10 hrs
Purification of ViPs-TT
10 hrs
conjugate
conjugate
ViPs-TT Fraction
10 hrs
ViPs-TT Fraction
10 hrs
Analysis
Analysis
Pooling and Sterile
3 hrs
Pooling and Sterile
3 hrs
filtration
filtration
Final conjugate analysis
2 hrs
Final conjugate analysis
2 hrs
(HPLC, Vi-content,
(HPLC, Vi-content,
protein content, ratio)
protein content, ratio)
Total time taken
45-50 hrs
Total time taken
25-27 hrs
Example 3
Vaccine Formulation and Stability
[0095] A typical single dose of the typhoid conjugate vaccine formulation claimed under this invention comprises of Vi-TT conjugate as antigen from 15 microgram (μg) to 25 μg dissolved in normal saline made up to a total volume of 0.5 ml for one injection for a complete vaccination schedule.
[0096] The vaccine formulation as claimed under this invention is also made available in the form of multi-dose vials. Multi-dose vials may be either of 5 doses (for 5 different vaccinees/subjects/intended vaccine recipients), or 10 doses (for 10 different vaccinees/subjects/intended vaccine recipients). In case of multi-dose vials, preservatives are added to the vaccine formulation to avoid contamination of the vaccine formulation for multiple pricking of the vial in order to vaccinate 5-10 different children from the same vaccine multi-dose vial. The multi-dose vials of ViPs-TT typhoid conjugate vaccine formulation of the present invention uses a unique preservative 2-phenoxy ethanol, which is free from mercury chloride and thiomersal. Disadvantages of using conventional preservatives such as mercuric chloride and thiomersal contributing to carcinogenicity has been reported in the current state of the art. Therefore, use of this unique preservative 2-phenoxy ethanol overcomes the disadvantages of the conventional preservatives mercuric chloride and thiomersal. The details of the multidose vials and their formulation is tabulated below:
[0000]
TABLE 3.1
Vaccine formulation of single dose and multidose vials
Vaccine
component
Single dose
5 dose multi vial
10 dose multi vial
Vi-TT conjugate
15 μg to 25 μg
75 μg to 125 μg
150 μg to 250 μg
Preservative
Not required
25 mg (10% v/v)
50 mg (10% v/v)
2-phenoxy
ethanol
Normal saline
Quantity
Quantity
Quantity
sufficient
sufficient
sufficient
Dose Volume
0.5 ml
2.5 ml
5.0 ml
[0097] The stability of the ViPs-TT conjugate vaccine of BBIL has been studied and confirmed in detail for 3 years. The Vi Ps typhoid conjugate ViPs-TT vaccine was subjected for stability study of both accelerated storage conditions (25° C.±2° C.) for 6 months and real time storage conditions (2° C. to 8° C.) for 36 months and found that the test results obtained are within the limits and complies for the required specification (Table 3.2 to 3.5).
[0000]
TABLE 3.2
Stability study of Typbar-TCV ™ (conjugated with linker molecule) at 2° C. to 8° C. (25 μg
per dose Vi-TT of 0.5 ml)
Abnormal
Test for
Toxicity
Description
Pyrogens
All
A Clear,
Summed
Animals
Colourless
responses
must
liquid, free
Identification
O-acetyl
of 3
Survive
Sterility
from
(Ouchterlony)
content
Vi
rabbits
for seven
Should
visible
Clear
pH
(Hestrin)
content
Free
should
days and
comply
particles.
precipitation
6.50
0.064 to
(Assay)
ViPs
not
show no
with the
by visual
arc should be
to
0.106 μmoles/
20-30 μg/
NMT
exceed
weight
Test for
Time
observation
observed
7.50
dose
dose
20%
1.15° C.
Loss
Sterility
Zero
Complies
Complies
7.08
0.099
29.30
6.3
0.6
Complies
Complies
day
3 rd
Complies
Complies
7.09
0.098
28.91
6.2
0.5
Complies
Complies
month
6 th
Complies
Complies
7.15
0.093
28.45
5.9
0.6
Complies
Complies
month
9 th
Complies
Complies
7.13
0.094
28.31
6.3
0.6
Complies
Complies
month
12 th
Complies
Complies
7.03
0.091
27.89
6.3
0.6
Complies
Complies
month
18 th
Complies
Complies
7.06
0.087
27.45
6.1
0.5
Complies
Complies
month
24 th
Complies
Complies
7.15
0.089
27.16
5.7
0.6
Complies
Complies
month
36 th
Complies
Complies
7.02
0.080
26.56
6.0
0.5
Complies
Complies
month
[0000]
TABLE 3.3
Stability study of Typbar-TCV ™ (conjugated with linker molecule) at 25° C. ± 2° C. (25 μg per
dose Vi-TT of 0.5 ml)
Abnormal
Test for
Toxicity
Description
Pyrogens
All
A Clear,
Summed
Animals
Colourless
responses
must
liquid, free
Identification
O-acetyl
of 3
Survive
Sterility
from
(Ouchterlony)
content
Vi
rabbits
for seven
Should
visible
Clear
pH
(Hestrin)
content
Free
should
days and
comply
particles.
precipitation
6.50
0.064 to
(Assay)
ViPs
not
show no
with the
by visual
arc should be
to
0.106 μmoles/
20-30 μg/
NMT
exceed
weight
Test for
Time
observation
observed
7.50
dose
dose
20%
1.15° C.
Loss
Sterility
Zero
Complies
Complies
7.15
0.098
28.82
4.5
0.3
Complies
Complies
day
1 st
Complies
Complies
7.13
0.097
28.52
4.1
0.4
Complies
Complies
month
2 nd
Complies
Complies
7.16
0.095
27.94
4.4
0.5
Complies
Complies
month
3 rd
Complies
Complies
7.12
0.093
27.35
4.9
0.5
Complies
Complies
month
6 th
Complies
Complies
7.10
0.092
26.8
5.3
0.4
Complies
Complies
month
[0000]
TABLE 3.4
Stability study of Typbar-TCV ™ (conjugated without linker molecule) at 2° C. to 8° C. (25 μg
per dose Vi-TT of 0.5 ml)
Abnormal
Test for
Toxicity
Description
Pyrogens
All
A Clear,
Summed
Animals
Colourless
responses
must
liquid, free
Identification
O-acetyl
of 3
Survive
Sterility
from
(Ouchterlony)
content
Vi
rabbits
for seven
Should
visible
Clear
pH
(Hestrin)
content
Free
should
days and
comply
particles.
precipitation
6.50
0.064 to
(Assay)
ViPs
not
show no
with the
by visual
arc should be
to
0.106 μmoles/
20-30 μg/
NMT
exceed
weight
Test for
Time
observation
observed
7.50
dose
dose
20%
1.15° C.
Loss
Sterility
Zero
Complies
Complies
7.03
0.101
29.60
6.0
0.5
Complies
Complies
day
3 rd
Complies
Complies
7.05
0.095
27.93
6.3
0.7
Complies
Complies
month
6 th
Complies
Complies
7.15
0.093
27.34
5.8
0.5
Complies
Complies
month
9 th
Complies
Complies
7.10
0.094
27.63
6.0
0.5
Complies
Complies
month
12 th
Complies
Complies
7.00
0.092
27.04
6.3
0.6
Complies
Complies
month
18 th
Complies
Complies
7.02
0.086
25.28
6.2
0.6
Complies
Complies
month
24 th
Complies
Complies
7.11
0.087
25.57
6.5
0.7
Complies
Complies
month
36 th
Complies
Complies
7.04
0.086
25.28
6.7
0.5
Complies
Complies
month
[0000]
TABLE 3.5
Stability study of Typbar-TCV ™ (conjugated without linker molecule) at 25° C. ± 2° C. (25 μg
per dose Vi-TT of 0.5 ml)
Abnormal
Test for
Toxicity
Description
Pyrogens
All
A Clear,
Summed
Animals
Colourless
responses
must
liquid, free
Identification
O-acetyl
of 3
Survive
Sterility
from
(Ouchterlony)
content
Vi
rabbits
for seven
Should
visible
Clear
pH
(Hestrin)
content
Free
should
days and
comply
particles.
precipitation
6.50
0.064 to
(Assay)
ViPs
not
show no
with the
by visual
arc should be
to
0.106 μmoles/
20-30 μg/
NMT
exceed
weight
Test for
Time
observation
observed
7.50
dose
dose
20%
1.15° C.
Loss
Sterility
Zero
Complies
Complies
7.10
0.093
27.30
5.0
0.3
Complies
Complies
day
1 st
Complies
Complies
7.12
0.095
27.93
4.9
0.6
Complies
Complies
month
2 nd
Complies
Complies
7.15
0.098
28.80
5.1
0.4
Complies
Complies
month
3 rd
Complies
Complies
7.13
0.094
27.63
5.3
0.5
Complies
Complies
month
6 th
Complies
Complies
7.11
0.095
27.93
5.7
0.6
Complies
Complies
month
Example 4
Clinical Trials
[0098] The final Vi-polysaccharide-tetanus toxoid conjugate bulks were formulated and tested for immunogenicity in Balb/c mice in comparison with native polysaccharide vaccine. Challenge study was carried to assess protective efficacy of the vaccine and preclinical trial was carried to ensure abnormal, acute and systemic toxicity in laboratory animals. Further, the effectiveness of the test vaccine Vi capsular polysaccharide-tetanus toxoid conjugate (Vi-TT) was studied at two different concentration doses (15 μg and 25 μg per dose) and revealed that both concentration elicited protective antibodies in infants, children's and adults. The immunogenicity and safety of BBIL's Vi-TT conjugate vaccine's typhoid Vi capsular polysaccharide-tetanus toxoid protein conjugate in comparison with reference vaccine ( Salmonella typhi Vi-polysaccharide vaccine Typbar® were evaluated.
[0099] In phase-II: A total 100 subjects were enrolled to evaluate the safety and immunogenicity of Typhoid Vi capsular polysaccharide-TT protein conjugate vaccine in comparison with reference Typhoid Vi capsular polysaccharide vaccine Typbar® in healthy teenagers of 13 to 17 years of age, children of 6-12 and 2-5 years old. The study demonstrated that the test vaccine Vi capsular polysaccharide-tetanus toxoid conjugate (Vi-TT) as superior to the reference Typhoid Vi capsular polysaccharide vaccine Typbar® with respect to the immunogenicity and reactogenicity in all age groups. The geometric mean of Vi IgG in terms of ELISA UNITS per milliliter (EU/ml) elevated more than four-fold raise 80%, 100% and 70% respectively when compared to the pre vaccinated sera for plain Typbar®.
[0100] The test Vaccine of Typhoid Vi Capsular Polysaccharide-tetanus toxoid conjugate Vaccine (Vi-TT) was administered 25 mcg/dose as single injection for age group 13-17 years teenagers and 2-6 years. The geometric mean of Vi IgG EU/ml elevated more than four-fold raise respectively 100% in both the age groups when compared to the pre vaccinated sera. Correspondingly the age group of 2-5 Years was injected with 25 μg/dose in two injections. The time interval for administration of second injection was 6 weeks respectively. The geometric mean of Vi IgG EU/ml elevated more than four-fold raise respectively 100% in this age group when compared to the pre vaccinated sera.
[0101] Another group was designed as 15 μg/dose as two injections for the age group between 2-5 Years age. The time interval for administration of second injection was 6 weeks respectively. The geometric mean of Vi IgG EU/ml elevated more than four-fold raise respectively 100% in the age group 2-5 years when compared to the pre vaccinated sera.
[0102] All test group injected with 25 μg as single injection, 25 μg as double injections per dose and 15 μg as double injection per dose showed 100% seroconversion. The antibody responses to the Vi-Polysaccharide-Tetanus Toxoid Protein conjugate vaccine is superior to the reference native polysaccharide vaccine in all age groups. Hence it can be concluded that the test vaccine Typhoid Vi Capsular Polysaccharide Tetanus Toxoid conjugate (Vi-TT) vaccine of BBIL was immunogenic to already commercially available reference vaccine Typbar® of BBIL.
[0103] In Phase-III Details of number of subjects: A total of 981 subjects allocated to the Typhoid conjugate ViPs-TT vaccine and reference vaccine Typbar® to evaluate the immunogenicity and safety of Typhoid Vi-polysaccharide-TT conjugate vaccine ViPs-TT (Typbar-TCV™) Vs. plain Typhoid Vi-polysaccharide vaccine (Typbar®, Reference vaccine). BBIL's typhoid conjugate ViPs-TT vaccine, Geometric Mean Titre (GMT) and % seroconversion-4-fold was analysed between three-age groups (6 month to 2 year, >2 to <15 years and 15 to 45 years) for typhoid conjugate test ViPs-TT vaccine (Typbar-TCV™). The GMT in subjects in the age group between 6 months to 2 years, >2 to <15 years and 15 to 45 years in Typhoid-TT conjugate vaccine at day 42 were 1952.03 EU/ml, 1555.51 EU/ml, and 812.97 EU/ml of Typhoid anti Vi IgG antibody by ELISA respectively. The percentage of seroconversion (4-fold titre rise) in subjects in the age group between 6 months to 2 years, >2 to <15 years and 15 to 45 years in the in the Typhoid-TT conjugate vaccine was 98.05%, 99.17% & 92.13% respectively at day 42 ( FIG. 12 ).
[0000]
TABLE 4.1
Typbar-TCV ™ phase III clinical trial data.
Age group
6 months to 2
2 years to 15
15 years to 45
Response
Time period
years (N = 307)
years (N = 242)
years (N = 90)
GMT EU/ml
Day 0
9.44 (8.66, 10.31)
9.61 (8.92, 10.35)
13.01 (10.60, 15.97)
(LCL, UCL)
Day 42
1952.03
1555.51
812.97
(1795.48, 2122.23)
(1371.33, 1764.43)
(637.66, 1036.46)
Seroconversion
Day 0 to
98.05%
99.17%
92.13%
(% age) (4 fold)
Day 42
[0104] In 2 to <15 year age group GMT in Typhoid-TT conjugate Typbar-TCV™ vaccine and Typhoid vaccine Typbar® group on day 42 were 1555.51 EU/ml and 426.63 EU/ml of Typhoid anti Vi IgG antibody by ELISA respectively (p=0.00001). The percentage of seroconversion (4-fold titre rise) on day 42 between Typbar-TCV™ vaccine and Typhoid vaccine Typbar® 99.17% and 94.86% respectively (p=0.0086).
[0105] In 15 to 45 year age group GMT in Typbar-TCV™ vaccine and Typhoid vaccine Typbar® group on day 42 were 812.97 EU/ml and 376.81 EU/ml of Typhoid anti Vi IgG antibody by ELISA respectively (p=0.0001). The percentage of seroconversion (4-fold titre rise) on day 42 between Typbar-TCV™ vaccine and Typhoid vaccine Typbar® group 92.13% and 89.01% respectively (p=0.4737).
[0106] The superiority of Typhoid-TT (ViPs-TT) conjugate vaccine is 3.16 times higher than plain polysaccharide vaccine with respect to GMT post vaccination. The estimated GMT of Post to Pre titre ratio of typhoid conjugate vaccine (test) is 3.53 times higher than that of plain polysaccharide vaccine (reference). With respect to seroconversion typhoid conjugate vaccine is significantly superior to plain polysaccharide vaccine at a margin of 0.016%.
[0107] Summary of phase III clinical trial data of ViPs-TT conjugate vaccine of BBIL Typbar-TCV™ is detailed below in comparison with reference vaccine Typbar® ( FIGS. 12 and 13 ) and as well with Peda Typh™ is provided in the below tables:
[0000]
TABLE 4.2
Typbar-TCV ™ vs. Typbar ®
Single injection of 25 μg
of ViPs-TT conjugate
vaccine Typbar-TCV ™
of BBIL to comprise a
complete vaccination
Plain ViPs vaccine of BBIL
schedule (single dose)
Typbar ®
% age
% age
Geometric
Serocon-
Geometric
Serocon-
Mean Titre at
version
Mean Titre at
version
Age group
day 42 (EU/ml)
on day 42
day 42 (EU/ml)
on day 42
6 months to 24
1952.03
98.05%
Not applicable
Not
months
Applicable
2 years to 15
1555.51
99.17%
426.03
94.86%
years
15 years to 45
812.97
92.13%
376.81
89.01%
years
Example 5
TCV and Measles Interference Study
[0108] Typbar-TCV™ is a preparation of Vi-polysaccharide vaccine conjugated to Tetanus Toxoid carrier protein. It has been proven that children who received the Vi conjugate vaccine achieved and maintained higher levels of anti-Vi IgG serum antibodies compared to those who received the plain Vi-polysaccharide vaccine. Typbar-TCV™ (ViPs-TT conjugate vaccine) is proposed in the immunization schedule to have been administered between 6 th month to 24 th month, and preferably in the 9 th month from child birth. Since, Measles vaccine immunization is also done at the same time, to combine both the vaccines and administer as a single injection will provide added benefits. In order to be able to do this, the interference of the two vaccines on each other's biological and chemical properties needs to be explored. In line with the above proposal, a study was designed to reconstitute the lyophilized Measles vaccine with the liquid Typbar-TCV™ (ViPs-TT conjugate vaccine) and conduct O-acetyl content test (for Typbar-TCV™) and Cytopathic Effect method (for Measles Vaccine) at 0 hrs, 4 hrs, 8 hrs and 12 hrs following incubation at 25° C. It was checked whether the physiochemical and biological parameters of both the vaccines were within specifications at the said temperature and time points. This study provided an overview of the laboratory findings for the reconstituted vaccine product for a short period of time.
[0000]
TABLE 5.1
Specification of Typhoid conjugate vaccine and measles vaccine
Typhoid Conjugate Vaccine
Measles vaccine
Typbar-TCV ™
Measles vaccine (LIVE) I.P
(ViPs-TT conjugate vaccine)
(Freeze-dried)
Single dose-0.5 mL
Single dose-0.5 mL
Test Performed: 0-Acetyl Content by Hestrin's Method
[0109] Vi-polysaccharide is a linear homopolymer composed of (1-4)-20acetamido-2-deoxy-α-D-galacturonic acid that is O-acetylated at carbon-3. The O-acetyl content of the purified Vi-polysaccharide is important for the immunogenicity of Vi and it can be measured by using Hestrin's method.
[0000]
TABLE 5.2
O-acetyl content by Hestrin method
S.
No.
Sample Detail
0 Hour
4 TH Hour
8 TH Hour
1.
Typbar-TCV ™ (ViPs-TT
0.098 μmoles/dose
0.098 μmoles/dose
0.098 μmoles/dose
conjugate vaccine) at
the start of time point 2-8° C.
2.
Typbar-TCV ™ (ViPs-TT
0.100 μmoles/dose
0.100 μmoles/dose
0.096 μmoles/dose
conjugate vaccine) kept at
25° C.
3.
Measles Vaccine
0.151 μmoles/dose
0.086 μmoles/dose
0.058 μmoles/dose
reconstituted with Typbar-
TCV ™ (ViPs-TT conjugate
vaccine) and kept at 25° C.
Specification
0.064-0.106 μmoles/dose
0.064-0.106 μmoles/dose
0.064-0.106 μmoles/dose
Results:
[0110] The Measles vaccine reconstituted with Typbar-TCV™ (ViPs-TT conjugate vaccine) was incubated at 25° C. was analyzed for O-acetyl content by Hestrin's method. As controls, the Typbar-TCV™ (ViPs-TT conjugate vaccine) kept at 2-8° C. and Typbar-TCV™ (ViPs-TT conjugate vaccine) at the start of time point 25° C. were also analyzed simultaneously. As expected, the O-acetyl content of the control samples at 2-8° C. and 25° C. were close to the initial value. The O-acetyl content of the combination vaccine (Measles+TCV) was higher than the acceptance criteria at 0 hrs (0.151 μmoles/dose). It decreased with time at 4 hrs and 8 hrs (0.086 and 0.058 moles/dose) which were within acceptance criteria, but different when compared to the Typbar-TCV™ only values at 2-8° C. and 25° C.
Test Performed: Potency Test by Cytopathic Effect (CPE) Method
[0111] Measles Vaccine is a live attenuated vaccine. To titrate the measles vaccine logarithmic dilution was prepared, each logarithmic dilution inoculated in to vero cell line with 8 replicates and incubated for 7-8 days and checked for the presence or absence of Cytopathic Effect. Virus titre is calculated by Spearman Karber formula. Results are as below:
[0000]
TABLE 5.3
Potency test by Cytopathic Method
Results (log10 CCID50/0.5 mL) of Measles Interference Study with TCV
S.
0
4
8
12
No.
Sample Detail
Hour
Hour
Hour
Hours
1
Measles Vaccine reconstituted with its diluent at the
3.50
3.40
3.50
start of each time point
2
Measles Vaccine reconstituted with its diluent and kept
3.50
3.45
3.50
3.40
at 25° C.
3
Measles Vaccine reconstituted with Typbar-TCV ™
3.30
3.15
3.00
2.80
(ViPs-TT conjugate vaccine) and kept at 25° C.
Specification
NLT 3.00
Results:
[0112] From the results, it is observed that Measles vaccine when reconstituted with its diluent, found stable for 12 hours and when reconstituted with the Typbar-TCV™ (ViPs-TT conjugate vaccine) is stable for 4 hours and fell between 4 and 8 hours. | Disclosed are stable conjugate vaccine formulations for protection against Salmonella typhi , and methods of conjugation between Vi-polysaccharide of S. typhi to tetanus toxoid as the carrier protein, responsible for producing improved T-dependent immune response against Typhoid fever caused by Salmonella typhi . The methods disclosed in this invention and the resulting formulations are capable of inducing immunity against typhoid fever including in children below 2 years of age, through only a single injection to comprise a complete vaccination schedule. | 0 |
TECHNICAL FIELD
The subject of the invention is a device for concentrating as a luminescence concentrator or for dispersing as a luminescence disperser as claimed in claim 1 , a process for production thereof as claimed in claim 4 and use thereof as claimed in claims 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 .
STATE OF THE ART
A luminescence concentrator, which we abbreviate to LC hereinafter, is a device which can concentrate both incident direct and diffuse light by frequency shifting and total internal reflection; see FIG. 1 . These concentration processes differ fundamentally from geometric concentrators. There is no limitation by Liouville's theorem, according to which the product of photon flux density and divergence of radiative flux always remains constant in a geometric concentrator. Given sufficient geometric dimensions of the collector plate, it is possible in principle in the LC to achieve an almost unlimited concentration; on this subject, see, for example, R. A. Garwin, Rev. Sci. Instr. 1960, 31, 1010; A. Goetzberger and V. Wittwer. Sonnenenergie, Teubner Studienbücher Physik, ISBN 3-519-03081-0, Verlag Teubner 1986; W. H. Weber, J. Lambe, Appl. Opt. 1976, 15, 2299; A. Goetzberger, W. Greubel, Appl. Phys. 1977, 14, 123; J. S. Batchelder, A. H. Zewail, T. Cole, Appl. Opt. 1979, 18, 3090; J. S. Batchelder, A. H. Zewail, T. Cole, Appl. Opt. 1981, 20, 3733; R. Koeppe, N. Sariciftci, A. Büchtemann, Appl. Phys. Lett. 90 (2007) 181126; P. Kittidachachan, L. Danos, T. J. J. Meyer, N. Alderman, T. Markvart, Chimia, 2007, 61, 780.
An inverted luminescence concentrator, which we abbreviate to iLC hereinafter, is a device which traps both directed and undirected incident light by frequency shifting and total internal reflection in a transparent body (for example glass or plastic) and emits it, i.e. couples it out of the body, in a diffuse or directed manner in homogeneous distribution over a surface by means of luminescent emission. An iLC can thus function as a luminescence disperser.
The significant problems with the LCs now known are: (A) the loss which occurs as early as the first emission because total internal reflection is limited by half the cylinder opening angle; (B) intrinsic absorption with subsequent re-emission, which in turn results in the same loss as (A), and which additionally proceeds with a yield of a little less than 100%; (C) the necessity to distribute (dissolve) the chromophores within a relatively thick layer of several millimeters, which means a considerable restriction for the optimization of the optical properties of the LC, and more particularly makes it impossible or at least considerably more difficult to build up materials of different refractive index in a structured manner; (D) the stability of the dyes which are generally dissolved in a polymer and are thus also exposed to plasticizers and other reactive species and can even migrate in the case of considerable temperature variations. These are problems which considerably limit or even put into question the efficiency, lifetime and flexibility—in the building of arrangements, functional units or apparatuses—and hence the range of use or even the usability of LCs; see the references given above.
The significant problem with the uses now known, based on light scattering, is homogeneous light emission over a relatively large area, i.e. homogeneously distributing the light emission intensity over an area. This is required, for example, for background illumination in LCDs. Background illumination is used for backlighting of LC displays (LCDs) of electronic units. Examples are digital instruments, cellphones or flat visual display units of televisions and monitors. In LCDs, this achieves an increase in contrast compared to the non-self-illuminating, purely reflective mode of operation. The purpose of background illumination is to illuminate the visual display unit from the rear, in a flat, homogeneous and efficient manner. The color of the light source must be white in the case of color visual display units (the individual color pixels of the LCDs allow the particular color thereof to pass through), whereas it may be selected as desired in monochrome displays. The light source must not flicker in order to prevent superimpositions or beats with the actuation of the display elements or pixels.
The light-emitting diodes are still very expensive as light sources in relation to their lighting intensity. They are used for background illumination in particular where their advantages—high efficiency, long lifetime, robustness and small dimensions—are particularly beneficial. A typical example is that of visual display units for small mobile units such as cellphones or navigation systems. LCD televisions equipped with LEDs are commercially available, but have to date (2008) not achieved wide acceptance. The most frequently used inexpensive light sources are luminophore tubes (in the case of large displays, usually cold cathode tubes). The UV radiation thereof is blocked by use of specific tube glass in order not to damage the surrounding plastic. Cold cathode tubes can be found in virtually all laptops, monitors, LCD televisions and some PDAs.
Light sources which appear particularly suitable for use as background illumination are those which are fundamentally flat radiators, because this significantly reduces the demands on the guiding of light. Since as early as about 1950 there have been electroluminescent films which are extremely flat with thicknesses of less than 1 mm. The efficiency, the lifetime and the achievable luminance of electroluminescent films are, however, such that use in monitors or televisions is impossible. Also implementable as flat radiators are xenon low-pressure lamps with dielectric hindrance of discharge (e.g. Planon from OSRAM) and organic light-emitting diodes (OLEDs). These could become commercially successful within a few years as soon as the efficiency and the lifetime meet market demands. Incandescent lamps are no longer used for backlighting.
The light emitted from point or linear light sources must be distributed very substantially homogeneously over the area of the background illumination. This is referred to as light guiding. In the case of relatively weak background illumination, the light is usually fed to the ends of a light conductor. In practise, the light conductor is a flat sheet of a transparent plastic, for instance acrylic glass. This contains extractors which emit the light from the light conductor. The emission can be achieved by scattering structures distributed in the light conductor material, by specific fine surface structures, or by fine printed patterns. The inhomogeneous distribution of the emitting structures has the effect that the homogeneous illumination of the surface is also achieved, for example, with only one cold cathode tube incident at the end. To increase the luminance, the light sources may, however, be mounted at two or all four end faces. Background illumination according to this principle is referred to as “edge-lit backlighting”. With increasing size of the light source (and constant side ratio, e.g. 16:9), the sum of the side lengths increases only proportionally to the length of one side, but the area increases as the square. Since the power or the efficiency of the light sources cannot be enhanced to an unlimited degree, the “edge-lit backlights” are fundamentally limited here. For larger formats, constructions derived from the known light boxes are therefore being used. The light sources in this case are in a flat trough which reflects the light diffusely in the interior thereof and only allows it to leave toward the open side. Specially shaped reflectors are often used for luminophore lamps, and diffuser lenses for LEDs, in order that the light exiting from the light trough is approximately homogeneous in spite of a small installation depth of the background illumination.
The light distributed by the light conductor or the light trough possibly still has a spatial structure and has to be distributed homogeneously with the aid of a diffuser in order that it approximates to an absolutely homogeneously white-illuminating surface. A simple solution is an opalescent scattering sheet between light conductor or light trough and LC visual display unit. It is usual, however, to use films which homogenize the light more efficiently than is possible with opalescent glass. 3M, for example, has developed the Vikuiti films which better exploit the light by a factor of two compared to an opalescent diffuser. These films reflect all that light which is unsuitable for the backlighting of the LCD in respect of direction and polarization back to the light conductor. This light is scattered within the light conductor, mixed in terms of direction and polarization, and goes back in the direction of the LCD. Similarly to a geometric series, the operation is repeated and leads to better exploitation of the light.
Especially the emission of the light from a light-conducting material is nowadays realized with solutions for diffuse light scattering. This can be achieved by means of scattering structures which are distributed in the light conductor material, by means of specific fine surface structures or by means of fine printed patterns. To solve this problem, according to the present state of the art, diffuse light scattering at rough surfaces is thus employed, or a flat radiator is used (e.g. luminophore tubes). These methods prevent the possibility of implementing the illuminated surface transparently and as a homogeneous light radiator; problem (E).
This problem (E) is solved by, instead of emission by scattering, effecting emission by means of luminescence using an iLC, since this can be made transparent. With the aid of the iLC presented here, principles analogous to those for the luminescence concentrator (LC) apply.
Over the course of several years, we have developed processes which allow the construction of luminescent materials with considerable optically anisotropic properties, in which radiationless energy transfer from donor molecules to acceptors, which then emit the light again as the luminescence, can be finely adjusted such that a varied spectrum of interesting properties is developed. Review articles which also illustrate the development of this work are: G. Calzaferri, CHIMIA 52 (1998) 525-532; G. Calzaferri, D. Brühwiler, S. Megelski, M. Pfenniger, M. Pauchard, B. Hennessy, H. Maas, A. Devaux, U. Graf, Solid State Sciences 2 (2000) 421-447; G. Calzaferri, S. Huber, H. Maas, C. Minkowski Angew. Chem. Int. Ed. 42, 2003, 3732-3758; G. Calzaferri, K. Lutkouskaya, Photochem. Photobiol. Sci., 2008, 7, 879-910.
We have already made earlier proposals that it would be worth using the dye-zeolite materials that we developed for LCs; on this subject see, for example: Orientierte Zeolith L Kristalle auf einem Substrat , G. Calzaferri, A. Zabala Ruiz, H. Li, S. Huber, Oriented zeolite material and method for producing the same , PCT/CH2006/000394; priority U.S. 60/698,480 and CH 1266/05 . Nanochannel Materials for Quantum Solar Energy Conversion Devices , D. Brühwiler, L.-Q. Dieu, G. Calzaferri, CHIMIA, 61, 2007, 820-822 . Dye modified nanochannel materials for photoelectronic and optical devices , G. Calzaferri, H. Li, D. Brühwiler, Chem. Eur. J., 2008, 14, 7442-4749. In these studies, certain aspects of the new materials which could be useful for the production of LCs are discussed.
We have found, more particularly, that it is possible to bind zeolite crystals into a polymer in such a way that the light scattering caused by the zeolite crystals can be completely suppressed within the relevant longer-wave range; on this subject, see: Transparent Zeolite - Polymer Hybrid Materials with Tunable Properties , S. Suárez, A. Devaux, J. Bañnuelos, O. Bossart, A. Kunzmann, G. Calzaferri, Adv. Funct. Mater. 17, 2007, 2298-2306 ; Transparent Zeolite - Polymer Hybrid Material with Tunable Properties , G. Calzaferri, S. Suarez, A. Devaux, A. Kunzmann, H. J. Metz, PCT European Patent application EP1873202.
Important terms such as zeolite L, antenna, organized dye-zeolite materials, etc. are explained in the study published in German language: Photon - Harvesting Host - Guest Antenna Materials ( Wirt - Gast Antennenmaterialien ) Gion Calzaferri, Stefan Huber, Huub Maas, Claudia Minkowski, Angew. Chem. 115, 2003, 3860-3888 ; Angew. Chem. Int. Ed. 42, 2003, 3732-3758. In FIG. 2 , we show a cylindrical zeolite nanocrystal with organized dye molecules, which function as donors (grey rectangles) and acceptors (black rectangles). In the left-hand part of the figure, the donors are in the middle regions and the acceptors are at the two ends of the channels; in the right-hand part, the donors are located at the ends and the acceptors in the middle part. The dye molecules which are ordered supramolecularly and organized in such a way in zeolites are formed so as to result in an antenna function, which luminescent sites are referred to as antennas. This achieves a significant shift in the luminescence to greater wavelengths. The enlargement shows details of a channel with a dye molecule whose electronic transition moment (double-headed arrow) is parallel to the channel axis in large molecules and deflected in smaller molecules. The diameter of a channel opening of zeolite L is 0.71 nm, with a greatest channel diameter of 1.26 nm. The distance from the middle of a channel to the middle of a neighboring channel is 1.84 nm.
DESCRIPTION OF THE INVENTION
The concept of the present study originated from the KTI project 9231.2 PFNM-NM (development of efficient LCs based on inorganic-organic nanomaterials for use in solar power generation). It is an object of the invention to realize the individual solutions to problems A) to D) in a new and integral manner in one device. This enables a functioning and highly efficient LC. Taking account of problem solution E), the result is even an iLC; see also claims 1 and 4 . Accordingly, the invention consists in using the solutions to the abovementioned problems (A) to (E) with LCs and iLCs by refined and rigorous exploitation of all research results known to date, such that LCs and iLCs become of interest for commercial utilization. This gives rise to new uses which are described in some examples; see also claims 5 to 13 .
The light-absorbing and light-transporting part consists essentially of three regions and is shown schematically in FIGS. 1 , 4 and 5 . (B 1 ) A transparent glass or polymer with refractive index n 1 and layer or sheet thickness x 1 , onto which the light is incident. (B 2 ) A light-absorbing and light-emitting part, which we refer to as antenna and which works as explained in FIG. 2 , consisting of one or more, generally aligned dye-zeolite layers (see FIG. 3 ) embedded into a transparent polymer. The thickness of the individual zeolite layers is typically in the range between 100 nm and 2000 nm. The length and thickness of the zeolite crystals used is likewise within this size range, disk-shaped crystals frequently being advantageous. The individual layers may be very tightly packed, or they may be separated via thin intermediate layers of a transparent material. The refractive index of the intermediate layers and of the polymer into which the zeolite layers are embedded is selected so as to result in optimal properties. (B 3 ) Next follows a transparent polymer or glass with refractive index n 2 and layer or sheet thickness x 2 . While the regions (B 1 ) and (B 3 ) meet customary requirements, are typically a few mm thick and can also be formed, for example, from two layers or sheets, for example a base body and a surface-treated layer or sheet or a glass part and a polymer part, the region (B 2 ) is of more complex structure and constitutes the actual core piece; see FIGS. 4 and 5 . FIG. 4 shows a luminescence concentrator having a dye-zeolite antenna layer. This antenna layer consists of one or more layers of aligned or unordered dye-zeolite crystals embedded in a thin polymer film, or coated with a thin polymer film. One of the two immediately adjacent layers or sheets, with thickness x 1 or x 2 , can be omitted if required. The refractive indices of the adjacent layers or sheets are n 1 and n 2 ; n s is the refractive index of the antenna layer and n 0 is the refractive index of the environment (typically air). δ s is the thickness of the antenna layer. FIG. 5 shows a two-dimensional view of an LC with two dye-zeolite antenna layers. The number of antenna layers can be increased as desired, the sum of the thicknesses of the antenna layers being much smaller than d. The antenna layers may have different structures, for example contain different dye-zeolite crystals. The designation of layer thicknesses and refractive indices is analogous to FIG. 4 .
This structure solves not only the problems (A) to (C) detailed under “State of the art” but has a considerable influence on the stability of the chromophores because the donor molecules pass on the energy absorbed via near-field interaction in the sub-picosecond range, such that barely any time remains for a reaction in the electronically excited state, and because the spatial delimitation by the nanotubes results in a cage effect, thus making impossible or at least considerably hindering both intra- and intermolecular movements which could lead to reactions. More particularly, it is also possible to quantitatively exclude small reactive molecules, for instance oxygen.
The incorporation of the dyes into the zeolite L crystals is effected from the gas phase in the case of uncharged dye molecules, and from a suitable solvent in the case of cationic dyes. Dyes adsorbed on the outer zeolite crystal surface are subsequently removed by washing with a solvent. The incorporation of different dyes can be effected sequentially or in parallel. Sequential incorporation results in defined dye domains, and the positioning of the acceptor molecules in the middle of the zeolite channels may be advantageous owing to the better screening from external reactive species. For other end uses or for certain chromophores, positioning at the ends of the channels gives rise to optimal properties. The parallel incorporation of different dyes leads to mixing within the crystal. To eliminate self-absorption, irrespective of the incorporation process, a large donor/acceptor ratio is selected, which is generally greater or considerably greater than 10:1.
The application of the dye-laden zeolite crystals to a substrate (for example glass) and the coating with a transparent polymer can be implemented, for example, as follows: (1) By production of a homogeneous mixture of polymer and zeolite crystals in a suitable solvent. The mixture is applied to the substrate by spreading (e.g. doctor-blading) or spin-coating. The evaporation of the solvent gives rise to a robust zeolite-polymer layer of defined thickness. (2) By production of one or more zeolite layers (directed or unordered) on the substrate and subsequent fixing with a little polymer. After the drying, the rest of the polymer layer is applied by spreading (e.g. doctor-blading) or spin-coating. In other cases, the method as illustrated in FIG. 3 may be advantageous; on this subject see: Organizing supramolecular functional dye - zeolite crystals , A. Zabala Ruiz, H. Li, G. Calzaferri, Angew. Chem. Int. Ed., 2006, 45, 5282-5287 ; Fabrication of oriented zeolite L monolayers employing luminescent perylenediimide - bridged Si ( OEt ) 3 precursor as the covalent linker , H. Li, Y. Wang, W. Zhang, B. Liu, G. Calzaferri, Chem. Commun. 2007, 2853-2854 ; Fabrication of oriented zeolite L monolayer via covalent molecular linkers , Y. Wang, H. Li, B. Liu, Q. Gan, Q. Dong, G. Calzaferri, Z. Sun, J. Solid State Chemistry, 2008, 181, 2469-2472. The crystals may also be aligned similarly to a nematic phase, in which case a considerably tighter packing than that depicted in FIG. 3 (on the right) is possible. FIG. 3 shows an electron micrograph on the left and a fluorescence micrograph on the right, and originates from: Organisation and Solubilisation of Zeolite L Crystals , Olivia Bossart and Gion Calzaferri, Chimia 2006, 60, 179-181.
In each case, if required, a covering material (for example a glass plate or a polymer film) can be applied to the zeolite-polymer layer. The relative position of the luminescent zeolite-polymer layer is controlled by the thickness of substrate and covering material. The covering material can be covered with a further dye-zeolite layer by repetition of the above-described procedure, which allows a structure as shown in FIG. 5 to be achieved. The application of further dye-zeolite layers and intermediate layers can be repeated as often as desired, which allows defined stacks of antenna layers separated by intermediate layers.
The structure of the iLC or of a luminescence disperser (LD) ( FIG. 8 ) is analogous to that of the LC ( FIG. 1 ). Instead of the receiver in the LC, an emitter is installed as excitation light (e.g. UV). Total reflection transports the light through the light conductor. When it hits a luminescent site, consisting of a dye-zeolite crystal, the light is absorbed and emitted again. By directed arrangement of the luminescent sites (dye-zeolite crystals), the emission angle is selected such that the photon leaves the light conductor (cf. FIG. 1 , exiting light flux). The body is transparent to wavelengths which enter the body and are not absorbed by the luminescent sites (dye-zeolite crystals). By virtue of the concentration distribution as a function of the emitter distance and/or as a result of the reflection at the body sides, it is possible to achieve homogeneous surface emission out of the body (the last step partly approximates to the light boxes with diffuse reflection in the box interior and an orifice through which the light is emitted diffusely from the box). The wavelength range within which the dye-zeolite nanocrystals used emit can be selected by adjusting the donor/acceptor combination from narrow-band emission to white light (on this subject see G. Calzaferri, S. Huber, H. Maas, C. Minkowski Angew. Chem. Int. Ed. 42, 2003, 3732-3758; G. Calzaferri, K. Lutkouskaya, Photochem. Photobiol. Sci., 2008, 7, 879-910).
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 . Drawing of a conventional luminescence concentrator (LC).
FIG. 2 . Luminescent sites: cylindrical zeolite nanocrystals with organized dye molecules, which function as donors (grey rectangles) and acceptors (black rectangles).
FIG. 3 . Oriented zeolite layer. On the left: electron microscope image of cylindrical zeolite L crystals on a glass substrate. On the right: the crystals may also be aligned similarly to a nematic phase (electron microscope and fluorescence microscope image).
FIG. 4 . Luminescence concentrator with a dye-zeolite antenna layer.
FIG. 5 . Two-dimensional view of an LC with two dye-zeolite antenna layers.
FIG. 6 . Luminescence concentrator-tandem solar cell apparatus.
FIG. 7 . Combination of luminescence concentrator-solar cell apparatus with hot water production.
FIG. 8 . Reverse utilization of LC. Instead of the receiver, an emitter is installed on the LC, and thus the LC is mutated to an iLC. The emitter emits excitation light into the luminescence disperser. The light is absorbed by the dye zeolite (luminescent site) and emitted again as luminescence. By suitable arrangement of luminescent sites, the luminescent emission can be directed such that the light leaves the light conductor.
FIG. 9 . LC using rare earth emitter antenna. The Ln 3+ is fixed according to: SOMC@PMS. Surface Organometallic Chemistry at Periodic Mesoporous Silica , R. Anwander, Chem. Mater. 2001, 13, 4419-4438.
FIG. 10 . Pyrene as a donor and some possible ligands, as examples (from left to right: pyrene, 2-carboxy-7-aminopyrene, 1-pyreneamine, 1-pyrenecarboxylic acid).
FIG. 11 . This diagram shows how an image can be projected onto the retina of the viewer (eye lens) instead of an object with the aid of a surface with directed emission. Individual image elements on the surface emit photons at the spatial emission angle alpha. The emission angle of the individual image point determines which pixel of the image to be projected has to be emitted by this image point.
FIG. 12 . Examples of cationic dyes which have been incorporated into zeolite L and are options for the use described here.
FIG. 13 . Examples of uncharged dyes which have been incorporated into zeolite L and which are options for the use described here.
MODES FOR CARRYING OUT THE INVENTION
1. Building an LC
The incorporation of the dyes into the zeolite L crystals is effected generally from the gas phase at elevated temperature in the case of uncharged dye molecules, and from a suitable solvent in the case of cationic dyes. Dyes adsorbed on the outer zeolite crystal surface are subsequently removed by washing with a solvent. The incorporation of different dyes can be effected sequentially or in parallel. In the case of sequential incorporation, the result is defined dye domains, in which case the positioning of the acceptor molecules in the middle of the zeolite channels may be advantageous owing to the better screening from external reactive species. The parallel incorporation of different dyes leads to mixing within the crystal. To eliminate self-absorption, a large donor/acceptor ratio is selected (>10:1). Examples of dyes which have been incorporated successfully into the channels of zeolite L in this way are compiled in FIGS. 12 and 13 .
The application of the dye-laden zeolite crystals to a substrate (for example glass) and the coating with a transparent polymer (e.g. PMMA, CR39, PVA) can be implemented, for example, as follows: (1) By production of a homogeneous mixture of polymer and zeolite crystals in a suitable solvent. The mixture is applied to the substrate by spreading (e.g. doctor-blading) or spin-coating. The evaporation of the solvent gives rise to a robust zeolite-polymer layer of defined thickness. (2) By production of one or more zeolite layers (directed or unordered) on the substrate and subsequent fixing with a little amount of polymer. After drying, the rest of the polymer layer is applied by spreading (e.g. doctor-blading) or spin-coating. In other cases, the method as illustrated in FIG. 3 may be advantageous; on this subject see: Organizing supramolecular functional dye - zeolite crystals , A. Zabala Ruiz, H. Li, G. Calzaferri, Angew. Chem. Int. Ed., 2006, 45, 5282-5287 ; Fabrication of oriented zeolite L monolayers employing luminescent perylenediimide - bridged Si ( OEt ) 3 precursor as the covalent linker , H. Li, Y. Wang, W. Zhang, B. Liu, G. Calzaferri, Chem. Commun. 2007, 2853-2854 ; Fabrication of oriented zeolite L monolayer via covalent molecular linkers , Y. Wang, H. Li, B. Liu, Q. Gan, Q. Dong, G. Calzaferri, Z. Sun, J. Solid State Chemistry, 2008, in press. The crystals can also be aligned similarly to a nematic phase, in which case a considerably tighter packing than that depicted in FIG. 3 (to the right) is possible. FIG. 3 shows an electron micrograph on the left and a florescence micrograph on the right, and originates from: Organisation and Solubilisation of Zeolite L Crystals , Olivia Bossart and Gion Calzaferri, Chimia 2006, 60, 179-181.
In each case, if required, a covering material (for example a glass plate) can be applied to the zeolite-polymer layer. The relative position of luminescent zeolite-polymer layer is controlled by the thickness of substrate and covering material. The covering material can be covered with a further dye-zeolite layer by repeating the above-described procedure, which allows a structure as shown in FIG. 5 to be achieved. The application of further dye-zeolite layers and intermediate layers can be repeated as often as desired, which allows defined stacks of antenna layers separated by intermediate layers to be produced.
2. Production of an LC with Exploitation of Surface-enhanced Plasmon Resonance
The controlled enhancement of luminescent properties of molecules by metal nanostructures (thin layers or particles) has been known for a few years (K. Aslan, I. Gryczynski, J. Malicka, E. Matveeva, J. R. Lakowicz, C. D. Geddes, Curr. Opin. Biotechnol. 16, 2005, 55). Studies regarding potential uses have concentrated to date on the biotechnology and LED fields. Together with the novel LCs described here, this gives rise to a series of innovative options for use of metal-enhanced luminescence: disk-shaped zeolite L crystals are first laden with donor molecules. The acceptor molecules present in deficiency are incorporated subsequently and are thus at the ends of the zeolite channels. The substrate consists of a conventional carrier material (e.g. glass) which is coated with a thin metal film. Thereafter, the disk-shaped, dye-laden zeolite crystals are applied such that any direct contact between the metallic substrate and the dyes is prevented. This is accomplished by the above-described process to form an aligned layer, which results in distances in the region of a few nanometers between metal film and acceptor molecules. In the case of such distances (direct contact between dye and metal film is not required and must generally be avoided), the emission of the dyes can be enhanced significantly by excitation of surface plasmons in the metal film and the associated increase in the electromagnetic field. With regard to the efficiency and stability of an LC, this structure may bring the following advantages: (i) Shortening of the lifetime of the excited state of the acceptor molecules and hence an increase in the photostability. (ii) Increase in luminescent quantum yield of the acceptor molecules and hence higher efficiency of the LC. There is additionally the possibility of using acceptor molecules which have a low quantum yield but have other advantageous properties (stability, cost). The same effect leads to enhanced absorption, but only in the region of a few nm removed from the metal surface.
3. Building an LC Using Rare Earth Chromophores as Emitters
It is well known that rare earths Ln 3+ can be incorporated in different form into the channels of zeolite L and lead to interesting luminescent properties ( Luminescence properties of nanozeolite L grafted with terbium organic complex , Y. Wang, H. Li, W. Zhang, B. Liu, Materials Letters, 2008, 62, 3167-3170; Highly Luminescent Host-Guest Systems Based on Zeolite L and Lanthanide Complexes, Y. Wang, Z. Guo, H. Li, J. Rare Earth, 2007, 25, 283-285 ; Sensitized near infrared emission from lanthanide - exchanged zeolites , A. Monguzzi, G. Macchi, F. Meinardi, R. Tubino, M. Burger, G. Calzaferri, Appl. Phys. Lett. 92, 2008, 123301/1-123301/3).
Here, we use a new kind of combination of an antenna hybrid material in which a rare earth ion serves as the emitter. The special feature of this combination is that the rare earth compounds—which have only comparatively low light absorption even when they are equipped with antenna ligands—can be excited by means of our antenna systems which have very high light absorption, without losing their ability to emit in a narrow band, as explained in FIGS. 9 and 10 . It is also possible to use, as antenna absorbers, molecules which have markedly nonlinear optical (NLO) properties, such that it is possible to work with two-photon excitation. Two-photon excitation antennas may be of high interest for solar uses, but also for microscopy ranging as far as diagnostics; on this subject see Cell - Permeant Cytoplasmic Blue Fluorophores Optimized for In Vivo Two - Photon Microscopy With Low - Power Excitation , A. Hayek, A. Grichine, T. Huault, C. Ricard, F. Bolze, B. Van Der Sanden, J.-C. Vial, Y. Mely, A. Duperray, P. L. Baldeck, J.-F. Nicoud, Microscopy Research and Technique 70, 2007, 880-885. We use, among other substances, pyrene derivatives because they bring very good prerequisites for successful sensitization of Eu 3+ . They have high absorption in the near UV, and have high luminescent yields and inter-system crossing; on this subject see: A. R. Horrocks, F. Wilkinson, Proc. Rpy. Soc. A. 306, 1968, 257-273. The coordination properties of pyrenes to lanthanide ions can be adjusted efficiently with the aid of simple synthesis (attachment of acid, ester, amide, amino groups and others). Substituents in the 2 position are notable in that the ligands fit better into the zeolite L channels. Eu 3+ -pyrene complexes can thus also serve as peg molecules which have comparatively very narrow-band emission. In a donor-acceptor cascade as shown in FIG. 9 , a donor-pyrene molecule (D) is electronically excited by light absorption. It then transfers its excitation energy radiationlessly via near-field interaction to neighboring molecules until it arrives at a pyrene ligand coordinated to Eu 3+ . From there, an emitting state of Eu 3+ is then occupied, which somewhat later emits a long-wave photon. The corresponding ligand synthesis and coordination chemistry is well known; on this subject see D. M. Connor, S. D. Allen, D. M. Collard, C. L. Liotta, D. A. Schiraldi, J. Org. Chem. 1999, 64, 6888-6890; A. Musa, B. Sridharan, H. Lee, D. Lewiss Mattern, J. Org. Chem. 1996, 61, 5481-5484; C. Yao, H.-B. Kraatz, R. P. Steer, Photochem. Photobiol. Sci. 2005, 4, 191-199. The absorption and luminescence spectra of Py, Py-NH 2 and Py-COOH are shown in FIG. 10 . It can be inferred therefrom that Py can serve very efficiently as a donor both for Py-NH 2 and for Py-COOH. Loading of zeolite L with subsequent installation of Eu 3+ -pyrene complexes and production of LCs based on these antennas leads to LCs with spectral properties of particular interest from a performance point of view. Intrinsic absorption becomes so low here that it can be neglected completely.
4. The Principles, Routes and Methods Described for the Building of LCs Also Apply to the iLCs.
Commercial Utility
1. LCs for Collection and Concentration of Sunlight
The use of LCs is well known from the literature. With regard to the principles in conventional use, there is at first no difference between the LCs being addressed here and previously described variants. However, the central difference is that the problems with the LCs known to date, which are described under “State of the art”, have been solved or at least reduced to a sufficient degree that they can now also be achieved for this use. Owing to the new way in which they are constructed, these LCs and the associated advantageous optical properties lead to a considerably better cost/benefit ratio of building-integrated photovoltaic systems and for collection and subsequent transport of light, for example in a glass fiber.
2. LCs for Tandem Solar Cell
The principle is that light in the range from near UV up to a wavelength limit which may, for example, be 600 nm is conducted via LCs to a “large band gap” solar cell, and that a “small band gap” solar cell on the reverse side of the LC collects the long-wave portion of the light. This allows building of a tandem solar cell which does not require “current matching” and in which no complex layers are needed; see FIG. 6 . This tandem arrangement allows a maximum thermodynamic efficiency of somewhat more than 43% compared to a maximum of 29% in a “single band gap” photovoltaic cell; on this subject see Peter Würfel, Physics of Solar Cells, Wiley-VCH, Weinheim, 2005.
3. Photovoltaic-hot Water Integration
Another possible use which becomes an option with partial LCs is the integration of photovoltaics into a hot water production system. This is an idea which is well known in principle. It consists in utilizing the long-wave portion of the incident solar radiation for hot water production and the shorter-wave portion to operate a photovoltaic cell. This has huge energetic advantages and can also contribute (in hot countries) to the cells not becoming too hot (for example by virtue of a 60° C. limit). By using the novel LC devices described here, it is possible to physically completely decouple the solar cell portion and the hot water portion, as outlined in FIG. 7 , and thus to solve the problems which are a consequence of the combined large area of the two transducers (thermal and electrical) and which lead in conventional systems to hurdles which can barely be overcome in practical use. The LC is transparent to infrared radiation over wide ranges, especially in the near IR.
4. Inverted LC
The term luminescence concentrator might seem curious for this “inverted device”. Owing to the analogy to the physical process, we wish nevertheless to use this name and to abbreviate it to iLC. The structure of an iLC is such that light is fed in laterally at one or more points, for example with the aid of an LED. The light is then absorbed by dye-zeolite antennas and passed on within the antenna system in an analogous manner to that in the LC until it meets a region in which it is absorbed by a second type of antenna crystals which are aligned such that the light is no longer reflected internally but leaves the layer. This can make a glass or plastic surface appear partially dark and partially as a diffuse emitter. Areas of use for such iLCs are various, and range from signaling systems, through illuminated signage, through room lighting, flat/diffuse light sources and background illumination.
One use consists in the possibility of implementing a visual display unit via a two-photon emission process. By loading the zeolites with a two-photon emission system, orthogonal incidence of the two excitation wavelengths induces one or more pixels to emission. The incident intensity of the excitation sources can be used to regulate the brightness of the individual pixels. Suitable emission wavelengths adjust the pixel color. Instead of diffuse emission, it is also possible to establish directed emission with a limited emission opening angle, in order to increase the emission intensity in the desired direction.
5. LCs Exploiting Surface-enhanced Plasmon Resonance
The phenomenon of surface-enhanced plasmon resonance (K. Aslan, I. Gryczynski, J. Malicka, E. Matveeva, J. R. Lakowicz, C. D. Geddes, Curr. Opin. Biotechnol. 16, 2005, 55) can be used in conjunction with the structure shown in FIG. 4 in an ideal manner to optimize the luminescent properties of the dyes. A thin metal layer adjoining the antenna layer leads to an enhancement of luminescence by molecules close to the interface between antenna layer and metal layer. The use of an antenna layer consisting of oriented zeolite L crystals (channels at right angles to the surface of the metal film) allows the distance of the metal surface from the acceptor or donor molecules to be controlled. This avoids direct contact between the dye molecules and the metal surface. In a conventional LC (consisting of dye molecules in a polymer layer) and in all other LC designs known to date, such an optimization of luminescent properties is not possible. In the concept that we have developed, use of surface-enhanced plasmon resonance is of particular interest for optimization of luminescent properties of the acceptor molecules.
6. LCs Using Rare Earth Chromophores as Emitters
Here we propose a new combination of an antenna hybrid material, in which a rare earth ion serves as an emitter. The special feature of this combination is that the rare earth compounds—which have only comparatively low light absorption even when they are equipped with antenna ligands—can be excited by means of our antenna systems which have very high light absorption without losing their ability to emit in a narrow band, as explained in FIGS. 9 and 10 . (The spectra shown in FIG. 10 have been taken from the literature: C. Yao, H.-B. Kraatz, R. P. Steer, Photochem. Photobiol. Sci. 2005, 4, 191-199.) The antenna absorbers used may also be molecules which have marked NLO properties, such that it is possible to work with two-photon excitation. Two-photon excitation antennas may be of high interest for use in solar technology, but also for microscopy ranging as far as diagnostics ( Cell - Permeant Cytoplasmic Blue Fluorophores Optimized for In Vivo Two - Photon Microscopy With Low - Power Excitation , A. Hayek, A. Grichine, T. Huault, C. Ricard, F. Bolze, B. Van Der Sanden, J.-C. Vial, Y. Mely, A. Duperray, P. L. Baldeck, J.-F. Nicoud, Microscopy Research and Technique 70, 2007, 880-885).
7. LC Device for Use as a Scintillation Detector
DMPOPOP and other highly fluorescent dyes which are used in scintillation counters for the measurement of ionizing radiation, for instance gamma quanta, can be incorporated into zeolite L in very high concentration, up to about 0.2 mol/l. They can pass on their electronic excitation energy to acceptors. For DMPOPOP, for example, it is possible to use PR149, DXP or oxonine as acceptors. With the aid of such dye-zeolite L materials, it is possible to build LCs as described in 1. to 3. and in FIGS. 4 and 5 . Such LCs are rendered reflective on the open sides and installed at a site in the detector. It is thus also possible to collect extremely sensitively ionizing radiation over a large area and convert it to luminescence of the scintillator dye. This is transferred via energy transfer to the acceptor, which then emits at a long wavelength. Via total internal reflection, the luminescence to be measured is transferred to the detector. It is particularly simple and inexpensive in such a device to protect the detector from incident ionizing radiation.
8. iLCs for Locally Directed Emission
Oriented dye-zeolite antennas allow the achievement of directed emission (on this subject see especially G. Calzaferri, K. Lutkouskaya, Photochem. Photobiol. Sci., 2008, 7, 879-910). Instead of the viewing of a visual display unit, it is thus possible to directly project images onto the retina of the eye, without external optical elements. This is illustrated schematically in FIG. 11 : individual image points emit at a defined angle alpha(i). Through the eye lens, this image point hits a particular site on the retina. The emission angle alpha determines the point on the retina at which the image point is depicted. By suitable arrangement, it is thus possible to generate one image per eye. By means of two corresponding images, a three-dimensional image can be transmitted to the viewer. The opening angle of the emission cone determines the pixel size on the retina and hence the sharpness of the image.
9. LCs for the Implementation of an Eye Replacement Device
In the case of a very inadequate or missing eye lens, it is possible to directly stimulate a functioning retina with a directed emission matrix. For this purpose, the emission matrix is applied very close to or directly to the retina, and the directed emission is fed directly to the individual light receptors on the retina. The image source can be generated externally by a camera or a mini-camera in the eye. A synthetic eye apparatus has thus been established. In the case of a poorly functioning retina, this process can be used to increase the light source intensity, such that the receptors respond to the enhanced light stimuli.
10. iLC Device for the Production of Spotlights
The directed emission can also be utilized to establish a spotlight with a defined emission cone angle. In this case, the emission elements should be arranged in parallel, with the same emission cone opening angle. | A luminescence concentrator (LK) may concentrate both incident direct and diffuse light by way of frequency shift and total internal reflection. It differs fundamentally from geometric concentrators. With sufficient geometric expansion of the collector plate, nearly arbitrarily high concentration can be achieved in the LK. A luminescence disperser is an apparatus which holds both directional and nondirectional incident light captive in a transparent body by way of frequency shift and total internal reflection and emits it diffusely or directionally uniformly distributed across an area by way of luminescence emission. The object of the invention is a method for the technical implementation of the LK and luminescence disperser, using zeolite crystals having a nanotube structure, into which the luminescent dyes are embedded such that they have antenna properties. Using the resulting novel structures, problems can be solved which made the technical use of LK impossible or at least considerably limited it. This results in completely novel usage possibilities for collecting and concentrating sun light and feeding it into photovoltaic systems, for converting it into electric and thermal energy in combined photovoltaic/hot water apparatuses, and for feeding it into fiber optic apparatuses. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of athletic socks, and more particularly to a sock which simulates the appearance of a stirrup being worn over the sock as used in baseball uniforms.
2. Description of the Related Art
A stirrup garment has been a part of the uniform in the game of baseball for many years. The stirrup is a covering for the shin and calf portion of the leg of the player and is partly held in place by its characteristic strap passing under the arch of the foot. It has been used by all classes of baseball players where a uniform is worn and may be used by softball players as well.
Although the traditional stirrup worn over the sock is appreciated for its appearance, it has a number of disadvantages as addressed and corrected by the invention herein disclosed.
One quite obvious drawback is that purchasing both a stirrup and a sock is expensive. A second recognized problem is that donning a stirrup over a sock is difficult because of the need to overcome both the bulk and the friction, especially for children. This bulk factor makes donning the shoe over both garments difficult and can interfere with proper fit and comfort. In addition, since the stirrup is not anchored over the toe, there is a risk that the stirrup can slip out of the heel area of the shoe and be an uncontained loop which could get caught on a base, a bat, or the foot of a player.
The problems pertain especially to the use of stirrups over socks by young baseball and softball players such as those who play in the Little League, Babe Ruth League, etc. These young baseball players also may tend to lose various parts of their uniform thus indicating a need for simplification. As can be readily appreciated, the youth baseball and softball uniform business entails a very significant, if not the dominant part of the market in uniform manufacture and sales. Virtually every town has its Little League team and cities often have many teams each. A significant number of players appear to like to display the appearance of a stirrup before other players both before and after they don their full uniform.
The discussion above focused on the problems of a separate stirrup to go over a sock from the perspective of the wearer. There are also a number of disadvantages for the manufacturer as well. To produce a stirrup, it is first necessary to knit a sock-like garment. Next, the parts that would be the toe and the heel are cut away, leaving a strap which will fit under the arch of the wearer. In order to avoid fraying of the cut knit edges, the edges are overstitched in another operation. Thus, a three step process is required to make this piece, as distinct from the manufacturing process for a sock which takes only knitting of the sock body and stitching the toe closed. Additionally, the fabric which is cut away to produce the stirrup straps is wasted.
In prior attempts to provide the desired stirrup-like appearance and to alleviate the problems enunciated above, socks have been produced to incorporate a side stripe for a stirrup-like look. Others have added a band around the top, creating a "T" pattern. A significant feature of the separate stirrup which is inherent in the characteristic look of a stirrup is the curvature at the top of the cut openings which creates a gradual taper from the calf portion to the straps. Both these prior styles of combination garment fail to accurately emulate the curved appearance of traditional stirrups. Hence, the previously available simulated stirrup over socks have been aesthetically unappealing to players seeking the stirrup look both before and after donning their full uniform.
In the prior attempts to create a one-piece sock which simulates the combined appearance of the stirrup and the sock, two ideas have been expressed in U.S. design patent. In U.S. Pat. No. Des. 242,829, a one-piece garment combining some features of the simulated stirrup on a sock is displayed. In U.S. Pat. No. Des. 254,101, similar features are shown, with the added characteristic of having a side stripe simulating a stirrup strap and shown extending to the bottom of the foot portion of the sock. While it is possible to produce the socks described in the patents in previously available manufacturing systems, the cost of this manufacture was excessive. A comparison is that the machine preparation time of the old system could be as much as forty (40) hours compared to less than one (1) hour for the system associated with the present invention. Also, the rate of production of the prior system was of the order of twenty-four (24) pairs per machine per eight (8) hour shift compared to approximately eighty (80) pairs per machine per eight (8) hour shift with the present invention. Therefore, the present invention adds both a factor of economy of production for the maker and economy of purchase for the buyer.
Therefore, a primary object of the invention is to create a sock which simulates the appearance of the original two garment sock-stirrup system as worn, without the attendant problems.
An additional object of the invention is to create a sock which creates the appearance of a stirrup being worn over the sock while having all the convenience and comfort associated with a single sock.
A further object is to create a sock having the appearance of a combination stirrup and sock but which is more economical to manufacture and to purchase.
Additional objects of the invention will become apparent from the following description.
SUMMARY OF THE INVENTION
The invention relates to a knitted sock having the appearance when worn of being a combination stirrup and sock and produced on a pattern controllable circular knitting machine having multiple yarn change capabilities. The resultant single garment closely duplicates the appearance and eliminates the majority of the disadvantages of the older two garment, sock-stirrup, system. In particular, a wide upper band is knit which blends with a smooth, gradual transition to vertical stripes which simulate the conventional stirrup straps. The resultant appearance is much closer to the traditional look of the stirrup than previously achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a traditional separate circular knit stirrup of the prior art, the opposite side view being a mirror image of the side shown.
FIG. 2 is a side view of a prior art sock which attempts to at least partially emulate the appearance of a stirrup by incorporating side stripes of a contrasting color to emulate the appearance of the stirrup straps, the opposite side view being a mirror image of the side shown.
FIG. 3 is an illustration of the prior art sock of FIG. 2 as worn in a baseball uniform with the uniform cut away to show the upper portion of the sock and showing its side stripe terminating above the shoe level which is undesired.
FIG. 4 is a side view of the simulated combination stirrup and sock of the present invention as seen in FIG. 5 and with the uniform cut away to show the upper portion of the FIG. 5 sock and also showing its side stripe terminating in the shoe of the wearer which is a desired appearance.
FIG. 5 is a side view of the simulated combination stirrup and sock according to the first embodiment of the inventor with bands of contrasting color in the upper part and a solid side stripe simulating the stirrup straps, the opposite side view being a mirror image of the side shown.
FIG. 6 is a side view of the simulated combination stirrup and sock with a solid upper part and a contrasting border along the side stripe according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As previously explained, the traditional uniform of the game of baseball has for many years used a circular knit stirrup similar to that depicted in FIG. 1 over a sock. The stirrup 115 has a leg portion 125 to cover the shin and calf extending below a top garter band 128. As can be seen in FIG. 1, the toe section 115a and heel section 115b are cut away and form apertures bordered by edges 120 which surround the vertical side straps 114 only one of which is shown. In some styles, border 130 comprises an overlocked stitched line to prevent unravelling of the cut knitted edge 120 and is stitched in a contrasting color for appearance. A portion of the front transitional inwardly curved taper 122 is typically located below the rear transition inwardly curved taper 124 as shown. The impetus to replicate the appearance of a traditional stirrup in a one-piece garment having the appearance of a stirrup and sock is for practical reasons, but carries with it the need to imitate the appearance of the two garments. To date, this has not, as previously mentioned, been successfully accomplished in a commercial product.
The type of prior art sock 225 shown in FIG. 2 is believed to be typical of earlier attempts to incorporate the appearance of a stirrup over a sock. FIG. 2 shows a contrast band 228 at the top which may at least in part constitute an elastic garter band and which is joined to the stirrup strap simulating vertical stripe 214 in a perpendicular transition. Front panel 218 and rear panel 216, in this example, are typically the same color as the foot portion 210 below reference line 212 whereas band 228 and stripe 214 are of a different contrasting color. Vertical stripe 214 which simulates the stirrup strap 114 extends downward to about the level of reference line 212 at which the top of the player's shoe would normally reside.
FIG. 3 illustrates the prior art sock 225 of FIG. 2 as worn whereas FIG. 4 depicts the FIG. 5 sock 15 of the invention as worn. From this comparision, it will be seen that the strap simulating stripe 214 of the prior art sock 225 leaves a gap above the line of the top of the shoe 11. In contrast, the simulated stirrup on the sock 15 of the present invention as in FIG. 4 has a simulated stirrup strap stripe 14 which continues below the level of the shoe top, leaving no gap. The sock 15 of FIG. 5 when worn as in FIG. 4 thus more closely simulates the appearance of the traditional separate stirrup of FIG. 1. Even though it has been known, as previously mentioned, to avoid the gap, it has not been known to avoid such gap with a sock such as provided by the construction of the invention.
It has been discovered that manufacture of the simulated combination stirrup and sock of the invention is best accomplished according to the present invention on a magnetic tape controlled 5 Cus model circular knitting machine manufactured by Sangiacomo of Brescia, Italy having 112 needles. Other derivations for greater or lesser definition of pattern can be made with the same model having from 72 to 200 needles, although 176 needles is the maximum allowed if a terry cloth is to be knitted. This type of weft knitting machine and method of knitting has been discovered to be particularly advantageous for simulating the respective front and rear transistional tapers 122, 124 of the stirrup as seen in FIG. 1. It has been discovered that the short, substantially straight angled edge or border lines such as lines 20, 22 in FIG. 5, very closely simulate when the invention sock 15 is worn the curved lines 122, 124 of FIG. 1 when seen from a relatively short distance of, for example, fifteen feet or less.
To achieve an athletic sock garment of proper fit and comfort requires a degree of stretch in the leg portion and a degree of cushioning in the foot portion. While a covered elastomeric yarn will achieve stretch, it interferes with good color control. Therefore, the leg portions of both of the illustrated embodiments of the sock of the invention as seen in FIGS. 5 and 6 are preferably made with predyed synthetic thermoplastic body and skeleton yarns that have been texturized. This obtains good stretch and shape retention while not sacrificing color control.
With respect to both the first embodiment of FIG. 5 and second embodiment of FIG. 6, the preferred body and skeleton yarns for knitting the entire upper section of the simulated combination stirrup and sock down to and somewhat below reference line 12 are texturized nylon yarns. In particular, a 140 denier texturized nylon yarn is used as the skeleton yarn to contribute a continuous base as the body yarn is being changed to switch color within a course in the garment. The body yarn which appears on the outer surface and works satisfactorily in both embodiments is a 400 denier texturized nylon. The 400 denier nylon body yarn in the stripe 14 continues to a level below the terry line 12 where the body yarn is also terried. The foot 10 up to the terry line 12 and on both sides of the stripe 14 is made of a 12's count cotton yarn.
While the construction will vary according to size, a typical construction which achieves the desired properties is made at a density of 24 courses per inch, has a relaxed body width of 71/4 inches and a stressed width of 81/2 inches. Measurement of the differential between the relaxed width and the stressed width is done by a standard spring tension Stretchette sock stretch measuring caliper.
The first embodiment of the invention as seen in FIG. 5 includes an elastic garter band 28 knitted on the machine previously described. A leg portion 25 includes both the top band 28, a connecting band 29a and a series of bands 26a, 26b, 26c of one color interspersed with bands 28, 29a, 29b, 29c and area 29d and stripe 14 of another color. As an example, when bands 28, 29a, 29b, 29c, area 29d and stripe 14 are of a blue color, bands 26a, 26b and 26c and stripe 14 are of a yellow color and the remainder of the sock is white, both an attractive appearance and a stirrup-like appearance are achieved. Leg portion 25 continues down to a point where the substantially straight line of rear transition taper 21 begins with the substantially straight horizontal border line 24 which joins angular border line 21 to connect with the rear edge line 14a of the stirrup strap simulating vertical stripe 14. Several courses further down on the leg portion 25 the substantially straight line of front transition taper 20, proceeding from the substantially border line 22, joins the front edge line 14b of the vertical stripe 14. The stirrup strap simulating vertical stripe 14 continues down each side of the sock 15, bordered by the body color which by way of example, may be white. Thus the pattern accomplishes an appearance closely resembling that of the traditional stirrup in a one-piece knit construction.
A particular feature of the present invention that distinguishes over the garments of the prior art is the ability to achieve what appears when the invention sock 15 is worn as a gradual transition taper between upper borders 22, 24 and vertical stripe 14. This is done by a series of finite steps in the change of yarn within a knitting course, changing one wale closer on each side of the vertical stripe 14 with each succeeding course of knitting. Even though the previously described relatively short border lines 22, 20 and 24, 21 are formed in steps, they appear when sock 15 or 17 is worn as substantially straight lines from a distance of a few feet much like the inwardly curved taper lines 122, 124 of FIG. 1.
The construction of the garment is completed with the foot section 10. From a level at approximately reference line 12 downward, the interior of the sock 15 is terried to create a cushioned and absorbent fabric. The terry loop is accomplished as is commonly known in the industry by the interception of the knitting yarn with a "sinker" to extend the yarn length and create the loop. A cotton or other compressible, absorbent yarn is desirable for this portion of sock 15. From line 12 which represents the level of the top of the shoe 11 (FIG. 4) and the top of the terrying, the vertical stripe 14 continues downward for a distance to end within the covering of the shoe 11 as worn.
In a second embodiment of the simulated combination stirrup and sock of the invention, depicted in FIG. 6, the upper portion of the sock 17 includes the elastic band 28' and area 28a as well as the simulated stirrup strap stripe 14' all of a common solid color. Vertical stripe 14' is however knitted with a contrasting color along front and rear edge lines 30, 30a to simulate the contrasting overlock stitching done on some of the traditional stirrups. Leg portion 25' is knit down to line 24' in the rear and to line 22' in the front. In the rear, transition taper 21' gradually angles toward and joins the rear edge line 30a of stripe 14'; in the front the transition taper 20' begins at a lower level and extends between line 22' and front line 30b of stripe 14' by following a complementary angle. Front panel 18' and rear panel 16' are typically kept in the color of the foot 10'. Stripe 14' extends below reference line 12' as previously explained.
While not shown, it is to be recognized that the stirrup-like appearance could be simulated by using yarns of contrasting color only on the borders of the stirrup portion of the sock of the invention with all other portions made of a common color.
Thus, as disclosed in the description above, the simulated combination stirrup and sock of the present invention has achieved its desired objectives and introduced useful improvements over the prior art. As will be understood by those skilled in the art, the principles outlined in this disclosure offer broad opportunities and, as such, are not to be interpreted as being limited by the specific embodiments herein. | A one-piece integrally circular knit athletic sock is provided which simulates the appearance of a separate stirrup being worn over the sock. The straps of the conventional stirrup are simulated and made prominent by a pair of stripes of a color which contrasts with the color of the body of the sock and which extend downwardly for a length sufficient to insure for the sake of appearance that the lower ends of the stirrup strap simulating stripes are below the normal level of the top of the athletic shoe. The curved front and rear edges of the stirrup straps are simulated by straight border lines but which resemble the curved lines when seen from a distance. | 3 |
FIELD OF THE INVENTION
The present invention relates to a device for selecting objects inserted for payment purposes into a dispenser of goods or services.
A particularly advantageous application of the invention lies in the field of dispensing services, such as tickets for travel or for vehicle parking.
A dispenser of goods or services in exchange for payment in coin is known, e.g. from American U.S. Pat. Nos. 5,393,891 and 5,404,986, in which coins are inserted one by one through an insertion orifice, generally in the form of a slot. The coins inserted into the dispenser in this way are received by a selector device mainly constituted by a circularly shaped transport member suitable for being rotated about its axis which extends horizontally. In said transport member, there is provided a housing corresponding substantially to a sector of a circle, in which the coins are received one by one after being inserted into the dispenser, said housing having previously been put into communication with the insertion orifice.
By rotating about its axis, the transport member brings the coin that is to be found in the housing to a measurement zone where various operations are performed to verify conformity, in particular the diameter of the coin is determined by measuring the time it takes to move past an optical sensor, and the metal from which the coin is made is analyzed by a magnetic measurement performed statically, with the transport member being stopped in the field of an electromagnetic detector.
Then, from said stop position, the transport member can turn either in a first direction of rotation to direct the coin to a pre-encashment block if the coin is recognized as being in conformity, or else, otherwise, in a second direction of rotation, opposite to the first, towards an outlet for returning the coin.
That selector device known in the state of the art nevertheless suffers from the drawback of requiring the movement of the transport member to be stopped in order to analyze the metal of the coin present in the housing, and that slows down the coin processing system.
OBJECTS AND SUMMARY OF THE INVENTION
Thus, the technical problem to be solved by the present invention is to propose a selector device for selecting objects inserted by way of payment into a dispenser of goods via an insertion orifice, said device comprising a transport member provided with a housing designed to receive said objects singly and suitable for bringing an object placed in said housing into a measurement zone where means are disposed for verifying conformity of said object, which selector device makes it possible to accelerate the operations of verifying conformity so as to reduce the length of time objects are present in the measurement zone and thus reduce the time interval between two successive objects being inserted by the user into the dispenser.
According to the present invention, the solution to the technical problem consists in that said selector device also comprises drive means suitable for imparting a non-reversible continuous movement to said transport member along a path during which said housing passes from an initial position of communication with said insertion orifice to a final or waiting position, passing through said measurement zone in continuous manner, said means for verifying conformity receiving sampling signals sampling the movement of the transport member.
Thus, as explained in detail below, it is possible for the metal constituting the coin to be analyzed, for example, without requiring a pause in the measurement zone, with this being a consequence of the fact that it is possible to establish indicative parameters specific to the metal used from measurements taken at accurately reproducible positions of the coin in the measurement zone, which positions are provided by the sampling signals.
It is in this sense that the invention provides for said means for verifying conformity to comprise means for magnetically analyzing the material of said objects, suitable for expressing said analysis in terms of characteristic values of a curve representative of the magnetic signature of said objects, said characteristic values being sampled by means of said sampling signals.
According to an advantageous disposition of the invention, said means for verifying conformity comprise means for geometrically measuring said objects, suitable for expressing said measurements in terms of numbers of steps in the sampling signals, independently of the speed of the transport member. The term "geometrical measurements" covers, for example, measurements of diameter and of thickness which are two parameters enabling conformity of coins to be verified.
The geometrical measurements performed by the selector device of the invention are thus performed dynamically, as is the diameter measurement described in the above-mentioned American patents. Nevertheless, it should be observed that in the prior art selector device, diameter is determined by measuring the time taken for the object to go past and optical sensor, with the result depending on the speed of rotation of the transport member. In contrast, in the present invention, the measurement is performed as a function of the position of the object to be recognized, which position is known very accurately because the drive means samples the movement of the transport member. The measurement is thus independent of the speed of said transport member, thus avoiding any need to control said speed very accurately, and making it possible for measurement to be unaffected by external disturbances that may be applied to the transport member, such as:
an attempt by the user to insert a second object while measurements are being performed on the previously inserted object; and
a deliberate attempt at fraud by braking the transport member while measurements are being taken for the purpose of disturbing them.
According to another characteristic of the invention that is particularly advantageous, provision is made for the path of the housing between the initial and final positions also to pass continuously through a zone for accepting or rejecting objects, directing them either to an encashment outlet or to a return outlet following after the measurement zone. This constitutes a same-direction extension of the continuous movement of the transport member until the objects are accepted or rejected following the operations of verifying conformity as previously performed in the measurement zone, whereas the above-mentioned American patents require firstly a stop and secondly switching between two possible directions of rotation depending on the result of the verification. It will thus be understood that since the invention requires neither a stop nor a reversal of direction, this makes it possible to further reduce the time between two successive objects being inserted into the dispenser.
In the specification below, the term "encashment" is used both for direct encashment of objects in the money box of the dispenser, and for pre-encashment including intermediate storage of objects so that it is possible for them to be returned in the event of the transaction being cancelled by the user.
More particularly, said encashment and return outlets are disposed in series facing the continuous movement of the transport member, an object placed in the housing being suitable, under the action of gravity, for passing through the encashment outlet if the object has been recognized as being in conformity on leaving the measurement zone, or for passing through the return outlet if the object is recognized as not being in conformity on leaving the measurement zone, a normally-open moving flap for shutting the encashment outlet being brought into a closed position.
Finally, in a preferred embodiment of the invention, the measurement zone is disposed on the path of the housing in such a manner that said means for verifying conformity are implemented during the continuous movement of the transport member starting from the housing's initial, communication position, and after said housing has ceased to be in communication with the insertion orifice. This disposition makes it possible to recognize objects inserted in the selector device of the invention without the measurements as performed by the means for verifying conformity being affected by the external environment, which is particularly important when using optical means that are sensitive to interfering light which could pass through the insertion orifice.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description given with reference to the accompanying drawings given as non-limiting examples, will make it well understood what the invention consists in and how it can be implemented.
FIG. 1 is a perspective view of a selector device of the invention.
FIGS. 2a to 2e are side views of the FIG. 1 selector device for various positions of the housing in the transport member.
FIG. 3a is an end view of means for measuring the diameter of an object inserted in the selector device of the invention.
FIG. 3b is a timing chart of the diameter measurement supplied by the means of FIG. 3a.
FIG. 4a is an end view of means for measuring the thickness of an object inserted in the selector device of the invention.
FIG. 4b is a timing chart of the thickness measurement provided by the means of FIG. 4a.
FIG. 5a is an end view of means for analyzing the metal of an object inserted in the selector device of the invention.
FIG. 5b is a timing chart of the metal analysis provided by the means of FIG. 5a.
FIG. 6 is a front view of the FIG. 1 selector device.
FIG. 7 shows a variant embodiment of the transport member shown in FIGS. 1 to 2e.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The selector device shown in perspective in FIG. 1 is designed to be fitted to a dispenser of goods or services in which objects, such as coins 1, are inserted by way of payment via an insertion orifice 10.
As shown in FIG. 1, said dispenser device comprises a transport member 100 having the general shape of a wheel in which a housing 110 is formed to receive the coins 1 singly.
The transport wheel 100 is suitable for being rotated about its axis 101 by drive means which, in the example of FIG. 1, are constituted by a DC motor 200 and a transmission mechanism 210 including stepdown gearing comprising two spur wheels 211, 212 coupled to a wormscrew co-operating with teeth (not shown) disposed on the periphery of the wheel 100. The helix of the wormscrew 213 is left-handed so as to urge the transport wheel 100 against the reference plane P during normal, clockwise rotation, thereby improving the measurement of the thickness of the coins 1 which, as explained below, constitutes one of the operations for verifying conformity applied to objects inserted into the selector device.
The motor 200 used is a high efficiency motor to keep down electricity consumption and a low-inertia motor to facilitate stopping the transport wheel 100 with good angular accuracy.
Under drive from the above-mentioned drive means, the transport wheel 100 is caused to rotate continuously and non-reversibly in the clockwise direction along a path during which the housing 110, starting from an initial position P1 shown in FIG. 2a, is brought to a measurement zone ZM in which means 301, 302, 303 are disposed for verifying conformity of the coin 1. Then, after passing continuously through said measurement zone ZM, the housing 110 arrives, still in the same movement, at a final position P2 shown in FIG. 2e and explained below.
As can be seen in FIG. 2a, when the housing 110 is in its initial position P1 it is in communication with the insertion orifice 10 so as to be able to receive a single inserted object 1.
Once an optical type detector 11 has recognized the object 1 as being opaque, and thus capable of being a coin, the motor 200 is put into operation so that the transport wheel 100 brings the coin 1 into the measurement zone where the operations of verifying conformity, as described below in detail with reference to FIGS. 3a to 5b, are performed continuously.
The means used for establishing conformity of inserted coins 1, include a diameter-measuring device shown in FIG. 3a, which device is essentially formed by an infrared emitter/receiver pair 302, for example. The measurement consists in recording the flux transmitted from the emitter to the receiver when the coin 1 goes past. As shown at (a) in FIG. 3b, the signal delivered by the receiver has a blanked-out time that is directly proportional to the diameter of the coin 1, but that also depends on the speed of rotation of the transport wheel 100. In order to obtain a result that is independent of the speed of rotation, the signal (a) coming from the emitter/detector couple 302 is compared with a sampling signal (b) relating to the movement of the transport wheel 100. Said sampling signal preferably comes from the drive means and not from the wheel itself, since given the stepdown ratio introduced by the transmission mechanism 210, it would be almost impossible in practice to achieve an equivalent sampling frequency from the wheel that is as high as that which can be obtained from the motor 200.
For this purpose, FIG. 1 shows a coder such as a coding wheel 300 having slots 310 and an optical fork (not shown) is mounted on the shaft 214 of the motor 200. The wheel 300 is constrained to rotate with the motor 200 and thus also with the rotation of the coding wheel 100. The sampling signal (b) from the motor is constituted by a series of pulses, each pulse corresponding to a slot in the code wheel passing through the optical fork. Two consecutive pulses are spaced apart by a constant angular distance which corresponds, via the transmission mechanism 210, to a known angular pitch for rotation of the transport wheel 100. To convert to the linear pitch of advance of the coin 1, said angular pitch is multiplied by the distance of the detector couple 302 from the axis 101 of the wheel 100. It then suffices to count the number n2 of steps in the sampling signal (b) observed during the blanked-out time t2 to obtain an expression for the diameter as a number of steps, independently of the speed of rotation of the transport wheel 100.
The thickness e of the coin 1 is measured in analogous manner, as shown in FIGS. 4a and 4b. The coin 1 passes initially through the emitter/receiver couple 302 used for measuring its diameter, and then through an identical second couple 303 placed on a slant, e.g. at an angle of 45°. The measured time t3 is the time between passing through the first couple 302 and passing through the second couple 303. It will be observed that the thicker the coin 1, the shorter this time. The time t3 is then expressed in terms of the number n3 of linear sampling steps, giving L-e and thus e, L being known by construction.
Naturally, the sampling signals shown at (b) in FIG. 3b and at (c) in FIG. 4b could also be obtained by an encoder constrained to move with the transport wheel 100 itself. Such a device shall make it possible to use the measured movement of the wheel 100 directly as a reference. In this way, the diameter and thickness measurements are made independent of any possible variations in the speed of rotation of the wheel, whether arising from the drive system or from external disturbances, for example faulty gearing, inexact spacing, motor quality, or braking of the transport wheel 100. By way of example, said encoder is implemented by associating slots (not shown) formed at the circumference of the wheel with an optical sensor fork (not shown), in the same manner as the code wheel 300 having slots 310 in FIG. 1.
The metal constituting the coin 1 is analyzed as follows. As shown in FIGS. 5a and 5b, the coin 1 driven in the housing passes through a magnetic field induced by a first coil 311 of a magnetic cell 301, and fed with an AC signal of fixed level and frequency. A measurement is performed on a second or receiver coil 321 placed facing the first or transmitter coil 311. It is thus possible to assess at the receiver coil 321 the disturbance to the magnetic field caused by the coin 1 passing through, said disturbance being characteristic of the metal of the coil. A sampled curve is thus obtained over time by means of the code wheel 300, each sample E1, . . . , E8 corresponding, for example, to a precise position of the coin 1 in the magnetic cell 301.
In order to characterize coins better, and as can be seen in FIG. 5b, the transmission frequency F can be changed at the instant when the coin 1 has passed halfway through the cell 301, e.g. by switching from F to 4F. This transition appears in FIG. 5b between sample E4 and E5.
From the response curve of FIG. 5b, which constitutes a kind of curve representative of the magnetic signature of coins, it is possible to express the analysis of the metal in terms of characteristic values taken from the curve.
These characteristic values can be of several types:
Attenuation type: this consists in identifying the sample at which the magnetic signal has been subjected to a drop of x%. In FIG. 5b, points E1, E2, E3 on one side and E8, E7, E6 on the other side are samples at which the signal is attenuated by 25%, 50%, and 75% respectively on the falling flank and on the rising flank of the signal.
Ratio type: this consists in taking the ratio of pairs of typical values for the magnetic signal. By way of example, in FIG. 5, the following ratios can be used:
ratio 1=Vmin1/Vrest
ratio 2=Vmin2/Vrest
ratio 3=Vmin1/Vmin2.
Overall signature type: this consists in characterizing the curve as a whole by means of a single value, e.g. the integral of the entire curve (area beneath the curve).
The accuracy, and above all the reproducibility of these measurements, and in particular the thickness measurement, require the object whose conformity is being verified always to be presented in the same position relative to the pairs of optical sensors and to the magnetic cell. For this purpose, various dispositions can be taken.
As shown in FIG. 6, provision can be made for the transport wheel 100 to press against the reference plane P, which plane is inclined at an angle α of 10°, for example, relative to the vertical V. The object placed in the housing is thus held by its own weight against said reference plane at least while passing through the measurement zone ZM.
Also, as mentioned above, the pitch of the wormscrew 213 is handed so that friction against the teeth of the wheel 100 causes the wheel to be pressed against the reference plane P.
Finally, it is advantageous for the housing 110 to have edges 111 and 112 that come into contact with the object 1 (as shown in FIG. 1) that are of an inclined profile suitable for encouraging the holding of said object against the reference plane P, as can be seen in FIG. 6 for the edge 111.
As shown more particularly in FIG. 2c, at the outlet from the measurement zone ZM where the object 1 has been recognized as in conformity or not, the transport wheel 100 continues to rotate without interruption so that the path of the housing 110 also passes in continuous manner through a zone ZO where objects are accepted or rejected by being put through an encashment outlet 401 or a return outlet 402, the accept or reject zone ZO naturally being after the measurement zone ZM.
In the embodiment shown in FIGS. 2c, 2d, and 2e, the encashment and return outlets 401 and 402 are disposed in series relative to the continuous movement of the transport wheel 100. The encashment outlet 401 may be closed by a moving flap 400 situated at the periphery of the wheel. By way of example, said flap 400 is moved in translation parallel to the axis of rotation 101 of the wheel 100, with the stroke of the flap then being slightly greater than the thickness of the housing 110 formed in the wheel. For thicknesses that are small compared with the other dimensions, the resulting stroke is very small and therefore enables very fast translation to be performed between the open position and the closed position.
The flap 400 under the control of an electromagnet (not shown) is normally in its open position and it is moved into the closed position only if the object 1 is recognized as not being in conformity on leaving the measurement zone ZM.
Thus, in the accept or reject zone ZO, the object 1 is liable, under the effect of gravity, to pass through the encashment outlet 401 assuming the object has been recognized as being in conformity.
In contrast, if it has not been recognized as being in conformity, the object 1 cannot pass through the encashment outlet 401 because the moving flap 400 will previously have been put into the closed position. As the movement of the transport wheel 100 continues, the object 1 is then taken to the return outlet 402 which remains permanently open. The position of the housing 101 shown in FIG. 2e and corresponding to said housing being put into communication with the return outlet 402 constitutes the final or waiting position P2. It is in this position P2 that the continuous movement of the transport wheel 100 is interrupted, waiting for a new object to be inserted into the selector device.
This waiting position P2 serves as a reference for the movement of the transport wheel 100. For this purpose, a slot (not shown) is formed in the rim of the wheel, and when it comes into coincidence with an optical fork (not shown), it provides a reference signal. This signal in association with the sampling signals makes it possible at all times to know the exact position of the wheel 100.
When a metal object is engaged in the insertion orifice 10, a magnetic presence sensor controls the motor 200 to bring the housing 110 from the waiting position P2 to the initial position P1 where it is in communication with the insertion orifice 10 so as to restart the cycle described above.
In FIG. 2e, it will be observed that to provide protection against acts of vandalism, when the housing 110 is in the waiting position P2, the transport wheel 100 completely closes the insertion orifice 10, since the width of the orifice is smaller than that of the wheel rim.
Finally, as shown in FIG. 2b, and to avoid external disturbances, the measurement zone ZM is disposed on the path of the housing 110 so that the means 301, 302, 303 for identifying conformity can be put into operation with a passing object 1 only after the housing 110 has ceased to be in communication with the insertion orifice 10. This serves in particular to avoid interfering light having any influence on the optical measurements.
The housing 110 shown in FIGS. 1 to 2e includes two rectilinear contact edges 111 and 112. Nevertheless, as shown in FIG. 7, it can be advantageous, given that the objects 1 and 1' such as coins, have respective centers, for the edges 111 and 112 to be shaped in such a manner that the centers of said objects lie on a common circle C that is concentric with the transport wheel 100, and regardless of the diameter and the thickness of any particular object 1, 1'. The circle C preferably passes at least through the means 301 and 302 for taking geometrical measurements of the objects, concerning diameter and thickness, thus making it possible to obtain measurements that are absolute and independent of the size of a particular object. The optical radius of the emitter/receiver couples 302, 303 always follows the same circular arc on an object, which arc is directly represented by the diameter and thickness measurements. The rounded shape of the housing 110 eliminates any interdependence between the diameter measurement and the thickness measurement. | A selector device for selecting objects (1) inserted by way of payment into a dispenser of goods or services via an insertion orifice (10), the device comprising a transport member (100) provided with a housing (110) designed to receive the objects singly and suitable for bringing an object (1) placed in said housing (110) into a measurement zone (ZM) where sensors (301, 302, 303) are disposed for verifying conformity of the object (1). According to the invention, the selector device also comprises drive mechanisms (200, 210) suitable for imparting a non-reversible continuous movement to said transport member (100) along a path during which the housing (110) passes from an initial position (P1) of communication with the insertion orifice (10) to a final or waiting position (P2), while passing through the measurement zone (ZM) in continuous manner, the sensors (301, 302, 303) for verifying conformity receiving sampling signals sampling the movement of the transport member (100). Applicable to dispensing services such as tickets for travel or parking purposes. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a means for carrying a bottle. In particular, the present invention relates to means for crying a bottle from at the point of sale in a convenient and simple manner.
BACKGROUND OF THE INVENTION
[0002] When goods are purchased from shops and other retail outlets it is common that the sales person or cashier will provide a bag or other type of packaging to the customer in order to assist the customer in carrying the goods from the shop.
[0003] For example bottle shops and liquor stores will typically place bottles of wine, spirits or beer purchased by a customer in a brown paper at the point of sale. Typically brown paper bags are not provided with handles and do not provide any significant protective advantage, or handling advantage over carrying the bottle alone. Additionally the effectiveness of any advertising on a paper bag is also minimal.
[0004] In use, a paper bag is typically twisted around the neck of the bottle in the act of grasping the bottle around the neck in order to carry the bottle. Thus any advertising slogans or pictures printed on the paper bag are creased or obscured from view while the bottle is being carried.
[0005] In the current climate of environmental awareness it is also desirable that packaging and carrying means are provided which use less material in their construction.
[0006] Therefore, clearly it is desirable to provide a means for packaging bottles at the point of sale which address at least one of the above drawbacks of current methods.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention there is provided a carrying means for a bottle of the type having a body portion, a neck portion and a tapered portion extending therebetween, said carrying means including;
[0008] a first bottle retention loop adapted to receive the body of said bottle therein;
[0009] a carry handle connected to said first bottle retention loop;
[0010] a second bottle retention loop adapted to receive the neck of said bottle therein, and
[0011] a body portion connecting said first and second loops together, wherein, in use the body of said bottle is retained in said first loop, and the neck of said bottle is retained in said second loop, such that when said carrying means is suspended by said carry handle, said bottle is substantially supported by said second loop against the tapered portion of the bottle.
[0012] Preferably the carrying means is unitary in construction.
[0013] It is also preferable that the carrying means is made from paper, plastics, fabric or woodfree paper.
[0014] In a preferred embodiment at least a portion, of at least one surface of said carrying means, has a decorative design, advertisement, logo or picture displayed thereon. Preferably at least one surface of said body portion has an advertisement printed thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Notwithstanding any other forms which may fall within the scope of the present invention, preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0016] [0016]FIG. 1A shows a front view of a carrying means according to a first embodiment of the present invention;
[0017] [0017]FIG. 1B shows a rear view of the embodiment shown in FIG. 1A;
[0018] [0018]FIGS. 2A to 2 D show a front view, side view, rear perspective view and front perspective view respectively of the carrying means according to an embodiment of the present invention holding a bottle;
[0019] [0019]FIG. 3 shows a perspective view of a carrying means according to an embodiment of the present invention in use carrying a bottle;
[0020] [0020]FIG. 4 shows a further embodiment of a carrying means according to the present invention; and
[0021] [0021]FIGS. 5A and 5C show three embodiments of the carrying means according to the present invention adapted to hold 2 bottles.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0022] The detailed description given herein will describe a series of embodiments of the invention, in particular in relation to a means for carrying a bottle.
[0023] [0023]FIG. 1A shows a front view of a first embodiment of the carrying means according to the invention. The carrying means 100 includes an elongate body portion 110 having an aperture 120 extending therethrough. The body portion 110 extends around the aperture 120 to define a first loop 115 . The carrying means 100 also includes a carry handle 125 attached to the loop 115 . At the opposite end of the elongate body portion 110 to the carry handle 125 a second loop 130 is attached.
[0024] Turning now to FIG. 1B which shows the rear side of the carrying means 100 of FIG. 1A. The rear side of the carrying means 100 similarly includes an elongate body portion 110 , with an aperture 120 extending therethrough defining a first loop 115 . The carry handle 125 is attached to the rear surface 111 of the elongate body 110 at the loop portion 115 . The handle 125 can be attached with an adhesive such as glue or double-sided tape to the rear surface 111 of the elongate body 110 . Retention of the carry handle 125 is aided by the placement of a generally annular reinforcing patch 140 which is attached to the rear side 110 of the carrying means 100 . Similarly the second loop 130 is glued to the upper surface 111 of the body portion 110 and held in place via a second reinforcing patch 150 . In addition to holding the carry handle 125 and second retaining loop 130 in position, the reinforcing patches 140 , 150 provide additional strength to the carrying means 100 in positions with high mechanical stress.
[0025] The carrying means may be made from a suitably flexible yet strong fabric, plastics, paper or woodfree-paper material. In the embodiment shown in FIGS. 1A and 1B the body portion 110 can be made of a synthetic paper-like material such as Tyvek made by DuPont, and the handle 125 and retaining loop 130 may be made of a reinforced paper ribbon such as is commonly used in the art to make handles for brown paper bags. Alternatively the carry handle and second retaining loop, can be plastic carry handles, such as ScotchPad™ Carry Handles from by 3M.
[0026] In this embodiment, the carry handle 125 and the retaining loop 130 are glued to the body portion 110 and the reinforcing patches 140 and 150 are made from a self-adhesive fabric-backed tape, such as gaffer tape or book binding tape. Alternatively, the reinforcing patches 150 can be made of the same material as the body 110 of the carrying means and be attached using a suitable adhesive.
[0027] In use, the carrying means may be applied to a bottle by firstly placing the first retention loop 115 around the bottle such that the body of the bottle protrudes through the aperture 120 of the carrying means 100 .
[0028] In general, there is no requirement that the loop portion 115 of the carrying means 100 passes over the entire bottle from the narrower end to the wider end in order to attain a position around the wider end of the bottle. Ideally, the aperture 120 is of a dimension which allows the easy insertion of the bottle but it should not be so large as to allow the bottle to move around freely within the aperture. The chief purpose of the first loop 115 is not to support the weight of the bottle in the carrying means, but rather it is to retain the bottle in a substantially inverted vertical alignment such that it does not fall over or fall out of the carrying means 100 .
[0029] Next, the neck of the bottle is placed through the second loop 130 . The second loop 130 is then moved along the length of the bottle to be carried until the loop 130 attains a tight fit around the shoulder, between the neck and body of the bottle.
[0030] Once the second retention loop 130 is in a position such that it will not move further along the body of the bottle, the carrying means can be lied by the handle 125 . When the carrying means is lifted by the handle, the weight of the bottle in the carrying means is supported substantially by the second retention loop 130 against the taper of the bottle's shoulder. The body portion 110 of the carrying means 100 acts as a sling connecting the second retention loop 130 to the carry handle, whilst the first retention loop 115 maintains the bottle in vertical alignment.
[0031] It should be noted that when an bottle is lifted using the carrying means it may be possible that the second retention loop 130 will slide along the bottle. In order to prevent this the length of the body portion 110 should not be so long that the second retention loop slips off the base of the bottle. Additionally, it is preferable that the weight of the bottle is supported only by the second retention loop 130 and not by the first retention loop 115 . In order to ensure that this is the case aperture 120 should be sized such that the first retention loop 115 is a loose fit around the body of the bottle to be carried.
[0032] [0032]FIGS. 2A to 2 D show a carrying means 100 according to an embodiment of the invention being used applied to a bottle 200 . The bottle 200 is of the type having a body portion 210 and a relatively narrow neck portion 220 with a tapered region 215 located therebetween The bottle 200 additionally has a base 205 . It can be seen from FIGS. 2A to 2 D that the carrying means 100 is placed on the bottle such that the first retention loop 115 is located around the body portion 210 of the bottle 200 in a location adjacent to the base 205 and the second retention loop 130 is positioned around the tapered portion 215 of the bottle between the neck 220 and the body 210 . The elongated body portion 110 of the carrying means 100 is pulled taut along the length of the body 210 of the bottle 200 .
[0033] The carrying means 100 can be applied to a bottle in a number of different ways. Typically, the carrying means will be applied to the bottle while the bottle is standing in an upright position on its base 205 supported by a table, bench or other support means. In this position, the carrying means can be placed on the bottle by sliding the first retention loop 115 over the neck 220 of bottle 200 and sliding it down to a position in the vicinity of the tapered portion 215 of the, bottle. Next, the second retention loop 130 can be placed over the neck 220 over the bottle 200 and slid down to a position adjacent to the first retention loop 115 . From this position the first retention loop 115 can be slid along the body 210 of the bottle 200 until the body portion 110 of the carrying means 100 is pulled taut along the side of the bottle 200 and the second retention loop 130 is pulled along the neck until it becomes tight against the tapered portion 215 of the bottle. The bottle can then be turned over and carried by the carry handle 215 . It will be clear that many other methods of placing the carrying means 100 on a bottle or other bottle are available such as placing the bottle 200 base first 205 through the first retention loop 115 and then sliding the first retention loop up the body 210 of the bottle 200 toward the tapered portion 215 until the second retention loop 130 can be placed over the top of the neck 220 of the bottle 200 . The carrying means can be then slid toward the base 205 of the bottle 200 until the second retention loop 130 becomes tight around the tapered portion 215 of the bottle and the weight of the bottle may be supported via the carry handle 125 .
[0034] [0034]FIG. 3 shows an embodiment of the carrying means applied to a bottle 300 in use. It can be seen that the weight of the bottle 300 is supported from the user's hand by the carry handle 125 through the side portions 115 A of the first retention loop 115 and down through the body portion 110 of the carrying means 100 to the second retention loop 130 .
[0035] [0035]FIG. 4 shows a preferred embodiment of the carrying means according to the present invention. The carrying means 400 comprises a single sheet of paper, fabric, plastic, wood free paper or other suitable material. The carrying means 400 consists of a general elongate body portion 410 having a first retention loop 415 , a carry handle 425 and a second retention loop 435 being defined by a series of apertures 420 , 440 and 430 respectively. The first aperture 420 and third aperture 440 are located next to each other, and spaced apart by a small amount at a first end of the elongate body portion 410 . The piece of body material, which remains between the two apertures 420 and 440 provides a first retention loop 415 , and the strip of material which remains between the third aperture 440 and the outer periphery 401 of the carrying means defines a carry handle 425 . Similarly, the second retention loop 435 is formed by leaving a strip of material between the outer periphery 401 of the packaging device 400 and the second aperture 430 .
[0036] In use, the carrying means 400 can be used in an identical fashion to the embodiment described in connection with FIGS. 1 to 3 .
[0037] The embodiment of the carrying means shown in FIG. 4 is particularly advantageous as it can, be made from a single sheet of suitable material. As discussed in connection with the embodiment of FIGS. 1 to 3 the carrying means can be made from fabric, paper, a synthetic paper alternative or plastics material. However, it should be noted that, as a single sheet of material is used in this embodiment and no reinforcing patches are used, the material from which this packaging is manufactured should be strong enough to support the weight of a full bottle adequately without tearing or stretching substantially.
[0038] [0038]FIGS. 5A, 5B and 5 C show three additional embodiments of the present invention which can be used to carry more than one bottle. These embodiments generally comprise a pair of package means as discussed in connection with FIGS. 1 to 4 , which are joined together, in order to allow two bottles to be carried. The 3 embodiments shown represent 3 configurations which may be obtained by joining 2 “single bottle” packages together at different positions.
[0039] Turning first to FIG. 5A which shows a carrying means 500 comprising an elongate body 510 with 3 pairs of apertures 521 , 540 , 550 , extending therethrough. The carrying means 500 is symmetrical about line A-A, with each half being adapted to carry one bottle. As discussed in connection with FIGS. 1 to 4 , the aperture is defined two retention loops 555 , 531 and a handle 520 . In use, the carrying means 500 is folded along line A-A to produce two identical, carrying means joined by the handle. As this embodiment is adapted to carry a greater weight than the embodiment of FIGS. 1 to 4 , it may be necessary to reinforce the handle portion 520 with a reinforcing patch as discussed in connection with FIGS. 1A and 1B. Alternatively, the material may be layered or laminated to provide additional strength over the entire carrying means 500 .
[0040] Turning now to FIG. 5B which shows an alternative embodiment of the carrying means 599 for carrying more than one bottle. In this embodiment, the carrying means 599 is symmetrical about line A-A providing two “single bottle” packages joined by their respective second retention loops 555 . As discussed in relation to FIG. 5A each half the carrying means 599 includes a series of three apertures thereby defining a first and second retention loops 530 and 550 respectively, and a carry handle 520 .
[0041] [0041]FIG. 5C shows a further alternative embodiment of a carrying means adapted to carry two bottles. The carrying means 598 includes a generally elliptical body portion 510 which is symmetrical about line A-A. This embodiment essentially represents 2 “single bottle” packages attached by their respective first retention loops 531 . Each half of the body portion 510 includes two apertures 530 , 550 which define two retention loops 531 and 555 in each half of the carrying means 598 . The carrying means 598 additionally includes a handle 600 which is attached to the body 510 of the carrying means 598 along the centre line A-A. The handle 600 can be made of suitable material such as reinforced paper or polymer material as discussed in connection with the embodiment of FIGS. 1A and 1B. The handle 600 is attached along the centre line A-A of the carrying means 598 , and in use defines a line along which the package will naturally fold.
[0042] In a preferred embodiment of the carrying means according to an invention, the surfaces of the carrying means can be adorned with decorative designs or advertising material advertising either the retail outlet selling the bottle to be carried, the supplier of the bottled product or a third party. The advertising slogans or images can be applied to the carrying means during manufacture, by simply printing the designs or advertisements onto the surface of the material from which the carrying means is made either prior to cutting the material or on the finished product.
[0043] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention.
[0044] The foregoing describes embodiments of the present invention and modifications, obvious to those skilled in the art can be made thereto, without departing from the scope of the present invention. | The present invention relates to a means for carrying a bottle ( 100 ). According to a first aspect of the present invention there is provided a carrying means ( 100 ) for a bottle ( 350 ) having a body portion ( 110 ), a neck portion and a tapered portion extending therebetween, said carrying means including; a first bottle retention loop ( 115 ) adapted to receive the body of said bottle therein; a carry handle ( 125 ) connected to said first bottle retention loop ( 115 ); a second bottle retention loop ( 130 ), adapted to receive the neck of said bottle ( 300 ), therein, and a body portion ( 110 ) connecting said first and second loops together, wherein, in use the body of said bottle ( 300 ) is retained in said first loop ( 115 ), and the neck of said bottle is retained in said second loop ( 130 ), such that when said carrying means is suspended by said carry handle ( 125 ) said bottle ( 300 ) is substantially supported by said second loop ( 130 ) against the tapered portion of the bottle ( 300 ). | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of making a moulded plastics article, especially where the plastics is an epoxy resin cured with an anhydride hardener.
Epoxy resins can be used to make moulded articles by what is called the Automatic Pressure Gelation Process (APG). In this process which is described for example in GB 1323343 and EP 0333456 an epoxy resin and a curing agent are mixed at a temperature at which they are liquid, usually 40°-60° C. The mixture is then passed, under slight pressure, into a mould which is at a high enough temperature for gelling and curing to take place. Further mixture is supplied to the mould under the application of pressure to compensate for shrinkage of the composition until the composition has set.
Depending on whether a thick-walled or thin-walled casting is being made the technique is slightly different. In order to produce a thick-walled cured plastics moulding a pre-heated liquid casting resin composition which is capable of setting within a period of three to sixty minutes is poured into a preheated mould substantially without the application of pressure so as substantially to fill the mould, the temperature of the mould being sufficient to initiate curing of the resin composition and the temperature of the composition being at least 10% below the temperature of the mould, said temperatures being measured in degrees centigrade, the temperature of the mould and the temperature of the resin composition being selected such that the temperature in the centre of the moulding composition will not reach the temperature of the composition at the mould wall until the composition has set sufficiently to enable it to be removed from the mould, and further composition is supplied to the mould with the application of pressure for compensating for shrinkage of the composition until the composition has set, whereafter the set moulding is removed from the mould.
In order to produce a thin-walled cured plastics moulding a pre-heated and de-gassed resin composition capable of setting within sixty minutes is supplied under pressure to a mould cavity of the shape of the moulding in a hotter pre-heated mould so as substantially to fill the mould cavity, gases are exhausted from the mould cavity as it is filled and are restrained from entering into the mould cavity during setting of the composition, and further composition is supplied under pressure to the mould cavity until the composition has set so as to compensate for shrinking of the composition, wherein the composition is pre-heated to a temperature of 50°-120° C. and is supplied to the mould cavity under a pressure of at least 4 psi (280 g/cm 2 ), the maximum temperature of the mould cavity is 120°-170° C. and the temperature of the mould is controlled to maintain a substantially linearly increasing temperature profile in the composition away from the entry for the composition into the mould cavity to peripheral regions of the cavity remote from the entry, whereby setting of the composition progresses through the mould cavity from locations remote from the entry back to the entry.
The typical epoxy resin/anhydride casting resin system comprises about 25-45% by volume of epoxy resin, 12-30% by volume of anhydride hardener and 30-65% by volume of mineral filler, together with minor levels of cure accelerator and other additives. As supplied to the processor the composition may be preformulated to reduce the number of parts needing to be mixed prior to use. In practice 2-part compositions are most popular although 3- or even 4-part compositions are not uncommon.
There are numerous disadvantages to this general form of presentation of the resin system.
Compounding of multi component blends is costly of time and labour. It introduces a high risk of operator error, particularly since large numbers of small batches are likely to be required and also because some of the components are used in relatively small amounts. Furthermore, costly facilities are necessary to prevent health hazards from inhalation of mineral fillers.
If compounded as a two part blend, the system is most usually processed through an automatic metering and mixing machine. Such equipment reduces labour and the risk of operator error, but incurs substantial extra capital costs.
Compounding as a two-part system creates difficulties in achieving the high loading of mineral fillers desirable from both cost and technical considerations. The liquid resin component can accommodate only about half as much filler as can the overall resin-hardener mixture. On the other hand, filling the hardener component creates severe problems of settlement during storage because of the very low viscosity of the normally used liquid anhydrides. Furthermore, the separate filling of both resin and hardener is inefficient because it involves an additional processing step with concomitant costs.
When processing the resin to make a moulded article, the resin is first preheated in an oven at about 90° C. The hardener is then added and the mixture is then mixed under vacuum to de-aerate it. The mixing temperature may be about 65° C. and the resulting mixture has a usuable life of about 3 hours at 65° C.
The mixture is then fed into a suitable mould and cured in the mould at 140°-190° C.
We have now found that it is possible to use a stable one-part system in the APG process which avoids the disadvantages of the conventional two or multi-part system and produces moulded articles at least as good.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a process for making a cured plastics moulding by introducing a pre-heated curable resin composition to a hotter mould which is at a temperature high enough to initiate curing of the resin, and supplying further resin under pressure to compensate for shrinkage of the composition, wherein the curable resin is an epoxy resin formulation comprising an epoxy resin containing more than one epoxide group per molecule on average, an acid anhydride hardener, an accelerator and a filler, the epoxy resin, hardener and accelerator being chosen so that the formulation is stable at 25° C. for at least 14 days.
DETAILED DESCRIPTION
When carrying out the process of the invention, the viscosity of the casting mixture should be in the range of 1000-5000 mPa s. Higher viscosities would necessitate the use of injection pressures in excess of 3 bar (0.3 MPa) which create unacceptable technical and safety problems. For the compositions used according to the invention the usable life or storage life is defined in terms of stability at 25° C., and the time quoted is that needed for the composition to double in viscosity at 25° C. Thus if a composition is said to be stable for 30 days at 25° C., this means that it takes 30 days for the viscosity to double at 25° C. This ensures that the compositions can be used in the process without needing to use the excessively high pressures mentioned above.
The curable epoxy resin formulation may be made by mixing the components in any order and at any temperature subject to two criteria, namely that the mixture viscosity can be accommodated by the mixer and that the temperature is substantially below the temperature of onset of the cure reaction. A margin of 50° C. is widely regarded as a desirable margin of safety in the latter respect.
A preferred process for producing a formulation containing a large amount of filler is to charge warm epoxy resin to a vessel, mix in any antioxidant and other minor additives, then about half of the filler, then all the hardener then, finally, all the remaining filler and catalyst (accelerator). The temperature may be allowed to fall as the filler and hardener are added.
It should be noted that the epoxy resin should be sufficiently hot for difficultly soluble additives to dissolve, for instance some antioxidants require a temperature of about 100° C. Also, in order to prevent premature reaction or reaction runaway, the mixture should be significantly lower in temperature than the activation temperature of the catalyst and the temperature of the walls of the vessel should also be at this lower level. Therefore the mixture should not be heated during or after addition of catalyst.
Accordingly, a more preferred process for producing a formulation comprises heating the epoxy resin to a temperature high enough to dissolve in antioxidant, dissolving this in the resin, adding about half the filler plus pigments and any other minor additives other than the catalyst and allowing the temperature to fall to about 50° C., adding the anhydride hardener, followed by the remaining filler, keeping the temperature at about 50° C., if necessary adjusting the temperature down to a level which ensures an adequate margin of safety between the mixture temperature and the activation temperature of the catalyst, and with the vessel unheated, adding the catalyst and stirring under vacuum until homogeneous.
The resulting mixture has a shelf life at 25° C. of at least 14 days and preferably at least 30 days. The shelf life is increased if the mixture is kept at a lower temperature, and is stable for several months if kept under refrigerated conditions.
Suitable epoxides include polyglycidyl esters, polyglycidyl ethers, and cycloaliphatic epoxides.
Epoxides which may be employed are preferably those containing, on average, more than one group of formula ##STR1## directly attached to an atom or atoms of oxygen or nitrogen, where R 1 denotes a hydrogen atom or a methyl group.
As examples of such epoxides may be mentioned polyglycidyl and poly(beta-methylglycidyl) esters obtainable by reaction of a compound containing two or more carboxylic acid groups per molecule with epichlorohydrin, glycerol dichlorohydrin, or beta-methylepichlorohydrin in the presence of an alkali. Such polyglycidyl esters may be derived from aliphatic polycarboxylic acids, e.g. oxalic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, or dimerised or trimerised linoleic acid; from cycloaliphatic polycarboxylic acids such as tetrahydrophthalic acid, 4-methyltetrahydrophthalic acid, hexahydrophthalic acid, and 4-methylhexahydrophthalic acid; and from aromatic polycarboxylic acids such as phthalic acid, isophthalic acid, and terephthalic acid.
Further examples are polyglycidyl and poly(beta-methylglycidyl)ethers obtainable by reaction of a compound containing at least two free alcoholic hydroxyl and/or phenolic hydroxyl groups per molecule with the appropriate epichlorohydrin under alkaline conditions or, alternatively, in the presence of an acidic catalyst and subsequent treatment with alkali. These ethers may be made from acyclic alcohols such as ethylene glycol, diethylene glycol, and higher poly(oxyethylene)glycols, proparte-1,2-diol and poly(oxypropylene)glycols, proparte-1,3-diol, butane-1,4-diol, poly(oxytetramethylene) glycols, pentane-1,5-diol, hexane-1,6-diol, hexane-2,4,6-triol, glycerol, 1,1,1-trimethylol-proparte, pentaerythritol, sorbitol, and polyepichlorohydrins; from cycloaliphatic alcohols such as resorcitol, quinitol, bis(4-hydroxycyclohexyl)methane, 2,2-bis(4-hydroxycyclohexyl)proparte, and 1,1-bis(hydroxymethyl)cyclohex-3-ene; and from alcohols having aromatic nuclei, such as 2,4-(dihydroxymethyl)benzene. They may also be made from mononuclear phenols, such as resorcinol and hydroquinone, and from polynuclear phenols, such as bis(4-hydroxyphenyl)methane, 4,4'-dihydroxydiphenyl, 1,1,2,2-tetrakis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl)-proparte, 2,2-bis(3,5-dibromo-4-hydroxyphenyl)proparte, and novolaks formed from aldehydes such as formaldehyde, acetaldehyde, chloral, and furfuraldehyde, with phenols such as phenol itself, and phenol substituted in the ring by chlorine atoms or by alkyl groups each containing up to nine carbon atoms, such as 4-chlorophenol, 2-methylphenol, and 4-tert-butylphenol.
Epoxides in which some or all of the epoxide groups are not terminal may also be employed, such as vinylcyclohexane dioxide, limonene dioxide, dicyclopentadiene dioxide, 4-oxatetracyclo[6,2.1.0 2 ,7.0 3 ,5 ]undec-9-yl glycidyl ether, the bis(4-oxatetracyclo[6.2.1.0 2 ,7.0 3 ,5 ]undec-9-yl ether of ethylene glcyol, 3,4-epoxycyclohexylmethyl 3',4'-epoxycyclohexane carboxylate and its 6,6 1 dimethyl derivative, the bis(3,4-epoxycyclohexane-carboxylate) of ethylene glycol, 3-(3,4-epoxycyclohexyl)-8.9-epoxy-2,4-dioxaspire[5,5]undecane, and epoxidised butadienes or copolymers of butadiene with ethylenic compounds such as styrene and vinyl acetate.
Epoxide resins having the 1,2-epoxide groups attached to different kinds of hetero atoms may be employed, e.g. the glycidyl ether-glycidyl ester of salicyclic acid. If desired, a mixture of epoxide resins may be used.
Preferred epoxides are polyglycidyl esters, polyglycidyl ethers of 2,2-bis(4-hydroxyphenyl)proparte, of bis(4-hydroxyphenyl)-methane or of a novolak formed from formaldehyde and phenol, or phenol substituted in the ring by one chlorine atom or by one alkyl hydrocarbon group containing from one to nine carbon atoms, and having a 1,2-epoxide content of at least 0.5 equivalent per kilogram, and 3,4-epoxycyclohexylmethyl 3',4'-epoxycyclohexane carboxylate.
The epoxy resin should be pure enough and have a low hydroxyl content so as to give stability in the presence of the hardener.
The hardener is preferably an acid anhydride. Suitable anhydrides are either liquid, or solids having a melting point of less than 50° C. Anhydride hardeners suitable for use include methyltetrahydrophthalic anhydrides, hexahydrophthalic anhydride, methylhexahydrophthalic anhydrides, methylendo methylenetetrahydrophthalic anhydrides, tetrahydrophthalic anhydride, phthalic anhydride, alkenylsuccinic anhydrides, maleic anhydride, succinic anhydride, glutaric anhydride or fumaric anhydride. Mixtures of such anhydrides may be used advantageously to depress the individual melting point and thereby repress crystallization of anhydride out of the one part casting mixture.
The anhydride hardener should have a low acid content in order to ensure stability of the formulation.
The accelerator may be any that enables the final mixture to have a shelf life of at least 14 days at 25° C. In order to achieve this, the accelerator should only become active at a temperature of at least 50° C. Thus the accelerator may be a latent accelerator or a non-latent accelerator which is protected by microencapsulation in heat sensitive barriers or by adsorption into molecular sieves.
Suitable latent accelerators include boron trihalide complexes of alkyldimethylamines having 1 to 18 carbon atoms in the alkyl groups, for example trimethylamine or n-decyldimethylamine or of aralkyldimethylamines, for example benzyldimethylamine. The boron trihalide is preferably boron trichloride, other suitable accelerators include quaternary ammonium or phosphonium salts, complexes of heavy metal carboxylates with imidazoles, or non-latent amine or imidazole accelerators protected by microencapsulation in heat sensitive barriers or by adsorption into molecular seives.
The filler is preferably one having a density similar to that of the rest of the mixture in order to minimise any settling or flotation. A wide range of fillers may be used, both fine and coarse particles. The filler may be inorganic such as china clay, calcined china clay, quartz flour, cristobalite, chalk, mica powder, glass powder, glass beads, powdered glass fibre, aluminium oxide and magnesium hydroxide, or organic such as powdered poly(vinyl chloride), nylon, polyethylene, polyester or cured epoxy resin. Flame retardant fillers such as trihydrated aluminium may also be used.
Mixtures of fillers may be used. For example in order to give a granite-like effect in a moulder product a mixture of calcined china clay and black mica of relatively large particle size may be used, for instance about 0.5 mm.
The filler may also have its surface treated with a silane or organotitanate coupling agent.
In general fillers having a particle size of from 10 to 3,000 microns may be used, preferably from 50 to 1000 microns. The amount of filler may be from 20-65% by volume of the total mixture, preferably from 40-60% by volume.
The maximum viscosity of the resulting mixture is preferably 25 Pa s at 50° C.
In order to assist in preventing any settling of the filler, a thixotropic agent may be added, but preferably in an amount less than is required to make the mixture thixotropic.
Suitable thixotropic agents include highly dispersed silicas, bentonite and silicates or organic compounds such as hydrogenated castor oil. The thixotropic agent is used in an amount less than that necessary to impart thixotropic properties to the resin. It may be used in amounts of from 0.5 to 10 parts by weight per 100 parts by weight of epoxy resin, preferably 1 to 3 parts by weight.
At higher temperatures such as those reached just prior to gelling in a mould, the viscosity of the mixture decreases and the thixotropic agent alone is insufficient to prevent the filler from settling. Its performance may be enhanced by the use of a polymer which dissolves in and thickens the hot mixture of epoxy resin and curing agent. This thickening prevents the filler from settling at temperatures up to the gelling temperature of the mixture.
Any polymer which is soluble in the hot mixture and enhances the effect of the thixotropic agent may be used. Examples of suitable polymers include poly(vinyl butyrals), polyoxyethylenes, poly(vinyl formals), polycaprolactones and polyamides. The polymer may be used in amounts of from 0.5 to 20 parts by weight per 100 parts by weight of epoxy resin, preferably from 1 to 3 parts by weight.
Other additives conventionally employed in moulding resin compositions may also be included in the composition. Examples of such additives are pigments, dyes, fibres such as glass and carbon fibres, flame retardants, antioxidants, light stabilisers, UV absorbers, surfactants, anti-foaming agents, toughening agents such as rubbers and core-shell polymers, and other stabilisers such as lower carboxylic acids.
Examples of suitable antioxidants include alkylated monophenols, alkylthiomethylphenols, hydroquinones and alkylated hydroquinones, hydroxylated thiodiphenyl ethers, alkylidenebisphonols, O-, N- and S-benzyl compounds, hydroxybenzylated malonates, hydroxybenzyl aromatics, triazine compounds, benzylphosphonates, acylaminophenols, esters and amides of β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionic acid, esters of β-(5-tert-butyl-4-hydroxy-3-methylphenyl)propionic acid, esters of β-(3,5-dicyclohexyl-4-hydroxyphenyl)propionic acid and esters of 3,5-di-tert-butyl-4-hydroxyphenyl acetic acid.
Examples of suitable UV absorbers and light stabilisers include 2-(2'-hydroxyphenyl)benzotriazoles, 2-hydroxybenzophenones, esters of substituted and unsubstituted benzoic acids, acrylates, nickel compounds, sterically hindered amines, oxalic acid diamides and 2-(2-hydroxyphenyl)-1,3,5-trizines.
When making the compositions according to the invention, the ingredients other than the hardener acid the accelerator are preferably added to the resin at elevated temperature at the beginning of the process.
When carrying out the process of the invention, there is no inherent hazard due to any exotherm because of the use of large amounts of filler. The high filler loading also means that there is less shrinkage when casting, the resulting cast product is harder, and the colour stability is better. In addition there is higher thermal conductivity when used in electrical applications.
The process of the invention may be used for the production of mouldings having thin or thick walls (cross sections). They are also particularly suitable for the production of mouldings having a large surface area, at least one large linear dimension or a complex shape. The compositions may be used, for instance, in the moulding of domestic sanitary ware such as sinks, baths, shower trays and basins, sheet slabstock for use in the production of articles such as domestic workshops, chemically resistant containers such as tanks and parts such as pumps, valves and pipes for handling corrosive fluids and impact-resistant mouldings for use in cars and other vehicles, and electrical applications.
When used to make a moulding no further mixing is required. It is only necessary for the user to preheat the mixture, e.g. to a temperature of 40° C. and then pump it directly to the mould.
There is no need for a de-aeration step. At a temperature of 40° C., the mixture has a usable life of about 48 hours.
The invention is illustrated by the following Example in which "parts" are parts by weight.
EXAMPLE
A diglycidyl ether of bisphenol A, having an epoxide content of 5.2 equivalents/Kg (100 parts) is heated to 100° C. A hindered phenol antioxidant (2.0 parts) is added to the hot diglycidyl ether of bisphenol A and the mixture stirred until the antioxidant has dissolved. Antifoam A, a proprietary air release agent, (0.1 parts); titanium dioxide (4.0 parts); A proprietary stearate treated calcium carbonate (10 parts); a proprietary calcined china clay (150 parts) are added and the temperature adjusted to 50° C. Methyltetrahydrophthalic anhydride (85 parts) is added, then further calcined china clay (160 parts) is incorporated under vacuum. With the temperature at 50° C. and vessel heating discontinued, a boron trichloride/N-octyldimethylamine complex (1 part) is incorporated under vacuum until the mixture is homogeneous. The mixture is then allowed to cool to give a storage stable formulation having a shelf life of 30 days at 25° C.
When moulded by the APG process to produce kitchen sinks, good sinks are obtained. | The present invention provides a process for making a cured plastics moulding by introducing a pre-heated curable resin composition to a hotter mould which is at a temperature high enough to initiate curing of the resin, and supplying further resin under pressure to compensate for shrinkage of the composition, wherein the curable resin is an epoxy resin formulation comprising an epoxy resin containing more than one epoxide group per molecule on average, an acid anhydride hardener, an accelerator and a filler, the epoxy resin, hardener and accelerator being chosen so that the formulation is stable at 25° C. for at least 14 days. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to photography, and, more particularly, to photographic apparatus for use in cameras of the type having distinct ambient and flash exposure modes of operation to measure scene brightness and provide the photographer with a signal which alerts him to the presence of a low scene brightness condition requiring that the camera be used in its flash mode of operation.
2. Description of the Prior Art
It is generally well known among photographers that the ambient light reflected from a scene to be photographed may be insufficient to take a sharp acceptably exposed picture without using a source of artificial illumination such as a photoflash lamp or strobe light. This is true for cameras which have manual shutters as well as for those which have automatic exposure control systems which have present programs of aperture and time that vary with scene brightness.
Determining exactly when it is too dark, however, is a fairly complex process which involves a consideration of such factors as film speed, camera exposure delivery capability, and the shutter speed at which camera motion is likely to cause blurred pictures. The relationships between these important factors and the brightness of the photographic scene may be correlated with the aid of a scene light brightness measuring device (light meter) to determine when it is necessary to use an auxiliary light source to avoid underexposed or blurred pictures or both.
Those skilled in the photographic arts have recognized the problem associated with determining when there is adequate ambient scene brightness and have provided scene light measuring apparatus by which a photographer is alerted that a scene brightness condition exists which will cause exposure problems.
For example, in U.S. Pat. No. 3,810,207 issued to Arthur Z. Mueller on May 7, 1974 and entitled "Exposure Control System", the patentee discloses a camera exposure control system which provides the photographer with a visual signal in the camera viewfinder that either an overexposure or underexposure condition exists. The exposure control system of this patent includes an exposure meter having light sensing means, such as a photocell, and drive means, such as a galvanometer. The light sensing and drive means are coupled in a manner which moves the drive means in relation to the intensity of the light sensed in the field of view of the camera. A lens system is included which defines an optical axis for the camera. Iris blade means are arranged to be driven across the optical axis between selected first and second positions. The blade means define an aperture means having a configuration which varies from a minimum to a maximum area so that the amount of light through the lens system is varied as the blade moves between the first and second positions. The aperture means is also arranged to maintain the minimum and maximum exposure areas for the lens system as the meter drive moves the blades a predetermined distance beyond the established first and second positions. Suitable indicia means are coupled to the blades to register overexposure when one of the blades moves beyond the second position and underexposure when another of the blades moves beyond the first position. No provision is made for taking flash pictures, and the exposure control system is only operative when the user depresses a switch which electrically connects the system to an electronic storage battery.
Another example is found in U.S. Pat. No. 3,855,601 issued to Takashi Uchiyama et. al. on Dec. 17, 1974 and entitled "Photometer". Here, the patentees provide a camera with a photometer capable of indicating the necessity of switching from a natural light exposure mode to a flash exposure mode or of automatically switching from the natural light exposure mode to the flash exposure mode, when the brightness of a portion of the field of view containing the object to be photographed becomes lower than that of the remaining field of view by more than a predetermined difference, regardless of the general level of brightness. This apparatus is relatively complex because of all the functions and decisions it is called upon to make and, as well, is only operative in response to the actuation of a multi-step camera actuating button.
A further example is described in U.S. Pat. No. 4,007,469 issued to Edwin H. Land et. al. on Feb. 8, 1977 and entitled "Photographic Apparatus with Plurality of Selectively Determinable Operational Modes". Here, the patentees disclose a camera having a viewfinder in which there is a plurality of selectively illuminable indicators, each responsive to a different set of conditions to produce an indication that the photographer should do something else in order to produce the correct exposure. A rather complex electronic circuit is provided for sensing the state of charge of a flash unit, the ambient light level, and a pair of shutter buttons and then indicating to the photographer, via the illuminable indicators, whether or not to make a flash exposure or an ambient light exposure, or displaying an appropriate indication to the operator of what to do next. The apparatus of this disclosure is also rather complicated because of its multi-functional nature and is not designed to be continuously on to determine the state of the ambient brightness level.
Therefore, it is a primary object of the present invention to provide a simple low scene brightness indicator for use in a camera to alert a photographer of the presence of a scene brightness condition which requires the use of a flashlamp or the like to get sharp adequately exposed photographs.
It is another object of the present invention to provide a low scene brightness indicator which continuously monitors the brightness of a photographic scene without operator intervention so long as the apparatus is connected with an appropriate power source.
It is another object of the present invention to provide a low scene brightness indicator having low power consumption characteristics which enable it to continuously monitor scene brightness levels over a relatively long period of time.
Other objects of the invention will in part be obvious and will in part appear hereinafter. The invention accordingly comprises the apparatus possessing the construction, the combination of elements, and arrangement of parts which are exemplified in the following detailed disclosure.
SUMMARY OF THE INVENTION
The present invention relates to a low scene brightness detecting and indicating apparatus in a camera of the type having distinct ambient and flash exposure modes of operation. The apparatus operates to provide the user with a visual signal which alerts him that it is too dark to take sharp well-exposed pictures without using the camera in its flash exposure mode of operation with an artificial light source to illuminate the scene to be photographed.
The camera comprises means for detecting the brightness of at least a portion of a scene to be photographed and providing an electrical output signal having a first characteristic whenever the scene brightness changes from a level below a predetermined reference scene brightness to a level at least equal to the predetermined reference scene brightness and having a second characteristic whenever the scene brightness changes from a level above the predetermined reference scene brightness to a level at least equal to the predetermined reference scene brightness. The predetermined reference scene brightness level defines a threshold scene brightness value above which the camera should be used in its ambient exposure mode of operation and below which the camera should be used in its flash exposure mode of operation with an artificial light source.
Additionally provided is a bistable magnetic indicator that is electrically energizable by the electrical output signal. The bistable magnetic indicator is mounted to provide a visual signal which indicates to the camera user which of the camera's exposure modes of operation should be used. The magnetic indicator is mounted with the camera for movement between a first stable position which indicates to the user that the camera should be used in its flash exposure mode of operation with an artificial light source and a second stable position which indicates that the camera can be used in its ambient exposure mode of operation. The magnetic indicator is moved into its first stable position in response to the electrical output signal when it has its second characteristic and into its second stable position in response to the electrical output signal when it has its first characteristic.
DESCRIPTION OF THE DRAWINGS
The novel features that are considered characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation together with other objects and advantages thereof will best be understood from the following description of the illustrated embodiment when read in connection with the accompanying drawings wherein like numbers have been employed in the different figures to denote the same parts and wherein;
FIG. 1 is a perspective view with parts broken away of a camera embodying the present invention;
FIG. 2 is a schematic of a circuit which forms part of the present invention;
FIG. 3 is a graph illustrating the variation in voltage of part of the circuit of FIG. 2 as a function of scene brightness; and
FIG. 4 is a side elevational view illustrating two positions of a portion of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a camera designated at 10 in which the present invention is incorporated.
The camera 10 is preferably a rigid body or box type camera and comprises a body 12, a front cover 14, and a door 16 which interconnect to define its outward appearance and serve as a protective enclosure for housing its interior components. The body 12, the front cover 14, and the door 16 are preferably fabricated of an opaque plastic using injection molding techniques in order to simplify their manufacture and reduce costs.
Located in a vertical forward wall 17 of the front cover 14 is a photographic objective taking lens 18 having an optical axis, OA, therethrough. The objective taking lens 18 is preferably a Cooke triplet or similar multi-element type of lens which may have its focal length changed by adjusting the axial air spacing between its optical elements. This may be accomplished in a well-known manner by rotating a bezel, such as that designated at 19, coupled with a screw-threaded lens mount (not shown).
Also located in the vertical forward wall 17 is an optical system 20 which is preferably used for collecting radiation in a selective manner from a photographic scene and directing the collected radiation onto a phototransducer (not shown) which, in turn, may be utilized to generate an output signal whose magnitude varies in accordance with the brightness of the photographic scene.
Generally designated at 22 is a well-known flash socket that is adapted to receive a linear photoflash array 24 which is also of a well-known type. Such a flash socket is described in considerable detail in, for example, U.S. Pat. No. 3,757,643 issued to John P. Burgarella on Sept. 11, 1973 and entitled "Photoflash Apparatus".
Included in the flash socket 22 are a pair of switch contacts 26 and 28 spaced apart to be normally open circuited. The linear flash array 24 includes a blade-like conducting strip 30 which contacts the switch contacts, 26 and 28, to provide an electrically conducting path between the switch contacts, 26 and 28, when the flash array 24 is inserted into the flash socket 22 (see FIG. 1). The purpose for shorting the contacts 26 and 28 will be explained more fully in the following discussion.
The camera 10 may be provided with a well-known electronic exposure control system by which a photographer may take pictures in either an ambient exposure mode of operation or a flash exposure mode of operation. In the ambient exposure mode of operation, available natural light is used as the source for illuminating the photographic scene and, in the flash exposure mode of operation, an artificial light source, such as the linear flash array 24, serves as the source for illuminating the photographic scene. A representative exposure control system which may be used to provide the camera 10 with its ambient and flash exposure modes of operation is described in detail in U.S. Pat. No. 4,035,813 issued to George D. Whiteside on July 12, 1977 and entitled "Exposure Control System for Selectively Determining Exposure Interval".
Located in the base of the body 12 is a well-known film cassette receiving chamber 32 that is adapted to hold a film cassette, such as that designated at 34, in position for exposure through the objective taking lens 18. The film cassette 34 is preferably of the type which includes a stacked array of self-processable type film units. Located in the base of the film cassette 34 is a rectangular flat thin battery 36 which may be used to supply power to the various electrical components of the camera 10. An example of such a film cassette is disclosed and described in detail in U.S. Pat. No. 3,872,487 issued to Nicholas Gold on Mar. 18, 1975 and entitled "Photographic Film Assemblage and Apparatus".
Extending rearwardly from the body 12 is an elongated hollow portion 38 of the body 12 in which is disposed a viewfinder 40. The viewfinder 40 is of the reversed Galilean type having an elongated eye relief aperture to improve magnification. Included in the viewfinder 40 is a viewfinder housing 42 which supports the various optical components of the viewfinder 40 and is configured to have an exterior geometry which is complementary to the interior geometry of the elongated viewfinder body portion 38. The rear end of the viewfinder housing 42 is supported at the rear end of the body portion 38 while its forward end is supported in a complementary configured aperture 43 located in the front cover 14.
The optical components of the viewfinder 40 comprise a negative lens 44 for forming a virtual image of a scene to be photographed and a positive eye lens 46 which is focused on the image plane of the negative lens 44 so that the virtual image may be observed. Spaced behind the positive eye lens 46 is an eye relief aperture 48 that is located at the rear end of the body portion 38. Those skilled in the art will recognize that the optical characteristics of the negative lens 44, the positive eye lens 46 and the spacing between these optical elements and the eye relief aperture 48 may be chosen so that the field of view of the viewfinder 40 may be made to be generally coextensive with the field of view of the camera 10. In this manner, viewfinder means are provided for the camera 10 which allow a photographer to aim the camera 10 so that the subject matter of the picture to be photographed may be framed within the field of view of the viewfinder 40.
Mounted on a bottom wall 49 of the viewfinder housing 42 is a bistable magnetic indicator 50 which, as will be seen, provides the photographer with a visual indication of which of the exposure modes of operation of the camera 10 to use. The bistable magnetic indicator 50 comprises an axle 52 which is disposed for rotation across an aperture 53 located in the bottom wall 49 of the viewfinder housing 42. As can be seen from FIG. 1, the aperture 53 is located between the positive eye lens 46 and the negative lens 44. The axle 52 is mounted in any conventional manner across the aperture 53 and transverse to the optical axis of the viewfinder 40 so that it freely rotates about it longitudinal axis.
Rigidly affixed to the axle 52 is a transparent flag 54 which rotates in conjunction with the rotation of the axle 52. The transparent flag 54 is preferably molded of a suitable plastic material which is preferably red in color. In its position shown in FIG. 1, the flag 54 occupies the entire field of view of the viewfinder 40. The density of the transparent flag 54 is preferably chosen so that the photographic scene can be observed through the viewfinder 40 when the ambient brightness level is relatively low (average room brightness) and the flag is in its position as illustrated in FIG. 1.
As best seen in FIG. 4 the transparent flag 54 includes a bent over base portion 55 which functions as a counterbalance to the upper portion of the flag 54 located above the axle 52.
Also included in the bistable magnetic indicator is a permanent magnet 56 which is rigidly affixed to one end of the axle 52. The permanent magnet 56 is disposed between a U-shaped ferromagnetic core 58 preferably formed of a material having a high magnetic retentivity. The U-shaped ferromagnetic core 58 includes a pair of free end portions, 60 and 62, respectively, and a base portion 64 around which is disposed a coil 66 for establishing the polarity of the free ends, 60 and 62. With this arrangement, the permanent magnet 56 is mounted between the free ends, 60 and 62, of the core 58 for rotation in conjunction with the axle 52 which is perpendicular to the plane of the core 58. Since the permanent magnet 56 carries the flag 54, the flag 54 may be positioned in or out of the field of view of the viewfinder 40 in accordance with the polarity of the free ends, 60 and 62, of the core 58.
The polarity of the free ends, 60 and 62, of the U-shaped core 58 is established by the direction of a current pulse which is fed into a pair of leads 59 and 61 that form a continuation of the coil 66. The leads, 59 and 61, are connected to an electronic control circuit generally designated as 72 which, among other things, provides the current pulses to change the state of the bistable magnetic indicator 50.
The bistable magnetic indicator 50 is preferably of the type which requires only a single current pulse to effect a switch in the polarity of the free ends 60 and 62. The polarity thereafter is maintained once the switching current pulse is removed. This polarity then may be changed to an opposite polarity by the application of another current pulse having a different direction. For a detailed description of a bistable magnetic device which is representative of the bistable magnetic indicator 50, referrence may be had to U.S. Pat. No. 3,540,038 issued to M. K. Taylor et. al. on July 31, 1969 and entitled "Multi-Color Single Axis Magnetically Actuated Display or Indicating Element".
Referring again to FIG. 1, there is shown an optical element 70 located in the vertical forward wall 17 of the front cover 14. Located behind the optical element 70, along an optical axis, OA, thereof is a photodiode 68. The purpose of the optical element 70 is to collect radiation from a select portion of the scene to be photographed and direct it onto the surface of the photodiode 68. The photodiode 68 in turn converts the light energy incident on its surface to an electrical output signal whose magnitude varies as a function of the intensity of the scene brightness. The output signal of the photodiode 68 is fed into the electronic control 72 where it is utilized in a manner to be subsequently described.
Also connected to the electronic control 72 via a pair of lines, 71 and 73, are the switch contacts, 26 and 28, respectively.
Turning now to FIG. 2 there is shown a schematic diagram for the circuitry of the electronic control 72 of this invention. The voltage required to operate the control circuit 72 and its associated elements may be derived from the battery 36 of the cassette 34 in a well-known manner. As an example, reference may be had to U.S. Pat. No. 3,705,537 issued to Richard Paglia on Dec. 12, 1972 and entitled "Apparatus for Interfacing Photographic Camera and Film Cartridge". The DC voltage of the battery 36 is connected between the terminal labeled V 0 and ground.
The photodiode 68 has its cathode connected to V 0 via a power line 74 and its anode connected to ground via a resistor 76. The anode of the photodiode 68 is also connected to the input of a level detector in the form of a Schmidt trigger 82 via a resistor 78.
Connected in this mode of operation, the photodiode 68 operates in a reversed biased manner to produce a current output which is linearly proportional to the intensity of the scene brightness as seen through the optical element 70. The current output of the photodiode 68 produces an IR drop, V S , across the resistor 76 (see FIG. 2). The voltage, V S , which provides the input signal to the Schmidt trigger 82, also varies linearly in correspondence with scene brightness. Curve 96 of FIG. 3 shows the variation of V S with average scene brightness where V S is expressed as a percentage of V O and average scene brightness is in units of candles/ft 2 . With this arrangement, the voltage across the resistor 78 provides a continuous input to the Schmidt trigger 82 so long as the photodiode 68 is coupled to V O .
The IR drop across the resistor 76 may be changed in accordance with the value of the resistor 76 so as to match the input requirements of the Schmidt trigger 82. Consequently the graph of FIG. 3 should be considered as illustrative of the type of variation in voltage which can be achieved using the arrangement thus far described. The absolute voltage, V S , will be a function of the particular characteristics of the photodiode chosen and the value of the resistor 76.
The photodiode 68 is preferably a silicon type which has the advantage of relatively fast response time, short memory, excellent linearity together with ready adaptability to convenient shapes and sizes. In addition, the spectral sensitivity of silicon can be readily controlled by appropriate color correction filters (not shown) to provide a photopic sensitivity if desirable.
Connected between the input of the Schmidt trigger 82 and ground is a low-frequency band pass filter comprising a capacitor 80 and the resistor 78 which cooperate with each other in a well-known manner to filter out low frequency noise which may be associated with the output signal of the photodiode 68.
The Schmidt trigger 82 is preferably a CMOS-IC having a high input impedance and a low output impedance and low power consumption characteristics.
The Schmidt trigger 82 is arranged to provide an output signal of opposite polarity to the input signal to provide a high output voltage signal (logic 1) at its output terminal whenever the average scene brightness changes from a value above a predetermined reference scene brightness level to a level at least equal to the predetermined reference scene brightness level, and a low output voltage signal (logic 0) whenever the scene brightness changes from a level below the predetermined reference scene brightness level to a level at least equal to the predetermined reference scene brightness level. The predetermined reference scene brightness level defines a scene threshold brightness above which the camera 10 should be used in its ambient exposure mode of operation and below which it should be used in its flash exposure mode of operation with an artificial source of illumination such as the linear flash array 24.
As illustrated in FIG. 3 there is a reference voltage which corresponds to the predetermined reference scene brightness level which defines the set point for the Schmidt trigger 82. For illustration purposes FIG. 3 indicates that the reference scene brightness level is 50 candles per square foot. However, it is obvious that the reference scene brightness level may be chosen to fit the particular circumstances of the camera with which the invention is to be used.
The Schmidt trigger 82 inherently includes some hysteresis. The hysteresis of the Schmidt trigger 82 should be chosen so that its triggering is less sensitive to small noise fluctuations in the signal level. If the hysteresis were, for example, ±10% of the reference voltage, as illustrated in FIG. 3, the logic 1 output signal would not be present unless the scene brightness changed from a level above approximately 55 candles per square foot to a level below approximately 45 candles per square foot. Conversely, the logic 0 signal would only be present when the scene brightness changed from a level below approximately 45 candles per square foot to a level above approximately 55 candles per square foot.
The output of the Schmidt trigger 82 is connected to the input of a conventional input inverting power amplifier 92 via a resistor 84. The amplifier 92 is also preferably fabricated as a CMOS-IC and provides a high output signal (approximately V O ) whenever the output of the Schmidt trigger 82 provides a logic 0 signal and a low output signal (substantially 0) whenever the output of the Schmidt trigger 82 provides a logic 1 signal.
Connected between the output of the Schmidt trigger 82 and ground is a voltage dividing network comprising a pair of resistors 86 and 88. In common connection to the resistors 86 and 88 is the base of an NPN transistor Q1. The collector of the transistor, Q1, is connected to the output of the Schmidt trigger 82 via the resistor 84, and the emitter of the transistor, Q1, is connected to ground via the switch contacts, 26 and 28, which, as will be recalled, are normally open circuited.
Also provided in the electronic control circuit 72 is a transistor switching network comprising a conventional NPN transistor Q3 and a conventional PNP transistor Q4. The transistors, Q3 and Q4, have their emitters coupled in common and their bases coupled in common. The bases of the transistors, Q3 and Q4, are connected to the output of the amplifier 92 which turns the transistor Q3 on when its output is high and turns the transistor Q4 on when the output is low.
The collector of the transistor, Q3, is connected to V O via the power line 74 while the collector of the transistor, Q4, is connected to ground.
A capacitor 94 is provided with its positive terminal coupled in common connection with the emitters of the transistors, Q3 and Q4, and its negative terminal coupled with one end of the coil 66. The remaining end of the coil 66 is coupled with ground. The capacitor 94 and the coil 66, thus arranged, enable the capacitor 94 to provide a current pulse through the coil 66 in one direction as the capacitor 94 is charged and a current pulse in the opposite direction as the capacitor 94 is discharged. As will be recalled, it is the direction of the current pulse through the coil 66 which establishes the polarity of the free ends, 60 and 62, of the U-shaped electromagnetic core 58.
Having described the construction of the invention and its control system, its operation will next be described with reference to FIGS. 2 through 4. In describing the operation of the invention, it is to be assumed that the electronic control 72 has been energized by the insertion of a film cassette into the camera 10. It will further be assumed that the average scene brightness level exceeds the reference scene brightness level so that the camera 10 can be operated in its ambient exposure mode of operation and that no artificial source of illumination, such as the linear flash array 24, is inserted into the camera 10. i.e., switch contacts, 26 and 28, are open circuited.
Under these conditions, the electronic control circuit 72 will be in a quiescent state. In this state, the current output of the photodiode 68 will be sufficient to create an IR drop across the resistor 76 which exceeds the reference voltage corresponding to the reference scene brightness level. In this condition, the output of the Schmidt trigger 82 is at a logic 0, and the output of the amplifier 92 is high so as to maintain transistor Q3 in a conductive state. At this time, there will be substantially no current flow through the coil 66 since the capacitor 94 is charged near the level of V 0 .
In this state, the free ends, 60 and 62, of the U-shaped ferromagnetic core 58 and the permanent magnet 56 are polarized in the manner illustrated in FIG. 4. With the polarities shown in FIG. 4, the flag 54 is biased in a down position as illustrated because of the magnetic torque generated by the differences in the polarities shown. When the flag 54 is in the down position, the photographer is presented with a clear field of view through the viewfinder 40 indicating that the camera should be used in its ambient exposure mode of operation.
When the camera is subjected to a change in the scene brightness from a high level above the reference scene brightness level to a level lower than that of the reference scene brightness level, the electronic control circuit 72 undergoes a transient condition which changes the polarity of the free ends, 60 and 62, of the U-shaped ferromagnetic core 58 thereby causing the sign 54 to assume its position as illustrated in FIG. 1. The transient condition of the electronic control circuit 72 occurs as follows. In going from a scene brightness level in excess of the reference scene brightness level to a scene brightness level below the reference scene brightness level, the current output of the photodiode 68 goes through a transition state from a high level to a low level causing the IR drop across the resistor 76 to pass through the hysteresis voltage zone of the Schmidt trigger 82 (see FIG. 3). When this occurs, the Schmidt trigger 82 produces a logic 1 at its output terminal causing the amplifier 92 to produce a low output voltage. The low output of the amplifier 92, in turn, biases the transistor Q4 on and turns off the transistor Q3. This causes the charged capacitor 94 to discharge through the coil 66 to ground. When this happens a transient current is momentarily caused to flow through the coil 66 from ground to the negative side of the capacitor 94. This current flow through the coil 66 causes the free ends, 60 and 62, of the ferromagnetic coil 58 to change polarity. The polarity assumed by the free ends, 60 and 62, of the ferromagnetic core 58, in response to the transient current thus induced in the coil 66, will be opposite to those illustrated in FIG. 4. This change is polarity in the free ends, 60 and 62, in turn causes a magnetic torque to rotate the sign 54 to its position illustrated in phantom in FIG. 4 and also shown in FIG. 1.
At this instant the capacitor 94 will be substantially discharged, and the current will substantially cease to flow through the coil 66. However, even though substantially no current flows through the coil 66, the bistable magnetic indicator 50 will remain in its second position as illustrated in FIG. 1 because of the high magnetic retentivity of the U-shaped ferromagnetic core 58, and it will remain in this position unit it receives another current pulse in the opposite direction as the capacitor 94 charges. The capacitor 94 will charge to provide the oppositely directed current pulse in response to the transistor Q3 being again turned on by the amplifier 92 assuming a high output voltage and the Schmidt trigger 82 switching back to a logic 0 output when the scene brightness changes from a low brightness level to a high brightness level above the reference scene brightness level.
When the transparent red flag 54 is positioned as shown in FIG. 1, the photographer is informed that the average scene brightness level is below the reference scene brightness level indicating that the camera 10 should be used in its flash exposure mode of operation with an auxilliary source of illumination.
Having been advised that the camera 10 should be used in its flash exposure mode of operation, the photographer then inserts the linear flash array 24 into the flash socket 22. When he does this, switch contacts 26 and 28 will short to connect the emitter of the transistor Q1 to ground. Thus insertion of the flash array 24 into the flash socket 22 causes the transistor Q1 to turn on and conduct. When Q1 is conducting, the logic 1 signal to the input of the amplifier 92 is substantially grounded. The output of the amplifier 92 therefore goes high thereby causing the transistor Q3 to turn on to provide a conductive path between V 0 and the positive end of the capacitor 94 and to cause transistor Q4 to turn off. The capacitor 94 then charges to a voltage level substantially equal to V 0 . Charging of the capacitor 94 in this manner causes a current to flow from the negative end of the capacitor 94 through the coil 66 to ground. This transient current, in turn, reverses the polarity of the free ends, 60 and 62, of the U-shaped ferromagnetic core 58 thereby causing the flag 54 to assume its position as illustrated in FIG. 4. Therefore, when the scene brightness level is below the reference scene brightness level and a flash array 24 is inserted into the flash socket 22, the flag 54 is moved out of the field of view of the viewfinder 40 to provide the photographer with a clear view of the scene to be photographed. This feature of the electric control circuit 72 therefore provides the camera 10 with a simulated high scene brightness condition whenever a flash array 24 is inserted in the camera 10 and the scene brightness is below the threshold value.
It can be appreciated by those skilled in the art that the invention thus described has low power consumption characteristics because of the components selected and because current only flows through the coil 66 whenever the camera experiences a change in scene brightness going from either a high scene brightness condition to a low scene brightness condition, or from a low scene brightness condition to a high scene brightness condition, or when a simulated high scene brightness condition is created by the insertion of a flash array 24 into the flash socket 22. The obvious advantage of this type of low scene brightness indicator is that it is automatically turned on when a film cassette is present in the camera 10 and can be allowed to remain on without any operator intervention for relatively long periods of time. This feature therefore eliminates the problems sometimes associated with other types of low scene brightness indicators because the photographer only has to look through the viewfinder in order to get an indication of whether or not the low scene brightness condition exists.
Certain changes may be made in the above described embodiment without departing from the scope of the invention, and those skilled in the art may make still other changes according to the teachings of the present invention. Therefore, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A photographic camera of the type having distinct ambient and flash exposure modes of operation is provided with a low power consuming, low scene brightness detecting and indicating apparatus by which a visual signal is displayed in the camera's viewfinder to alert the camera user of the presence of a low scene brightness condition requiring that the camera be used in its flash exposure mode of operation with an artificial light source to illuminate the scene. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is the U.S. national phase of PCT Appln. No. PCT/EP2009/058617 filed Jul. 7, 2009 which claims priority to German application DE 10 2008 040 475.6 filed Jul. 16, 2008.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an industrial method for preventing the polymerization of unsaturated organosilicon compounds in the preparation and handling thereof
2. Description of the Related Art
Organosilicon compounds having unsaturated organic functional groups, e.g. vinyl, acryl or methacryl groups, are widely employed as bonding agents between inorganic and organic materials, e.g. in sizes for glass fibers, as crosslinkers in organic polymers or for the treatment of fillers.
Processes for preparing such compounds comprise, for example, the reaction catalyzed by metal compounds between silanes having SiH bonds and multiply unsaturated organic compounds. A further customary route is reaction of chloroalkylsilanes with alkali metal (meth)acrylates. All these processes proceed exothermically at elevated temperatures. There is therefore a risk of polymerization of the products via the unsaturated organic group during the reaction, as a result of which product is lost and reaction apparatuses used have to be subjected to costly cleaning.
In addition, the silanes bearing unsaturated organic groups are usually purified by distillation, which likewise entails a considerable polymerization risk due to the thermal stress necessary for the distillation. Finally, there is also a risk of polymerization during storage of these compounds.
Various methods of minimizing the risk of polymerization of organosilicon compounds having unsaturated organic groups are known. U.S. Pat. No. 4,276,426 describes, for example, the synthesis of 3-methacryloxypropylsilanes from allyl methacrylate and various silanes having SiH bonds with rapid pump circulation of the reactants in a loop reactor, as a result of which polymerization can be prevented.
Numerous methods of preventing the polymerization of organosilicon compounds bearing unsaturated organic groups involve the use of free-radical polymerization inhibitors: DE 11 83 503 describes stabilization by addition of 50-500 ppm of hydroxyphenyl compounds such as hydroquinone or hydroquinone monomethyl ether together with 0.5-10% by weight of an alcohol which is soluble in water and the silane. DE 22 38 295 describes the use of quinones together with the corresponding enols. U.S. Pat. No. 4,563,538 describes stabilization of the unsaturated organosilicon compounds by means of 2,6-di-tert-butylbenzoquinone, while a combination of 2,6-di-tert-butylhydroquinone and methanol is used in U.S. Pat. No. 4,722,807. Another way is described in U.S. Pat. No. 4,894,398: here, stabilization of the unsaturated organosilicon compound is effected by addition of a sufficient amount of a hydroxylamine. DE 38 32 621 C1 describes the combination of two different polymerization inhibitors, consisting of a compound from the class of N,N′-disubstituted p-phenylenediamines and a compound from the class of 2,6-di-tert-butyl-4-alkylphenols. U.S. Pat. No. 4,780,555 describes a further method of preventing the polymerization of unsaturated organosilicon compounds: here, the combination of phenothiazine together with a gas atmosphere containing at least 0.1% by volume of oxygen, which is brought into contact with the unsaturated organosilicon compound, effects stabilization. A disadvantage of this method is the need for a defined amount of oxygen to be present, which is technically complicated, especially during a distillation, and is also disadvantageous in terms of safety. A further combination of compounds, which is described as having a stabilizing effect in U.S. Pat. No. 5,145,979, is a mixture of a sterically hindered phenol, an aromatic amine and an alkylamine. Further compounds which can be used for stabilizing organosilicon compounds bearing unsaturated organic functional groups are, for example, specific 2,6-dialkyl-4-N,N-dialkylaminomethylphenols, either alone or in combination with other compounds having a stabilizing effect (EP 0 520 477 B1), tertiary amines (DE 44 30 729 A1), nonaromatic, stable free radicals such as 2,2,6,6-tetramethylpiperidinyl oxide (“TEMPO”, U.S. Pat. No. 5,616,753, U.S. Pat. No. 5,550,272), N,N′-disubstituted p-quinodiimines (EP 0 708 081 B1), dialkylamides of unsaturated organic acids (e.g. in EP 0 845 471 A2), zinc salts of 2-mercaptobenzothiazole or dimethyldithiocarbamate (e.g. in EP 0 845 465 A2).
All the methods described have the disadvantages that relatively large amounts of stabilizing compound have to be added, generally 50-2000 ppm by weight based on the weight of the silane, that these compounds are often quite expensive, and that the methods described are often, as in the case of contacting with an oxygen-containing gas mixture, problematic in terms of safety. Furthermore, most of the compounds described still involve the risk, despite a stabilizing effect on unsaturated organosilicon compounds, that the unsaturated organosilicon compound will polymerize and thereby be lost. Finally, a further disadvantage is the fact that most of the compounds described as polymerization inhibitors are solids which can only be metered using complicated working steps or apparatuses.
U.S. Pat. No. 6,441,228 B2 describes the use of molybdenum-containing steel alloys in the synthesis of methacrylic acid. WO 2005/40084 describes the use of copper-containing alloys for the preparation, purification, handling or storage of ethylenically unsaturated compounds. A disadvantage here is the use of unconventional alloys.
SUMMARY OF THE INVENTION
It was therefore an object of the present invention to develop a method of preparing, purifying, handling or storing unsaturated organosilicon compounds, which is suitable for industrial production and does not have the disadvantages of the prior art. These and other objects are surprisingly achieved by processing in an industrial apparatus, at least 70% of the surfaces of which come in contact with the unsaturated organosilicon compound contain less than 1% iron.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention thus provides a method of preventing polymerization in the preparation or handling of unsaturated organosilicon compounds (S) of the general formula (1)
H 2 C═C(R 1 )[C(O)O] w (O) x —(R 2 ) y —Si(R 3 ) z (OR 4 ) 3-z (1)
where
R 1 is a hydrogen atom or a linear or branched hydrocarbon radical having 1-10 carbon atoms, R 2 is a linear or branched hydrocarbon radical which has 1-40 carbon atoms and may contain one or more heteroatoms selected from among the elements nitrogen, oxygen, sulfur and phosphorus, R 3 and R 4 are linear or branched hydrocarbon radicals having 1-10 carbon atoms, w can be 0 or 1, x can be 0 or 1, y can be 0 or 1 and z can be 0, 1 or 2,
where w and x must not at the same time be 1,
wherein at least one step of the preparation or handling is carried out in an industrial apparatus (A) whose surfaces which come into contact with the organosilicon compounds (S) comprise at least 70% of an iron-free material, where a material is designated as iron-free when it contains less than 1% by weight of iron,
and the industrial apparatus (A) is either an apparatus for a batch process having a fill volume of at least 200 l or an apparatus for a continuous process having a throughput of at least 15 l/h.
When iron-free materials are used, the polymerization of organosilicon compounds (S) is greatly slowed or completely prevented during the preparation or handling thereof.
The method prevents polymerization in all preparative or handling steps such as synthesis; purification such as separation of a solid from the organosilicon compound (S) by filtration, distillative purification of the organosilicon compound (S) by removal of low-boiling impurities or distillative purification of the organosilicon compound (S) by distillation of the organosilicon compound (S) itself; transport and storage; and further processing to produce downstream products.
The surfaces of the apparatus (A) which come into contact with the organosilicon compound (S) preferably comprise at least 90% and more preferably 99% of an iron-free material. Here, the term iron-free means that the respective material contains less than 1% by weight of iron, preferably less than 0.1% by weight, more preferably less than 0.01% by weight, and in particular less than 0.001% by weight, of iron.
Examples of iron-free materials are glass, enamels, nickel, copper, titanium, zirconium, niobium, tantalum and alloys thereof having an iron content of <0.5% by weight, plastics such as PTFE, graphite, oxide ceramics such as aluminum oxide, silicon carbide and silicon nitride. Preference is given to metal-free materials such as glass, enamels, plastics such as PTFE, graphite, oxide ceramics such as aluminum oxide, silicon carbide and silicon nitride. Particular preference is given to glass, enamels, graphite, oxide ceramics such as aluminum oxide, silicon carbide and silicon nitride, in particular glass, enamels and graphite.
The synthesis of the unsaturated organosilicon compounds (S) can be carried out in various ways. Thus, the reaction of unsaturated organic compounds such as ethyne or allyl methacrylate with silicon compounds having Si—H bonds in the presence of catalysts, e.g. platinum compounds, leads to the desired unsaturated organosilicon compounds (S).
Particular preference is given to the synthesis in which silanes (S) of the general formula (2)
H 2 C═C(R 1 )C(O)O—(R 2 ) y —Si(R 3 ) z (OR 4 ) 3- z (2)
are prepared from a haloalkylsilane of the general formula (3)
X—(R 2 ) y —Si(R 3 ) z (OR 4 ) 3- z (3)
and a salt of a (meth)acrylate having anions of the general formula (4)
H 2 C═C(R 1 )C(O)O − (4)
where X is a halogen atom and all other variables are as defined for the general formula (1).
This synthesis is frequently carried out in the presence of a phase transfer catalyst. Examples of such phase transfer catalysts are tetraorganoammonium or tetraorganophosphonium salts. The reaction is preferably carried out at temperatures in the range from 60 to 150° C. and more preferably at temperatures in the range from 70 to 120° C. The halogen salts formed as by-product and any residues of the (meth)acrylate salts with anions of the general formula (4) which may be present are preferably separated off by filtration. The product is then preferably purified by distillation, with one or more purification steps being carried out.
Low-boiling impurities are preferably separated off first by distillation. This preferably occurs under reduced pressure and at temperatures in the range from 20 to 120° C., preferably from 40 to 80° C. The silane (S) of the general formula (2) itself may subsequently be distilled, with this distillation step, too, preferably being carried out under reduced pressure so that the temperature at the bottom during the distillation is below 200° C., preferably below 150° C. and most preferably below 130° C.
In the general formulae (1) to (4), R 1 is preferably a hydrogen atom or an alkyl radical having 1-3 carbon atoms, in particular CH 3 ; R 2 is preferably an alkyl radical having 1-6 carbon atoms, in particular a CH 2 or (CH 2 ) 3 group; R 3 is preferably CH 3 or an ethyl radical; and R 4 is preferably a methyl, ethyl, propyl or isopropyl radical, with particular preference being given to methyl and ethyl radicals. X is preferably chlorine or bromine, particularly more preferably chlorine.
In the preparation or handling of the unsaturated organosilicon compounds (S), conventional stabilizers such as hydroquinone, hydroquinone monomethyl ether, phenothiazine, N,N-disubstituted aminomethylenephenols and/or oxygen can be present.
Examples of apparatuses (A) for the preparation or handling of unsaturated organosilicon compounds (S) of the general formula (1) or (2) are stirred vessels, tube reactors, distillation columns and internals and packings therein, thin film evaporators, falling film evaporators, short path distillations, including internals thereof, e.g. wipers in thin film evaporators, and also heat exchangers and tanks.
In a preferred embodiment of the invention, the apparatuses (A) are stirred vessels for a batch synthesis and/or distillation of the organosilicon compounds (S) having a fill volume of at least 200 l, with particular preference being given to fill volumes of at least 500 l or at least 1000 l.
In a further preferred embodiment of the invention, the apparatuses (A) are reactors for a continuous synthesis having a throughput of at least 15 l/h, with particular preference being given to throughputs of at least 30 l/h or at least 100 l/h.
In a further preferred embodiment of the invention, the apparatuses (A) are thin film evaporators, falling film evaporators or short path distillations having a throughput of at least 15 l/h, with particular preference being given to throughputs of at least 30 l/h or at least 50 l/h.
The process steps carried out in apparatuses (A) are preferably those in which the unsaturated organosilicon compounds (S) of the general formula (1) or (2) are thermally stressed, e.g. the synthesis and the purification by distillation. The purification by distillation is particularly preferably carried out in apparatuses (A). Preference is given here to using an apparatus (A) for a batch distillation, more preferably a thin film, falling film or short path evaporator. The thin film, falling film or short path evaporator may in this case be of a single-stage design, e.g. when only the low boilers have to be removed to achieve sufficient purification of the product, or else in a two-stage process the low boilers are separated off first and the product itself is distilled in the second pass through an evaporator. It is likewise possible to use a two-stage thin film, falling film or short path evaporator, with the low boilers being removed in the first stage and the product itself being distilled in the second stage. In this case, any thin film evaporator stage represents an apparatus (A) for the purposes of the present invention. In a preferred embodiment, only one of the two thin film evaporator stages consists of an apparatus (A), but preference is given to both thin film evaporator stages being apparatuses (A).
In a preferred process, at least two of the process steps selected from the synthesis of organosilicon compounds (S), separation of a solid from the organosilicon compounds (S) by filtration, distillative purification of the organosilicon compounds (S) by removal of low-boiling impurities or distillative purification of the organosilicon compounds (S) by distillation of the organosilicon compounds (S) themselves are carried out in an industrial apparatus (A) having the abovementioned properties. Particular preference is given to carrying out all process steps in such apparatuses (A).
Examples of unsaturated organosilicon compounds (S) of the general formula (1) are vinylsilanes such as vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriphenyloxysilane, vinyltriisopropoxysilane, vinyltris(2-methoxyethoxy)silane, vinyl(dimethoxy)methylsilane, vinyl(diethoxy)methylsilane, vinyl(diphenyloxy)methylsilane, vinyl(diisopropoxy)methylsilane, vinylbis(2-methoxyethoxy)methylsilane, allylsilanes such as allyltrimethoxysilane, allyltriethoxysilane, allyltriphenyloxysilane, allyltriisopropoxysilane, allyltris(2-methoxyethoxy)silane, allyl(dimethoxy)methylsilane, allyl(diethoxy)methylsilane, allyl(diphenyloxy)methylsilane, allyl(diisopropoxy)methylsilane, allylbis(2-methoxyethoxy)methylsilane, 3-allyloxypropyltrimethoxysilane, 3-allyloxypropyltriethoxysilane, 3-allyloxypropyltriphenyloxysilane, 3-allyloxypropyltriisopropoxysilane, 3-allyloxypropyltris(2-methoxy-ethoxy)silane, acrylsilanes such as acryloxymethyltrimethoxysilane, acryloxymethyltriethoxysilane, acryloxymethyltriphenyloxysilane, acryloxymethyltriisopropoxysilane, acryloxymethyltris(2-methoxyethoxy)silane, acryloxymethyl(methyl)dimethoxysilane, acryloxymethyl(methyl)diethoxysilane, acryloxymethyl(methyl)diphenyloxysilane, acryloxymethyl(methyl)diisopropoxysilane, acryloxymethyl(methyl)bis(2-methoxyethoxy)silane, acryloxymethyl(dimethyl)methoxysilane, acryloxymethyl(dimethyl)ethoxysilane, acryloxymethyl(dimethyl)phenyloxysilane, acryloxymethyl(dimethyl)isopropoxysilane, acryloxymethyl(dimethyl)(2-methoxyethoxy)silane, 3-acryloxypropyltrimethoxysilane, 3-acryloxypropyltriethoxysilane, 3-acryloxypropyltriphenyloxysilane, 3-acryloxypropyltriisopropoxysilane, 3-acryloxypropyltris(2-methoxyethoxy)silane, 3-acryloxypropyl(methyl)dimethoxysilane, 3-acryloxypropyl(methyl)diethoxysilane, 3-acryloxypropyl(methyl)diphenyloxysilane, 3-acryloxypropyl(methyl)diisopropoxysilane, 3-acryloxypropyl(methyl)bis(2-methoxyethoxy)silane, 3-acryloxypropyl(dimethyl)methoxysilane, 3-acryloxypropyl(dimethyl)ethoxysilane, 3-acryloxypropyl(dimethyl)phenyloxysilane, 3-acryloxypropyl(dimethyl)isopropoxysilane, 3-acryloxypropyl(dimethyl)(2-methoxyethoxy)silane or methacrylsilanes such as methacryloxymethyltrimethoxysilane, methacryloxymethyltriethoxysilane, methacryloxymethyltriphenyloxysilane, methacryloxymethyltriisopropoxysilane, methacryloxymethyltris(2-methoxyethoxy)silane, methacryloxymethyl(methyl)dimethoxysilane, methacryloxymethyl(methyl)diethoxysilane, methacryloxymethyl(methyl)diphenyloxysilane, methacryloxymethyl(methyl)diisopropoxysilane, methacryloxymethyl(methyl)bis(2-methoxyethoxy)silane, methacryloxymethyl(dimethyl)methoxysilane, methacryloxymethyl(dimethyl)ethoxysilane, methacryloxymethyl(dimethyl)phenyloxysilane, methacryloxymethyl(dimethyl)isopropoxysilane, methacryloxymethyl(dimethyl)(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane, 3-methacryloxypropyltriethoxysilane, 3-methacryloxypropyltriphenyloxysilane, 3-methacryloxypropyltriisopropoxysilane, 3-methacryloxypropyltris(2-methoxyethoxy)silane, 3-methacryloxypropyl(methyl)dimethoxysilane, 3-methacryloxypropyl(methyl)diethoxysilane, 3-methacryloxypropyl(methyl)diphenyloxysilane, 3-methacryloxypropyl(methyl)diisopropoxysilane, 3-methacryloxypropyl(methyl)bis(2-methoxyethoxy)silane, 3-methacryloxypropyl(dimethyl)methoxysilane, 3-methacryloxypropyl(dimethyl)ethoxysilane, 3-methacryloxypropyl(dimethyl)phenyloxysilane, 3-methacryloxypropyl(dimethyl)isopropoxysilane, 3-methacryloxypropyl(dimethyl)(2-methoxyethoxy)silane.
Examples of particularly preferred unsaturated organosilicon compounds (S) of the general formula (2) are those in which R 2 is a methylene group. These silanes often have a particularly high reactivity and, associated therewith, a particularly high tendency to polymerize. Very particular preference is given to: acryloxymethyltrimethoxysilane, acryloxymethyltriethoxysilane, acryloxymethyl(methyl)dimethoxysilane, acryloxymethyl(methyl)diethoxysilane, acryloxymethyl(dimethyl)methoxysilane, acryloxymethyl(dimethyl)ethoxysilane, methacryloxymethyltrimethoxysilane, methacryloxymethyltriethoxysilane, methacryloxymethyl(methyl)dimethoxysilane, methacryloxy(methyl)diethoxysilane, methacryloxymethyl(dimethyl)methoxysilane and methacryloxymethyl(dimethyl)ethoxysilane.
All the above symbols in the above formulae have their meanings independently of one another. In all formulae, the silicon atom is tetravalent.
In the following examples and comparative examples, all amounts and percentages are, unless indicated otherwise, by weight and all reactions are carried out at a pressure of 0.10 MPa (abs.) and a temperature of 20° C. BHT is butylhydroxytoluene (3,5-di-tert-butyl-4-hydroxytoluene).
Comparative Example 1
A crude batch of methacryloxymethyldimethoxymethylsilane (contains 3500 ppm of KOH) stabilized with 200 ppm of BHT and 200 ppm of phenothiazine was heated in air at 150° C. in a glass flask in the presence of stainless steel wool. The product gelled after 60 minutes.
Example2
A crude batch of methacryloxymethyldimethoxymethylsilane (contains 3500 ppm of KOH) stabilized with 200 ppm of BHT and 200 ppm of phenothiazine was heated in air at 150° C. in a glass flask in the absence of stainless steel wool. The product gelled after 180 minutes.
Comparative Example 3
A crude batch of methacryloxymethyldimethoxymethylsilane (neutralized with methanesulfonic acid) stabilized with 200 ppm of BHT and 200 ppm of phenothiazine was heated in air at 150° C. in a glass flask in the presence of stainless steel wool. The product gelled after 2 hours 20 minutes.
Comparative Example 4
A crude batch of methacryloxymethyldimethoxymethylsilane (neutralized with phosphoric acid) stabilized with 200 ppm of BHT and 200 ppm of phenothiazine was heated in air at 150° C. in a glass flask in the presence of stainless steel wool. The product gelled after 6 hours.
Example5
A crude batch of methacryloxymethyldimethoxymethylsilane (neutralized with methanesulfonic acid) stabilized with 200 ppm of BHT and 200 ppm of phenothiazine was heated in air at 150° C. in a glass flask in the absence of stainless steel wool. The product gelled after 7 hours.
Comparative Example 6
A crude batch of methacryloxymethyldimethoxymethylsilane (neutralized with phosphoric acid) stabilized with 200 ppm of BHT, 200 ppm of phenothiazine and 200 ppm of copper acetylacetonate was heated in air in a glass flask in the presence of stainless steel wool. The product gelled on heating to 120° C.
These laboratory-scale experiments show the influence of an iron-containing material on the stability.
Example7
Production in Enamel Vessel
A crude batch of methacryloxymethyldimethoxymethylsilane is prepared as described in DE 101,18,489 C1, but in an enameled stirred vessel from 200 kg of chloromethyl-dimethoxymethylsilane and potassium methacrylate.
Polymer formation is checked as follows:
1.5 ml of methacrylsilane are placed in a 20 ml snap-top bottle, 6 ml of isohexane are then added thereto and 6 ml of water are introduced as a layer under the mixture. The bottle is closed and shaken. After phase separation, the two-phase solution remains clear. 3 l of the crude batch are purified in a glass short path distillation (type) (80° C., 0.2 mbar). The bottoms are homogenous and have a low viscosity.
Comparative Example 8
Production in Steel Vessel
A crude batch of methacryloxymethyldimethoxymethylsilane is prepared as described in DE 101,18,489 C1 in an unenameled stirred vessel made of VA steel from 200 kg of chloromethyldimethoxymethylsilane and potassium methacrylate.
1.5 ml of methacrylsilane are placed in a 20 ml snap-top bottle, 6 ml of isohexane are then added thereto and 6 ml of water are introduced as a layer under the mixture. The bottle is closed and shaken. After phase separation, a lump of polymer is formed at the interface of the two phases.
3 l of the crude batch are purified in a glass short path distillation (type) (80° C., 0.2 mbar). The bottoms have gel-like lumps and are distinctly viscous.
Comparative Example 9
Distillation Using Steel Short Path Distillation
The crude batch from example 7 is distilled via a two-stage short path distillation (VA steel with graphite/PTFE wiper blades, evaporator area 0.25 m 2 , temperature 80° C., vacuum 0.2 mbar, throughput 25 kg/h). After 60 minutes, increased formation of polymer occurs, so that production is stopped.
Example10
Distillation Using Glass Short Path Distillation
The crude batch from example 7 is distilled via a single-stage short path distillation made of glass (QVF (Mainz, Deutschland), evaporator area 0.6 m 2 , temperature 120° C., vacuum 13 mbar, throughput 24 kg/h). The product can be distilled without formation of polymers. | Undesired polymerization of (meth)acrylatoalkoxysilanes during their industrial preparation and handling is accomplished by avoiding contact with surfaces containing more than 1% by weight of iron. | 2 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured, used and licensed by or for the United States Government for Governmental purposes without payment to us of any royalty thereon.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to fluidic elements and, more particularly, is directed towards fluidic systems having improved operating ranges.
2. Description of the Prior Art
One of the major problems present in laminar fluidic systems is the limited operating range of these systems due to the transition from laminar to turbulent flow. This phenomena exists in systems comprising active fluidic elements known as the laminar proportional amplifier (LPA) and laminar jet angular rate sensor (LJARS). The laminar-to-turbulent transitional Reynolds number, N R , for a standard "C" format LPA is only about 1100 while a fully developed laminar pipe flow has a transitional N R of about 2300. Therefore there is room for improvement. The useful operating range of a standard LPA is also limited by its low pressure gain below a Reynolds number of about 500 and its variable pressure gain over its operating range.
The problem of premature laminar-to-turbulent transition is caused by flow noises generated by the supply nozzle and venting areas around the splitter in these active devices. At low Reynolds numbers, these flow noises can be dampened by the viscous action of the fluid. However, at high Reynolds numbers, they can trigger the laminar-to-turbulent transition and thus limit the operating range of the laminar flow fluidic devices. If these flow noises could be suppressed or dampened, the operating range can be extended.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of this invention to extend the operating range of fluidic systems.
Another object of the invention is to devise a technique for suppressing or damping flow noises that are generated in fluidic systems.
A further object of the invention is to produce a more constant pressure gain region within the laminar flow regime of fluid systems.
An additional object of the invention is to extend the operating range of fluidic systems without any modification to their basic configuration.
The foregoing and other objects are obtained in accordance with the present invention through the provision of a filter which comprises a thin laminate plate having a plurality of holes forming a screen. The filter is positioned between a vent laminate and exhaust laminate commonly found in fluidic systems. The placing of a filter in this manner breaks up large eddies coming from the supply nozzle and vent areas, thus reducing flow noises as the flow proceeds through the system. The reduction of flow noises increases the system's operating range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a typical laminate stack for a LPA integrated circuit assembly.
FIG. 2 shows a laminate with a LPA element formed therein with flow noises.
FIG. 3 shows turbulent non-uniform flow being transformed to a more uniform less turbulent flow.
FIG. 4 shows a filter screen that may be used in accordance with this invention.
FIG. 5 shows the stacking arrangement of an extended operating range LPA circuit assembly in accordance with this invention.
FIG. 6 shows a graph of the differential output pressure versus supply pressure in a LPA circuit assembly with and without filter screens.
FIG. 7 shows a graph of the blocked load pressure gain versus Reynolds number for a typical LPA circuit assembly.
FIG. 8 shows a graph of the blocked load pressure gain versus Reynolds number for an extended range LPA circuit assembly in accordance with this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, like reference numerals represent identical or corresponding parts throughout the several views. FIG. 1 illustrates an exploded perspective view of a previously known laminate stack buildup of a LPA integrated circuit fluidic assembly 1. Each laminate within the stack follows a standard "C" format. The standard laminate is planar with two flat sides 3.3 cm×3.3 cm (1.3 in.×1.3 in.) square and has a thickness which depends on the functional purpose and method of fabrication of the laminate. For stamped or photochemically milled laminates, individual laminate thicknesses are usually between 0.1 mm (0.004 in.) and 0.64 mm (0.025 in.). For ease of description all laminates will be refered to by their function according to the particular functional element formed therein.
FIG. 1 is an example of a two sided venting stacking arrangement for a single stage LPA integrated circuit assembly. An LPA laminate 2 is surrounded on both sides by vent laminates 3, vent collector laminates 4 and exhaust laminates 5. In addition to the LPA, vent and exhaust laminates shown, those of ordinary skill in the art will appreciate that gasket laminates are required to block off specific flow passages and transfer laminates are required to transfer a signal from one location to another. Filter screens are also used, located in the laminate stack near the base plate/manifold, for providing last chance filtering of dirt particles in the fluid.
Depending on amplifier design and operating conditions, satisfactory operation may be possible with the LPA laminate vented from only one side; a plain gasket would then be used adjacent the LPA laminate on the opposite side as the vent laminate.
During the operation of the amplifier assembly, fluid is injected into the supply nozzle of the LPA laminate. FIG. 2 shows a typical LPA laminate plate 2 with an LPA element 6 formed therein. The LPA has a supply nozzle 7, control nozzle 8, vents 9, output 10, and splitter 11. A differential output pressure is generated at the outputs 12. Flow noises in the form of large eddies are generated in the LPA element at the supply nozzle 7 and vents 9 creating turbulent flow. Breaking up this non-uniform turbulent flow will extend the operating range of the device. Using a filter screen, like the type used for filtering dirt, may break up this non-uniform turbulent flow.
FIG. 3 shows large eddies 13 creating turbulent flow 14 passing through a filter screen 15 forming small eddies 16 creating a more uniform flow 17. A filter screen 15 is shown in FIG. 4 comprising holes 18 of a diameter of about 0.25 mm and about 0.53 mm apart 19. In general, a screen with smaller openings can filter the flow noise better than a screen with larger openings. However, one also has to consider the area ratio between total openings and the screen. If this area ratio is too small, the flow resistance of the filter screen will waste too much energy because of the excessive pressure drop. Therefore one has to minimize this energy loss without compromising its performance. A filter screen with the dimension discussed herein has only a flow resistance of 0.01 mm Hg/LPM per screen for a 2.25 mm diameter screen. No discernable pressure flow difference is experienced with a screen with this resistance.
What is more important than the filter or screen size is the placement of the filter screens within the stack assembly. FIG. 5 shows a stacking arrangement for a two sided venting single stage LPA circuit assembly with the order of stacking as shown. Filter screens 15 are positioned in the stack between vent laminates 3 and vent collector laminates 4. This position of the screen 15 within the stack provides the best noise reduction and increase in laminar flow operating range.
Positioning the screens between the LPA laminate 2 and vent laminate 3 does not result in a workable design. The symmetrical stacking arrangement also has screens placed between exhaust laminates 5 as shown. These screens help further reduce flow noise within the system. The placing of filter screens throughout a fluidic system in this fashion will help reduce flow noise and thus increase the laminar operating range of the system. It is understood that the placement of screens is identical for one sided venting systems.
FIG. 6 shows a typical plot of the differential output pressure, P 0 , versus the supply pressure, Ps, of a single stage two sided vented LPA circuit assembly with and without filter screens placed as shown in FIG. 5. FIG. 6 shows that the transition from laminar to turbulent flow using the screens has been significantly delayed. It also shows that the noise levels in the turbulent flow region in the new design are much lower than those without the screen.
FIGS. 7 and 8 show plots of the block load pressure gain of the old and new design LPA circuit assemblies respectively as a function of the Reynolds number (N R ). As shown in the old design, FIG. 7, the transitional Reynolds number is about 1100 while in the new design, FIG. 8, the transitional Reynolds number has been extended from about 1100 to about 1700. It is also evident that within the laminar regime the pressure gain is relatively constant from N R =700 to 1700 for the new design and from N R =700 to 1100 for the old design. This represents a two and a half times improvement on the operating Reynolds number range in which the pressure gain is relatively constant.
The use of filter screen laminates with the approximate mesh size described herein, together with active elements such as LPA and LJARS laminates in stacking orders of the type detailed above defines a technique that will extend the useful operating range of these active elements by significantly delaying their transition to turbulent flow.
We wish it to be understood that we do not desire to be limited to the exact details of construction shown and described as it is obvious the concept applies to any other laminate configurations that are used to construct fluidic circuits containing laminar flow active elements. | A fluidic system is provided in which the laminar flow operating range haseen increased. The fluidic system uses stacks of laminate plates in which filter means is placed between vent and exhaust laminates for breaking up eddies and flow noise created from supply nozzle and vent areas. | 8 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
The invention relates to a self-pumped heat energy collection and transfer system and, in particular, to a single pipe, two stroke system suited to solar energy applications which may require remote collection of energy at an elevation higher than that of the energy use or storage means.
B. Prior Art
The use of solar energy has frequently been proposed for both heating and for domestic hot water (i.e., water for cooking, washing, and the like). In either application, a storage tank of sufficient capacity to supply the heated water in the quantities required is maintained at the desired temperature by energy supplied to it from a solar collector. While the collector may be positioned at a high elevation, e.g. the roof of a house or other building, in order to obtain maximum exposure to solar radiation, the storage tank, because of its substantial weight when filled, is preferably located at some other point, such as in the basement of the home.
Solar energy systems previously proposed for delivering heat to a lower elevation thermal storage reservoir include both active and passive approaches. Active systems generally employ a circulating pump, sensors, a control package, and a complete piping loop in addition to the solar collector panels and means for storing the thermal energy collected. For example, in the low reservoir version of the solar heating device of U.S. Pat. No. 3,390,672, issued July 2, 1968 to C. D. Snelling, a pump, actuating device or switch, and liquid return pipe are required, in addition to electric power to drive the pump.
Passive down-pumping solar heating concepts generally employ multiple conduits, floats, valves, and frequently sensors, control circuitry, and valve actuators. Thus, the U.S. Pat. No. 4,061,131 issued Dec. 6, 1977 to H. R. Bohanon, for example, a thermal storage reservoir is positioned below the heat collector and flow of a circulating fluid is regulated by a float valve in a liquid trap, a check valve, and further, by a dual level control system in a transfer tank employing various floats, a drain valve, and requisite mechanical linkage.
Somewhat simpler passive designs are in use in which the thermal storage reservoir is either directly exposed to the sun--the "breadbox" type--or located above the heat collectors and charged by a gravity "thermosyphon" loop of either single or two phase fluid. These latter designs have demonstrated impressive long-term effectiveness due in large part to functional reliability. Architectural restrictions on the placement of the components and the inescapable need to support the weight of the thermal storage reservoir above the heat collectors, however, limit their common application to domestic hot water systems, with their relatively compact and light reservoirs. Heated water must still be drawn down a relatively long pipe to the use point, with attendant heat loss and lag time.
Active low reservoir systems have the potential for optimum efficiency and allow considerable architectural freedom, but high capital cost, significant operating cost, and faults in design, materials, installation, and control are common. In short, reliability is frequently lacking.
None of the passive low reservoir schemes referred to above have yet been convincingly demonstrated in field use, but their generic dependence on moving mechanisms, tightly sealing but frequently operated valves, and multiple pipe fluid circuits suggests cost and reliability disadvantages comparable to those of active systems.
The utilization of a heat pipe for passively pumping heat energy is discussed in U.S. Pat. No. 4,050,509 issued Sept. 27, 1977 to Bienert et al, and its possible applicability to residential heating systems is considered in U.S. Department of Energy Report COO-4484-02. Among other disadvantages, the device described there relies upon the inclusion of a noncondensible gas to accomplish the return pumping stroke, forcing the heat collector to operate at a correspondingly higher temperature than that of the thermal storage reservoir and thereby substantially reducing collection efficiency.
SUMMARY OF THE INVENTION
In view of the foregoing, it is a principal object of the present invention to provide a solar energy collection and transfer method and system that is self-pumped, simple, highly reliable and responsive to storage temperature and heat source availability.
It is a further object of the present invention to provide a solar energy collection and transfer system that allows maximum design freedom regarding the components of the system, particularly placement of the thermal storage reservoir relative to the heat collectors.
It is another object of the present invention to provide a solar energy collection and transfer system that eliminates separate energy input into the system for circulating the working fluid and that additionally eliminates circulation controls such as pumps, valves, floats and sensors.
It is yet another object of the present invention to provide a freeze proof system for daily heat collection in variable climates at high thermal efficiency and reduced cost.
In contrast to many prior systems, the present invention employs no moving parts other than its working fluid, is passive in operation, and allows arbitrary relative placement of its heat collector and thermal storage reservoir.
The present invention comprises a system in which the heat collector operates at a temperature only slightly higher than that of the thermal storage reservoir and, additionally, tracks rapid and frequent variations in reservoir temperature due to demand loads. Further, it applies the concept of a heat pipe to a case where the heat input (e.g., solar radiation) is periodic or intermittent.
The invention diverges from the classical heat pipe in, among other aspects, the manner of returning liquid to the collector to complete the thermodynamic cycle. Heat pipes cycle continuously, with condensate return to the collector via either gravity or capillary action. The former requires that the collector be situated below the condensor; the latter can elevate liquid to only an extremely small extent. The present invention does not cycle continously, but instead employs a cycle comprised of two discrete, discontinuous "strokes", a delivery or "day" stroke to transfer heat by means of vaporized working fluid in the daytime and a return or "night" stroke to return liquid phase working fluid at night.
Specifically, heat absorbed by the collector during the daytime vaporizes a volatile working fluid supplied to the collector from an elevated day tank by means of an insulated downcomer, the fluid storage capacity of the day tank being adequate for at least a full day's operation. The vaporization effectively maintains the surface temperature of the collector substantially near the boiling temperature of the working fluid. The vapor thus formed flows through a conduit free from additional energy input and enters a heat exchanger or condenser in which the vapor gives up heat to a thermal storage reservoir in contact with the heat exchanger and thus condenses to the liquid phase. Small temperature and pressure gradients between the collector and the heat exchanger and its associated thermal storage reservoir drive the flow of vapor phase working fluid during the delivery stroke. Liquid condensed in the heat exchanger drains through a further conduit to a sealed sump where it is accumulated under its own vapor pressure.
During the return stroke, nighttime heat loss condenses vapor in the upper portions of the collector and its working fluid reservoir, thereby reducing the pressure in that part of the system. The sustained vapor pressure in the sump then pumps the liquid from the sump through the heat exchanger and back to the collector and day tank against the steadily diminishing pressure of the latter. The return stroke is completed when the collector and day tank are liquid filled, there being no more vapor to condense in the collector or day tank to continue the process further. The liquid-filled collector is then ready for the next cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of one embodiment of my invention that is especially suited to working fluids having a high vapor pressure vs. temperature gradient;
FIG. 2 is a frontal view of the collector of FIG. 1, with portions broken away for clarity;
FIG. 3 is a diagrammatic view of an alternative embodiment of my invention that is especially suited to use of working fluids having a moderate vapor pressure vs. temperature gradient and/or to the use of a remote working fluid sump.
DETAILED DESCRIPTION OF THE INVENTION
Although the invention may be applicable to other than solar energy collection, the following description discloses the invention as applied to collecting and transferring solar energy.
In FIGS. 1 and 2, an energy collection and transfer system in accordance with the present invention includes a heat collector 10 (shown in side cross-sectional view) having a transparent cover 12 supported by a weather-proof enclosure 14. Solar radiation transmitted through the cover 12 impinges on a flat collector plate 15 of metal or other heat-absorbing material (FIG. 2) and heat-collecting tubes 16 in close thermal contact with the plate 15; for reasons to be described, at least the tubes 16 are of restricted cross-section to thereby limit counter-current flow therein. The tubes terminate in headers 20, 22, and are in turn connected to a reservoir 24 by tubes 26, 28, respectively.
The reservoir 24 comprises an extended storage chamber of sufficient volume to hold, together with the collector tubes and headers, a supply of working fluid adequate for a full cycle of operation as described more fully below. Advantageously it is formed from an elongated cylindrical chamber 24A having a smaller upper vapor chamber or bell 24B formed thereon. It is sealed fluid-tight except for its connections to the collector headers 20, 22 through the conduits 26, 28, and its penetration by a downcomer 32 whose upper end 32A terminates just below the top of the bell 24B and whose lower end connects the reservoir to a heat exchanger and sump 46. Insulation 30 surrounds the reservoir 24 and the back portion of the collector plate and tubes; similarly insulation 34 surrounds the downcomer 32.
The tank 42 comprises a thermally insulated container having a lower chamber 44 and an upper chamber 46. The downcomer 32 penetrates the lower chamber 44 and is formed into a heat exchange coil or condenser 48 within the lower portion of this chamber. It exits from this chamber and continues upwardly as a riser 50 having an end 50A which terminates in the upper portion of the chamber 46. A restricted orifice 52, positioned at the lower portion of the chamber 46, also communicates with the riser 50. For purposes of illustration, the riser 50 and its discharge end 50A may be considered as having an internal diameter of 1/4 inch and the orifice 52 an internal diameter of 1/8 inch. A water inlet pipe 54 and an outlet pipe 56, are connected to the lower chamber 44. The pipe 54 supplies water 58 to the chamber 44 for heating by the coil 48; the pipe 56 removes the heated water from the chamber 44 and supplies it for external use. The pipes are then connected into the domestic hot water system in a conventional manner. Insulation 60 surrounds the chambers 44, 46 and limits heat loss to the environment. A wall 62 of controlled conductivity is interposed between the chambers 44, 46. It limits short-term heat transfer (i.e., during a period of less than a few hours) from the liquid 58 in the upper portion of chamber 44 to the working fluid 64 in chamber 46 during the day or delivery stroke, but is of sufficient conductivity to allow gradual heat transfer (i.e., over the course of several hours or more) from the liquid 58 to working fluid 64 during the night or return stroke sufficient to vaporize a portion of the working fluid at night for the return stroke when conditions warrant.
The system comprising the collecting tubes 16, the reservoir 24, the downcomer 32, coil 48, riser 50, and chamber 46, form a hermetically sealed system containing the liquid and vapor phases of a working fluid 64 which cycles back and forth diurnally between the chamber 46 and the collector 10 in a manner that will now be described in detail.
The collector 10 is positioned at a point where it will receive unobstructed exposure to incident solar radiation. For example, it may advantageously be placed on the roof of a home. Similarly, the unit 42 is placed below the level of the collector 10, for example, in the basement. The system operates on a cycle comprising a "day" stroke in which vapor phase working fluid, and thus solar energy, is transferred from the collector 10 to the unit 42, and a "night" return stroke in which liquid phase working fluid is returned to the collector 10 to complete the cycle.
At the start of a given cycle, that is, at the beginning of a day, the entire liquid phase working fluid inventory 64 of the system is stored substantially in the reservoir 24 and the collecting tubes 16 and their interconnecting headers 20, 22 and conduits 26, 28; only a small amount is stored in the downcomer 32, coil 48, and riser 50. As solar radiation impinges on the collector plate 15 and tubes 16, it rapidly heats the liquid in the tubes 16, bringing this liquid to a boil. The vaporized fluid caused by this boiling travels up the tubes 16 to the header 20 and thence through the connecting tube 26 to the reservoir 24. In so doing, it may carry with it liquid phase working fluid from the tubes 16 which is separated from the vapor stream in the bell 24B and collects in the bottom of the reservoir 24. Liquid from the reservoir returns down the tube 28 to replenish the fluid supply in tubes 16.
The vapor expelled from the tubes 16 collects above the liquid pool in the reservoir 24 and thence flows downwardly through the downcomer 32 and into the heat transfer coil 48. In passing through this coil, the vapor condenses, giving up its latent heat to the liquid 58 surrounding the heat exchanger. The heat liquid (e.g. water) in chamber 44 may remain for further heating or be removed from the chamber by means of pipe 56, and further liquid may be supplied via pipe 54 for subsequent heating in the manner described.
As noted previously, the tubes 16 are of relatively small internal diameter (bore). As they receive heat, the fluid within them is brought to the local boiling temperature. When the collector, and thus the tubes, are positioned at an angle to the horizontal, as shown in FIG. 1, the localized boiling temperature increases because of the increased "head" pressure as one moves from the upper end of the tubes adjacent the reservoir 24, to the lower end thereof remote from the reservoir. With tubes of a diameter sufficiently large as to present insignificant fluid resistance, boiling would simply occur primarily at the upper section of the tubes, and the varporized fluid would be replenished at a corresponding rate from the header 22. However, because of the reduced size of the bore of tubes 16, the escape of vaporized fluid at the upper end of the tube is sufficiently retarded that significant boiling can occur at the lower end of the tubes. The result is a periodic "percolation" or "geysering" in the tubes which propagates pressure surges through the reservoir 24, downcomer 32, and thence to the heat exchanger 48. When the rate of vapor delivery to the heat exchanger 48 momentarily exceeds the condensing rate (as when the collector 10 delivers a surge of vapor), uncondensed excess vapor, along with condensed liquid, exits the heat exchanger and flows with substantial velocity through the riser conduit 50 to the sump 46.
The bulk of the surge of liquid and vapor flows directly to the sump vapor space via the discharge end 50A of riser 50. The excess vapor thus accumulates momentarily in the vapor space above the liquid 64 without bubbling through it and thus without depositing its energy disadvantageously in the liquid. When the collector surge dies down and the heat exchanger catches up with the system vapor inventory, the excess vapor in the sump vapor space backflows down through the riser 50 to the heat exchanger 48; at the same time, a small amount of sump liquid flows from chamber 46 through the restricted orifice 52 to riser 50 and returns to the condenser coil 48. The sump thus serves both as a long term (i.e., the duration of a "day" stroke) accumulator for condensed working fluid, as well as a short term accumulator for surges in the vapor output of the collector 10. Because of the oscillating vapor flow superimposed upon the net flow of the "day" stroke, the thermal communication between the sump vapor space and heat exchanger is excellent, encouraging thermodynamic equilibrium throughout the system and guaranteeing the dominance of the heat exchanger in setting system pressure and temperature.
Because sump heat gain from the reservoir top in the configuration of FIG. 1 is properly restricted, for example by appropriate control insulation 62, the cooling effect of incoming condensate from the heat exchanger dominates the sump heat balance during the period of heat collection, and the sump tracks just a few degrees above reservoir bottom temperture all day. It is not until useful collection trails off to some arbitrarily low rate near sunset that heat gain from the reservoir top begins to dominate in the control of sump temperature and pressure, as the system begins to ready itself for the return stroke. As the return pumping occurs, the hot sump liquid passes first through the heat exchanger, returning any "borrowed" heat to the cold water portions of the reservoir before traveling up the downcomer to the day tank and collector.
For the return stroke to occur, the fluid in sump 46 must achieve a temperature adequately higher than the minimum nighttime ambient temperature (since the collector is at approximately this temperature), depending upon the working fluid and overall elevational difference. Summer operation of a domestic hot water system in a hot, humid climate is probably the most adverse case. High nighttime ambient temperature and sky haze may prevent cooling of the collector below day's end sump temperature, especially if hot water demand were high during the day. To ensure that the liquid in the sump will achieve a temperature adequately above the minimum nighttime ambient temperature to execute the return stroke under such adverse conditions, thermal communication is provided between the sump 46 and the warmer top portion of the storage reservoir 44 by means of the control insulation 62. Given enough time, such as between sunset and 2:00 AM, the sump approaches the temperature of the hottest portion of the reservoir (140 to 160 degrees Farenheit), ensuring successful pumping. The upper portion of reservoir 44 may be equipped with a conventional backup heating element such as electric coil or other element (not shown) for periods of inclement weather.
In transporting heat from collector 10 to the storage reservoir 44, the system functions as a heat pipe. Liquid phase working fluid boils in the collector upon absorbing solar energy input and transfers this heat to the storage reservoir via heat exchanger 48 where it condenses back to the liquid phase. Because the evaporator is producing vapor and the heat exchanger is "consuming" it, a pressure gradient is maintained which drives the flow of vapor continuously from the collector to the heat exchanger during the day stroke. The collector temperature is therefore determined by the temperature in the storage reservoir, and tracks this temperature within a few degrees Farenheit. This results in operation of the collector at the lowest feasible collection temperature, and thus greatly enhances collector and system efficiency and reliability.
The detailed characteristics of a particular embodiment of the invention may vary with climatic conditions, design temperatures, and size and weight restraints under which the system might be required to operate. FIG. 1, for example, shows a mode of the invention best suited for cyclic operation under conditions where the nighttime ambient temperature may be only minimally below the temperature of the sump fluid at the end of the heat absorbing period of a day. Certain working fluids, namely, those with a substantially high vapor pressure/temperature ratio, perform well under such conditions, since they require only a small difference between the nighttime ambient temperature and the sump temperature at the end of the day to power the fluid return stroke.
Table 1 displays a partial listing of typical working fluids suitable for use in the present invention, along with their thermodynamically important characteristics. For a given minimum nighttime ambient temperature and elevation of heat collectors above the thermal storage reservoir, each fluid will execute the fluid return stroke at a sump temperature determined by its liquid phase density ρ f , and the slope of its vapor pressure curve. The last column in Table 1 lists this fluid return temperature, T fr , based upon a 60 degree nighttime ambient and 30 foot elevation of the heat collectors above the thermal storage reservoir. The capacity of the day tank and sump are determined by the latent heat of vaporization, h fg , and liquid phase density of the working fluid. The column headed V D for example displays the requisite day tank volume per square foot of solar collector for each fluid listed.
TABLE 1______________________________________Working Fluid Characteristics Fluid Name ##STR1## ##STR2## ##STR3## T.sub.fr(°F.)______________________________________Formaldehyde 45 306 .453 68Methylamine 41 351 .434 70Dimethylamine 40 250 .624 76Acetaldehyde 48 252 .516 89Isopropyl Amine 43 225 .645 92Acetone 50 234 .533 120Methanol 50 504 .248 139______________________________________
As an example of use of the system for domestic hot water applications, typical household usage is of the order of 20 gallons per day per person. Using methanol as the working fluid, approximately two pounds of methanol absorbing radiation over a collector surface of one square foot will suffice to produce one gallon of suitably hot domestic water per day and thus a collector of twenty square feet, charged with forty pounds of methanol, will produce sufficient domestic hot water during the day for a single person's needs.
Because economy and weight considerations suggest use of a compact day tank and storage sump, a working fluid with substantially high latent heat of vaporization should be used. However, if such a working fluid does not also exhibit a high P(vapor)/T, fluid pressure rise in the heat exchanger and collector above that in the sump in order to overcome the static head of liquid in the riser 50 will produce a substantial temperature rise and performance penalty in collector operation. Accordingly, when conditions warrant the use of fluids of low P(vapor)/T or when remote sump placement is desirable, an embodiment such as illustrated in FIG. 3 may be employed.
In FIG. 3, a combined water storage and sump tank 70 includes a sump chamber 72 positioned below, and thermally insulated from, a water storage chamber 74 by means of insulation 78 which extends not only between these chambers but substantially completely around them to minimize heat loss to the surrounding environment. A further chamber 80 is positioned above the chamber 74 and is placed in controlled thermal contact with it by means of an area of limited insulation 82 which allows the attainment of long-term (i.e. several hours or more) thermal equilibrium between the liquids in the chamber 74 and 80, respectively, while limiting the attainment of short term (less than a few hours) equilibrium between these chambers. The downcomer pipe 32 (see FIG. 1) includes a section formed as a heat transfer coil 76 in chamber 74, as was previously the case, and continues in a conduit 88 which extends at first downwardly, via leg 88A, past the sump chamber 72 and then upwardly to the chamber 80. The bottom leg of this conduit is below the bottom of chamber 72 to allow complete drainage of the latter as subsequently described below. An orifice 90 of restricted dimensions relative to the bore of conduit 88 interconnects the bottom of the chamber 72 and conduit 88. The conduit 88 enters the chamber 80 at the upper portion of the latter; the liquid phase of the working fluid in conduit 88 is deposited in chamber 80 during surges in collector output as previously described, and accumulates in this chamber until it reaches the height of an outlet tube 92 at which time it passes down through this tube into the sump chamber 72. The vapor phase of working fluid in the tube 88 for the most part passes directly through the chamber 80, through the pipe 92 and thence into the vapor space above the liquid in the chamber 72. Operation of the system of FIG. 3 is similar to that of FIG. 1, with the exception that during delivery surges the working fluid (both liquid and vapor phase) passes first through the chamber 80 prior to its ultimate return to the sump 72.
Specifically, after heat collection in the collector 10 trails off after sunset, the pressure in sump 80 rises due to heat transfer through control insulation 82 from the liquid at the top of chamber 74. As this occurs, the pressure in the collector 10 progressively diminishes, while that in the sump 80 progressively increases, until the transfer flow (from the collector to sump) ultimately stops and then reverses; this occurs when the vapor pressure in sump 80 exceeds the back pressure of collector 10 plus the pressure resulting from the difference in hydrostatic "heads" between the liquid level in the outer leg 88B of conduit 88 and that in the inner leg 88A of the conduit and its extension in coil 76 and downcomer 32. Similarly, the accumulated liquid in sump chamber 72 drains from this chamber into conduit 88 through orifice 90 when the vapor pressure in sump 80 (and thus in sump 72 because of the interconnection of these via conduit 92) exceeds the back pressure of collector 10 plus the difference in hydrostatic "head" between the liquid level in the inner leg 88A of conduit 88 and its extension in coil 76 and downcomer 32 and that in the sump chamber 72.
Because saturation conditions exist in both the collector 10 and the heat exchanger 76 and pressures in those two components differ only by the amount needed to drive the vapor flow, temperature in the collector is only minimally higher than that in the heat exchanger. The collector temperature therefore will "track" the temperature in the thermal storage reservoir 74. Thus, the system is thermally self-regulated. It "switches on" whenever the solar input is adequate to heat the evaporator up to storage reservoir temperature, and drives the working fluid in direct proportion to energy input. Moreover, the intrinsic operating efficiency of the collector is enhanced by maintaining the evaporator surface near the lowest useful temperature, as this minimizes heat loss to the surroundings.
CONCLUSION
From the foregoing, it will be seen that I have provided an improved heating system comprising a passive, two-stroke system utilizing a heat-pipe transfer principle, but providing positive pumping for the return stroke by means of a sump chamber separate from the condenser. The system of the present invention allows the energy collection portion of the system to be separated by a substantial vertical distance from the energy storage portion of the system, so that only a relatively small, lightweight structure need be positioned at the top of the house or other building in which the heating system is located. The system utilizes a single, active, working fluid, and is such that the collector temperature tracks that of the heat exchanger to within a few degrees, thus resulting in a highly efficient heat collection and transfer. The collector is provided with a number of parallel-connected tubes of limited bore to ensure a geysering action during the collection stroke for transferring the condensed vapor of the working fluid to storage sumps for accumulation in preparation for the return stroke. The geysering also ensures good thermal communication between the condenser and the sump, so that the temperature of the latter tracks that of the former to within a few degrees also. | The present invention relates to a cyclic method and single pipe system for collecting and transferring heat energy from a periodic heat source to a thermal storage reservoir and preventing the back flow of such heat energy. The system is responsive to the temperature of the thermal storage reservoir and the availability of the heat source without reliance upon other external energy inputs or controls such as valves, pumps, floats, sensors, or electronic circuitry. During the heat collection stroke of the cycle an evaporator containing a volatile liquid generates a flow of vapor to a remote heat exchanger where the vapor gives up its latent heat of vaporization to the thermal storage reservoir thereby condensing. Condensate flows from the heat exchanger to an insulated pressure sustaining sump that efficiently accepts pulsatile fluid delivery. During periods of heat source unavailability, heat loss from the evaporator to its surroundings condenses the vapor therein, reducing evaporator pressure and allowing vapor pressure in the sump to return the sump liquid through the heat exchanger to the evaporator, this return stroke completing the cycle. The sealed single pipe system employs no moving parts and is applicable to any periodic or intermittent source of heat such as solar insolation. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This Continuation-in-Part application claims the benefit of U.S. Continuation-in-Part patent application Ser. No. 11/295,910 filed Dec. 7, 2005 and U.S. Provisional Application Ser. No. 60/775,950 filed Feb. 23, 2006.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates generally to fire barriers and more particularly to fire and cycle tested, inside-mounted, one-step, drop-in installation, one-piece continuous construction, multi-directional fire barriers for multi-directional architectural expansion joints, and tools for installing said fire barriers.
The background information discussed below is presented to better illustrate the novelty and usefulness of the present invention. This background information is not admitted prior art. The particular versions of the invention as described below are provided, in part, as illustrative and exemplary. Thus, the described versions should not be taken as limiting. Additionally, the invention is not limited to the examples provided.
Modern building codes require building design to take into account the stresses that buildings often experience, such as extreme or repetitive changes in temperature, the force of wind impinging on the building, forces due to seismic events, settling of subsoil, remodeling of the building, excavation on or near the site, and other forces. To accommodate these stresses, buildings must now be constructed with code mandated spaces between wall, floor, and ceiling structures. These spaces, referred to as “expansion joints,” allow differential building movement to take place without risking damage to the whole structure.
While expansion joints do serve the function for which they are employed, that is to improve the integrity of the structure when the building units are subjected to contraction or expansion, expansion joints also present a major risk to the structure. During a fire the expansion joint spaces act as chimney flues providing pathways for gases, flame, and smoke to spread rapidly throughout the structure creating what is known as the “chimney effect.” To counter this effect, building codes for public and commercial structures generally require fire barriers to be installed in the expansion joint spaces to prevent flames and smoke from passing through the joint spaces. Although various fire barriers are presently available, there are no tested, ready to be installed, fire barriers ready for use in multi-directional expansion joint spaces.
Logically, fire barriers should be classified into two major structural categories: straight-line barriers and multi-directional barriers. Presently available barriers are referred to as “straight line barriers.” These barriers are designed to fit into straight-line expansion joint spaces, such as the joint space that occurs between two adjacent building wall units. An expansion joint space, however, often intersects one or more other expansion joint spaces. These intersection joint spaces are found at the juncture of a plurality of building structures, such as when four walls meet to create a cross-wise gap, or where two exterior walls and an interior wall meet creating a “T”-shaped gap. Such multi-directional expansion joints require multi-directional fire barriers as it is structurally impossible for straight line barriers to accommodate the multi-directionality of multi-dimensional intersection joint spaces. Presently, the fire barrier industry is able to provide only jerry-rigged, untested, fire barriers for multi-directional expansion joints. These jerry-rigged barriers are constructed, on-site, from spliced together parts of straight line barriers. It is well-accepted, however, that spliced joints are weak joints. The seams created by splicing are not air-tight and, thus, would allow hot air, smoke, toxic gases, and the like to travel throughout the interior joints of a building greatly reducing any effective time fire-fighters have to get to the fire or for people to leave the burning structure in safety. In addition to being pre-assembled to fit the various multi-dimensional expansion joints, fire barriers should be capable of accommodating the complex differential movement building structural units undergo and be able to retain their resiliency over an extended period of time under dynamic conditions. On-site spliced fire barriers cannot be fire or cycle tested. Additionally, site assembly is time consuming and requires more than one installation person increasing the total construction cost. Because of the inherent weakness of spliced barriers, they are unlikely to hold under even mild stress conditions. During a fire event, building joints are likely to be subject to even greater stress than usual, thereby making it essential that the fire barriers retain their integrity to prevent the migration of gases, flame, and smoke.
In many instances, fire barriers are draped into a joint space with planned for excess side material overlapping the edges of a building unit, such as the top ends of a wall unit. Attachment means, such a screws or bolts are inserted into the top ends of the wall units through the overlap fire barrier material to provide a means of securing the fire barrier to the wall. There are situations, however, where the building specifications do not permit attachment means extruding from the top ends of wall units, for example. In this case, the fire barriers should be “inside-mounted,” that is, the opposing sides of a barrier that is forming a “U” between two wall units will serve as the material through which mounting means will be secured into the building units during the installation process.
Presently available tested fire barriers and the on-site spliced barriers are often the cause of installer injury. Fire barriers usually comprise at least a sheet of stainless steel foil. As each fire barrier has to be handled by the installers the arms and hands of the installers often suffer injury from the sharp protruding edges of the stainless steel foil. Moreover, whenever a fire barrier made with some type of fiber glass material or the like is jerry-rigged on-site, the cutting process emits fibers, some of which are small enough to be breathable creating a breathing air hazard. What is needed are not only pre-assembled fire barriers, but an installation tool that reduces or eliminates direct handling of the barriers. More over, to save cost the installation tool should be low cost, size-adjustable and reusable.
One way to insure that installed fire barriers prevent the passage of smoke, gas, heat, or flame from traveling through the barrier from one floor to another, for example is to ensure that the sides of the barrier (the sides forming the “U” of the installed barrier) are secured tightly to the sides of the building units leaving no gaps between the barrier and the building unit. It would be a great asset to have a means for press-fitting the barrier to the building units as they are readied for the barrier to building unit attachment means to secure the barrier to the building units.
It is clear then that a fire and cycle tested, pre-assembled, straight-line and multi-directional fire barriers constructed as single-piece, continuous units requiring no on-site splicing and providing for one-step, drop-in inside-mount installation by one person into multi-directional joints to prevent the migration of gases, flame, and smoke as well as providing for inside-mounting are urgently needed. Also clearly needed are re-useable, size-adjustable installation tools that provide for one person, one-step, drop-in installation of pre-assembled, continuous, multi-directional/multi-dimensional fire barriers that require no splicing.
SUMMARY
Accordingly, the invention described herein addresses these several interdependent heretofore unmet needs. The present invention solves the problem of reducing or preventing the “chimney effect” cause of rapid spread of flames, heat, and smoke throughout a structure by teaching fire and cycle, code tested, straight-line, multi-directional/multi-dimensional structural fire barriers for installation into the spaces created by the intersection of architectural expansion joints, where the barriers are constructed as stand-alone units requiring no splicing to fit into intersection or corner-type joint spaces. Accompanying low-cost, re-useable, size-adjustable, installation tools designed expressly for one-step, drop-in, inside-mount installation are also taught. And to insure a tight-fit between each installed fire barrier and the building units forming the expansion joint space spreader press-fit tools which may, if desired, serve as fire barriers covers, are also provided.
The fire and cycle tested fire barriers of the present invention are unique in several ways. One point of novelty is the variety of inside-mounted, fire and cycle tested, straight-line, multi-directional, and three-dimensional configurations that can be constructed as continuous one-piece devices using the fundamental layer regardless of the number or kinds of fire-resistant sheets that are used to construct a fundamental layer. A favored embodiment described herein is an inside-mounted, one-piece T-shaped fire barrier that needs no splicing to be installed into a T-shaped expansion joint space created by the convergence of three building structures, such as three walls. The T-shape, as illustrated, is only one of a large number of possible configurations that are embodied with the principles of the mount present invention. The present invention contemplates inside-mounted, one-piece fire barriers shaped to fit into cross-shaped, T-shaped, and L-shaped expansion joint spaces. L-shaped fire barriers include barriers having one horizontal and one vertical arm that can occur in various configurations to meet specific requirements, and barriers having two horizontal arms.
Yet another feature of the present invention is that regardless of the structure of multi-dimensional expansion joint system that the fire barrier is designed to fit, all of the barriers are constructed to be able to undergo movement including expansion and contraction to match the expansion and contraction suffered by the structural units to which the barriers are attached. To this end the barriers of the present invention are constructed to withstand the rigors of cycle testing. Additionally, each of the materials used in the construction of the fire barriers meets Underwriters Laboratory, Inc. required specifications for materials used in a fire barrier joint system. Moreover, to date, the horizontal/vertical L-shaped barrier and the straight line have passed both the fire and cycle UL tests.
Additionally, each style of fire barrier is accompanied by its own low-cost, size-adjustable, reusable installation tool that provides, in most cases, for one person, one-step, drop-in installation of the fire barriers made according to the principles of the present invention. The installation tool is not only reusable it is also easily and rapidly resized for use with different sized versions of the same style barrier.
All of these benefits and more are made available by providing for a fire barrier system, comprising:
unitary fire resistant barriers pre-assembled and shaped for drop-in no splicing installation of the barriers into multi-dimensional architectural expansion joint spaces formed by the intersection of two or more architectural expansion joint spaces, each of the joint spaces defined by a first and a second building unit, comprising:
at least one fire barrier structural unit branching seamlessly from at least one second fire barrier structural unit,
each fire barrier structural unit comprising at least one flexible sheet of a fire barrier material, and
each of the flexible sheets of a fire barrier material comprising a first portion attached to a first building unit attachment area by a first attachment means and a second portion attached to a second building unit attachment area by a second attachment means, and an intermediate portion having a width located generally in the joint space.
Additionally, the fire barrier system further comprises:
an installation tool for the installation of the fire resistant barriers, the tool comprising:
a) a frame functionally shaped and sized for:
i) fitting within the fire resistant barrier, ii) detachably attaching to the fire resistant barrier, and simultaneously iii) being supported by the building units;
b) attachment means fixedly attached to the frame for the detachable attachment of the installation tool to the fire resistant barrier providing for the drop-in installation of the fire resistant barriers and for the removal of the installation tool from the fire resistant barrier when the installation is complete. The installation tool further comprises grasping means attached to the frame for lifting the frame while attached or detached from the fire resistant barrier.
A favored embodiment is where the fire barrier system comprises wherein the fire resistant barrier is constructed as an L-shaped vertical/horizontal-shaped fire barrier. This embodiment was tested and rated in accordance with ASTM E1966-01 Standard Test Method for Fire Resistive Joint Systems , in addition to having successfully met the conditions of Type IV movement according to Cycle test ASTME 1399.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that these and other objects, features, and advantages of the present invention may be more fully comprehended, the invention will now be described, by way of example, with reference to the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
FIG. 1 is a perspective view illustrating a T-shaped fire barrier installation tool of the present invention attached to a T-shaped fire barrier of the present invention for the inside-mount installation of the barrier into a T-shaped building expansion joint.
FIG. 1 a is a perspective exploded view of area “ FIG. 1 a ” as indicated in FIG. 1 to more clearly illustrate the temporary attachment means used for the temporary attachment of the installation tool to the barrier.
FIG. 1 b is a perspective view of the width determining exchangeable installation tool segments used to accommodate the size of the barrier to be installed.
FIG. 2 is a perspective view illustrating the T-shaped barrier installation tool supporting the T-shaped fire barrier for inside-mounting the barrier in the T-shaped building expansion joint.
FIG. 2 a is a perspective exploded view of area “ FIG. 2 a ” as indicated in FIG. 2 to more clearly illustrate the attachment means used in the inside-mounted attachment of the T-shaped fire barrier to the T-shaped building units.
FIG. 3 is a perspective view illustrating the inside-mounted T-shaped fire barrier after the T-shaped barrier installation tool is detached.
FIG. 4 is a cross-section view taken along line FIG. 4-FIG . 4 of FIG. 2 illustrating the inside-mount attachment of the T-shaped fire barrier to T-shaped building units before the T-shaped barrier installation tool is detached from the barrier.
DEFINITIONS
Attachment means, as used herein, referring to attachment means used to attach the fire barriers as taught herein to the building units creating the expansion joint spaces includes bolts, screws, staples, and glue or other adhesive.
Branch, as used herein, refers to something, such as a structural unit, that extends from, enters into, or is an offshoot of a main body or structural unit, with no defining break or distinction of the material of the structural unit, as one river branching from another, a tree branch branching from another, or an arm or leg branching from the trunk of a body.
Building units, as used herein, refers to structures such as walls, floors, ceilings, and the like, and may be referred to as structural units.
Common material, as used herein, refers to material that is common to more than one unit or part of a unit, where such a part of a unit is referred to herein as a structural branch. Such a material, displaying the same properties, but found in a biological setting is a coenosarc, which is material linking polyps in a colony, such as is found in the colonial form of coral, the polyps (the colonial animals) each are a part or unit of their common coenosarc.
Intumescent as used herein, refers to those materials having properties that cause them to expand (or intumesce) to several times their original size when activated by high temperatures to prevent the spread of flames and smoke to other parts of a building, for example passive fire-seals contain intumescent compounds.
Insulation blanket, as used herein, refers to any number of insulation materials, including fiber blankets made from alumina, zirconia, and silica spun ceramic fibers, fiberglass, and the like.
High-temperature thread, as used herein, refers to any thread that is fire resistant or any thread that will not support combustion, such as a ceramic thread.
Metallic backing layer, as used herein, refers to fire resistant metal or metallicized foil, such as stainless steel, or the like.
Multi-directional and/or multi-dimensional architectural expansion join or joint, as used herein refers to any joint that is formed by the convergence of more than two structural units, such as the convergence of three wall units or two walls and a floor unit. These joints create spaces between building units that act like chimney flues carrying gases, hot air, flame, and smoke throughout a structure.
Multi-directional and/or multi-dimensional fire resistant barrier, as used herein, refers to any fire barrier that is shaped to functionally fit into a multi-directional and/or multi-dimensional architectural expansion joint.
Protective cloth, as used herein, refers to a flexible, strong, protective, fire-resistant material that is designed to mechanically support the insulation material and to protect the insulation material from mechanical damage, as the insulation is mechanically weak and can be easily damaged by tearing or ripping either accidentally or intentionally during or after installation thus largely compromising the integrity of the fire resistant barrier. The fire resistant layers, such as a layer of insulation material together with a layer of intumescent material, can freely move with respect to the one or more protective layers or they may be attached together via threads or other attaching means. Protective cloths may be manufactured from continuous filament amorphous silica yarns, polymeric material, fiber reinforced polymeric material, high-temperature resistant woven textiles, or a metalized, fiberglass cloth. Metalized cloth may include fibers of stainless steel, aluminum, or copper, for example. Protective materials may also include metal foils or metal screens.
Seaming, as used herein, refers to connecting one part to another part, for example where a cloth is folded and the two parts of the cloth that have been brought together by the folding are subsequently “seamed” together along a predetermined line. The seaming may utilize stitching, using an adhesive, stapling, pinning, or any other means that will connect the two parts to each other.
Spreader, also referred to as press plate, as used herein, refers to any implement or apparatus for applying a pushing force directly to a generally stationary object upon which pressure or tension is to be exerted. It comprises jacks (including lifting jacks, floor jacks, and analogous implements), extracting apparatus (including stump pullers and nail extractors), tensioning apparatus (including belt, carpet and wire stretchers), hoist trucks, and cable-type load hauling or hoisting apparatus, and pressure plates under spring tension including torsion springs.
Strapping, as used herein, refers to off-the-shelf fire-resistant strapping used in construction and fabrication for holding, binding, and/or attaching, such as commonly available steel strapping.
Structural unit, as used herein, refers to such constructs as a wall, floor, ceiling, or the like and may be referred to as building units.
Tributary, as used herein, refers to a construct which flows uninterruptedly into another construct (see Branch).
Tri-dimensional, as used herein, refers to either an expansion joint that has three member parts, such as a T-shaped expansion joint where the T-joint is made up of three co-joint-arms or to a fire barrier that is functionally shaped to accommodate a T-shaped joint.
Torsional, as used herein, refers to the force with which a wire returns to a state of rest after having been twisted round its axis, referred to as torsional force, whereas torque, by definition, is a force that produces rotation.
Torsion springs, as used herein, refer to springs that exert a force (torque) in a circular arc, and that have arms rotating about the central axis. Torsion springs, whose ends are rotated in angular deflection, offer resistance to externally applied torque. The wire itself is subjected to bending stresses rather than torsional stresses, as might be expected from the name. Springs of this type are usually close wound, reduced in coil diameter, and increase in body length as they are deflected. The designer must consider the effects of friction and arm deflection on the torque. Special types of torsion springs include double torsion springs and springs having a space between the coils to minimize friction. Double torsion springs consist of one right-hand and one left-hand coil section connected together, and working in parallel. The sections are designed separately with the total torque exerted being the sum of the two. It is customary to specify torque with deflection or with the arms at a definite position. Formulas for torque are in pound-inches or inches-pounds. If ounce-inches are specified the value should be divided by 16 to use the formulas in the inch-pound system. When a force is specified at a distance from a centerline, or the torque, the distance is called moment, which is equal to the force, multiplied by the distance. Force can be in pounds or ounces with the distance in inches or the force can be in meters with the distance in millimeters. Formulas for torques are based on the tangent to the arc of rotation with a rod to support the spring. The stress in bending caused by the moment is identical in magnitude to the torque, provided that a rod is used.
Tests
Fire Test ASTM E1966-01 Standard Test Method for Fire Resistive Joint Systems (UL 2079)
Cycle Test ASTM E 1399 Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems
A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE INVENTION
20 Intumescent strip material.
22 High-temperature thread.
30 Protective cloth.
40 First insulation blanket.
41 Metallic layer adhered to 40 .
42 Second insulation blanket.
43 Metallic layer adhered to 42 .
50 First fire-resistant supporting mesh.
52 Second fire-resistant supporting mesh.
60 Fire-resistant strapping.
70 Friction-fit washer to attach fire barrier to building unit 90 .
70 B Friction-fit washer to attach fire barrier sheets to each other to form a layer.
70 T Friction-fit washers to attach installation tool to fire barrier.
72 Pin to attach fire barrier to building unit 90 .
72 B Pin to attach fire barrier sheets to each other to form a layer.
72 T Pin to attach installation tool to related fire barrier.
74 T Spacer.
76 T Fasteners to attach installation tool to related fire barrier.
90 Building unit.
302 Width determining exchangeable installation tool segments.
306 Tool grasping means.
350 Three-way or T-shaped fire barrier for inside installation.
355 Installation tool for installing 350 .
DETAILED DESCRIPTION
Referring now particularly to the drawings which show views of exemplary versions of the inside-mount barriers, and installation tools contemplated by this invention. The drawings also illustrate how the above described disadvantages have been overcome. It should be noted that the disclosed invention is disposed to versions in various sizes, widths, depths, shapes, contents, layers, materials, and forms. Therefore, the versions described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the versions described herein.
FIG. 1 , a perspective view of two favored embodiments of the present invention, illustrates a T-shaped inside-mount fire barrier installation tool 355 securely attached to an inside-mount T-shaped fire barrier 350 . T-shaped fire barrier 350 comprises outer protective cloth 30 overlain by first insulation blanket 40 with adhered metallic backing layer 41 and edged with intumescent strip material 20 that is stitched to first insulation blanket 40 by means of high-temperature thread 22 , first fire-resistant supporting mesh 50 , second insulation blanket 42 with adhered metallic backing layer 43 , second fire-resistant supporting mesh 52 , and fire-resistant strapping 60 . T-shaped fire barrier installation tool 355 is securely, but detachably attached to fire barrier 350 via attachment means (described in detail below and illustrated in FIG. 1 a ) via fire-resistant strapping 60 . Fire-resistant strapping material 60 as illustrated is a common and inexpensive metal strapping material, having apertures along its length. Installation tool handles 306 are positioned for easy and sure grasping of tool 355 by one person. Installation tool 355 provides for the secure, yet detachable, attachment of the tool to barrier 350 so that one person may attach the tool to the barrier, carry the barrier with minimal effort to the installation site, and position the T-shaped fire barrier within a T-shaped building expansion joint, as illustrated, for the secure attachment of the barrier to the building units.
T-shaped fire barrier installation tool 355 , as illustrated in FIG. 1 , is constructed using readily available 80/20 The Industrial Erector Set® modular framing strips, although it is to be understood that the invention does not depend on this particular material. In the illustrations provided, the framing that is used is the T-slotted framing provided by 80/20 Inc. although any other suitable strong, yet light-weight material, such as aluminum or wood strips would work just as well. It is to be understood that the invention does not depend on the exact material used to construct the installation tool. It is also contemplated that the installation tool is to be manufactured using a time and cost efficient, assembly line, molding-type of manufacturing. The use of the installation tool is not an absolute necessity for the installation of the fire barriers, although its use greatly reduces the time, effort, and cost required for installation. The use of the tool for installation also improves the safety of the installers and ensures the integrity of the barrier during the installation process. As illustrated, T-shaped fire barrier installation tool 355 is provided partially assembled, with tool grasping means 306 fixedly attached to the top side of the tool readily available for use. The top side of the tool is that side that is open to view between the building units after the barrier and the attached tool have been inserted into the expansion joint space defined by the building units. Because expansion joints occur over a range of sizes, from about four to twelve inches wide and because fire barriers must be provided over a range of widths, installation tools must also be available in a range of widths. The present invention accommodates this need and minimizes cost and materials needed for installation by providing installation tool width adjusting means. The width of the size-adjustable installation tool is rapidly and easily adjusted using segments 302 , as illustrated in FIG. 1 b , and a screwdriver. The last step in the construction of the installation tool as illustrated, although the order of the steps given here is for example only and could be rearranged while staying in the principles of the present invention, is the additional of the attachment means that will be used to attach the tool to the barrier. The attachment of this L-shaped bracket is not an inventive step as such attachment means are well-known in the art and comprise screws, bolts, soldering, and the like and need not be discussed further here. If the use of a single unit attachment tool is preferred, the tool is available completely formed through the molding-type manufacturing process with a built-in sliding means of width size adjustment.
FIG. 1 a , a perspective exploded view of area “ FIG. 1 a ” as indicated in FIG. 1 , illustrates the attachment means used for the temporary attachment of installation tool 355 to fire barrier 350 . Installation tool 355 is positioned on barrier 350 by fitting apertures of fasteners 76 T over ends of pins 72 T that extend from the outer side of protective cloth 30 through first insulation blanket 40 with adhered metallic backing layer 41 , first fire-resistant supporting mesh 50 , second insulation blanket 42 with adhered metallic backing layer 43 , second fire-resistant supporting mesh 52 , and fire-resistant strapping 60 . As illustrated in FIG. 1 a spacer 74 T is then placed over the end of pin 72 T that now extends out from one surface of fastener 76 T. To secure the attachment of installation tool 355 to barrier 350 , friction fit washer 70 T is positioned over spacer 74 T. Once T-shaped fire barrier installation tool 355 is securely attached to barrier 350 and barrier 350 is positioned in a T-shaped building expansion joint as illustrated in FIG. 1 , barrier 350 is ready to be permanently attached to building units 90 .
FIG. 2 , a perspective view, illustrates T-shaped barrier installation tool 355 supporting T-shaped fire barrier 350 as T-shaped fire barrier 350 is being inside-mounted onto the building units 90 that form T-shaped building expansion joint. Fixedly attaching T-shaped fire barrier 350 to building units 90 is accomplished in this exemplary embodiment using attachment means 70 , which means are better illustrated in FIG. 2 a , a perspective exploded view of area “ FIG. 2 a ” as indicated in FIG. 2 . It is to be understood that the attachment means used to fixedly attach the barrier to the building units may be any known or yet to be known attachment means, such as bolts, screws, nails, staples, and adhesive to name a few.
Pin 72 is illustrated in FIG. 2 a being inserted into an aperture in strapping 60 to pass through second fire-resistant supporting mesh 52 , second insulation blanket 42 with adhered metallic backing layer 43 , first fire-resistant supporting mesh 50 , first insulation blanket 40 with adhered metallic backing layer 41 , protective cloth 30 , and into the building unit 90 to fixedly attach fire barrier 350 to building unit 90 . Washer 70 assures the secure fit of pin 72 . Pin 72 illustrates one mounting means for mounting a fire barrier to a building structure. Where the building structure is concrete, the mounting means would have to be any mounting means adapted for mounting an object to a concrete structure, such as a Hilti Gun. Accordingly, if the building structure is of a material other than concrete, the mounting means would be adapted accordingly. Such mounting means are well known in the art and need not be discussed further here.
Also illustrated in FIG. 2 a is the removal of friction fit washers 72 T, spacers 74 T, and pins 72 T from installation tool 355 to prepare for the removal of the installation tool from the fire barrier so that the installation tool may be used to install the next fire barrier. Spacer 74 T provides for easy removal of installation tool 355 from barrier 350 once the installation of barrier 350 into a three-way expansion joint is complete in that spacer 74 T provides for friction fit washer 72 T to be easily and rapidly removed from pin 72 T using only a simple pair of pliers. Spacer 74 T is then simply lifted from 72 T using only finger effort. When all of the washers and spacers are removed from the installation tool the tool is removed ready for the next installation, and the pins are clipped close to the surface of the strapping.
FIG. 3 , a perspective view, illustrates inside-mounted T-shaped fire barrier 350 fixedly attached to building units 90 after T-shaped barrier installation tool 355 is detached. The installation of T-shaped fire barrier 350 is now complete.
FIG. 4 , a cross-section view taken along line FIG. 4-FIG . 4 , illustrating the inside-mount attachment of the T-shaped fire barrier to T-shaped building units before the T-shaped barrier installation tool is detached from the barrier. FIG. 4 illustrates one way that the various sheets of fire resistant materials may be attached to each in the early stages of the formation of the fire barrier. In this example, outer protective cloth 30 is attached to first insulation blanket 40 with adhered metallic backing layer 41 and edged with intumescent strip material 20 that is stitched to first insulation blanket 40 by means of high-temperature thread 22 and to first fire-resistant supporting mesh 50 using pins 72 B and capping friction fit washers 70 on each end. Likewise, second insulation blanket 42 with adhered metallic backing layer 43 is attached to second fire-resistant supporting mesh 52 using pins 72 B and capping friction fit washers 70 on each end.
It should be obvious that each of the styles of spreader disclosed is as suitable for fitting around a corner as it is for fitting along a straight line fire barrier segment.
Thus it has been shown that the present invention comprises fire and cycle tested pre-assembled, multi-directional fire barriers, constructed as single-piece units that require no spicing for installation purposes, are designed for inside-mount installation into multi-directional architectural expansion joints formed by the intersection of two or more architectural expansion joints to prevent the migration of heat, gases, flame, and smoke through the expansion joint spaces of structures, where each barrier is provided with a one-step, low cost, and a reusable installation tool for drop-in installation. | Multi-directional, one-piece, tested and rated, inside-mount fire barriers requiring no splicing to fit into expansion joint corner-type spaces are presented. Accompanying low-cost, re-useable, size-adjustable installation tools designed for one-step, drop-in, installation of each style barrier, are also taught. To insure a tight-fit between each installed barrier and the building units forming the joint space, spreader press-fit tools which, if desired, may serve as fire barriers covers are taught. Described herein is a barrier that needs no splicing to be installed into a T-shaped joint space that is created by the convergence of three building structures. The present invention contemplates inside-mounted, one-piece barriers shaped to fit cross-shaped and various L-shaped expansion spaces. L-shaped fire barriers include barriers having a horizontal and a vertical arm that can occur in various configurations and barriers having two horizontal arms. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a servo device for a multineedle sewing machine, and more particularly to a servo device for a multineedle sewing machine which includes two needle bars; driving and stop means for said needle bars; means for engaging and disengaging the two needle bars relative to the driving and stop means; a feed-length adjustment device associated with at least one feed dog for the transport of the material being sewn; an adjustable thread tensioning device for the needle threads; means for locking each needle bar selectively in its highest position; positioning drive means for the multineedle sewing machine; and means including a position indicator attached to an arm shaft of the multineedle sewing machine, for adjusting the speed of rotation and positioning the needle bars in predetermined positions.
A switching device for a multineedle sewing machine for optionally engaging and disengaging the needle bars is disclosed in Federal Republic of Germany Utility Model No. 83 35 949, expressly incorporated by reference herein. In that disclosure, the switching device makes it possible for each needle bar, by activation of an electromagnet in cooperation with a pivotally mounted lever mechanism, to be locked in its highest position. In this position, the needle bar is in its disengaged position, i.e., it now cannot be moved either up or down.
The above-mentioned arrangement for engagement or disengagement of the needle bars has the following disadvantages:
1. If the engagement or disengagement is to take place exactly at the top dead center of the needle bars, i.e., at their highest position during the course of their movement, then in the case of so-called corner seams, it will not be possible to terminate two parallel-extending seams precisely at the correct point, before the disconnecting of a needle bar, to provide the proper course of the seam. This problem is due to the relatively large distance between the top surface of the workpiece being sewn and the tips of the sewing needles. As a result, the correct course of the seam is not assured when making corner seams.
2. On the other hand, if the engagement or disengagement is not to take place at the top dead center of the needle bars, then if the seam terminates directly before the disengagement of a needle bar, the above-mentioned distance is decreased or becomes equal to zero, if the tips of the sewing needles contact the top surface of the workpiece, or pass through the workpiece. However, the needle bar which is to be disengaged can only be locked at the top dead center. Therefore, until the moment of disengagement, the part being sewn continues to be pushed forward by an amount which is referred to hereinbelow as a partial stitch length. To avoid damaging the part being sewn, the sewing machine operator must commence the aforementioned termination of the seam in advance, by an amount equal to this partial stitch length, if exact corner sewing is to be obtained. In actual sewing operations, this early termination of the seam, directly before the disengagement of a needle bar, cannot be achieved with the required precision. Thus, here also, the correct course of the seam is not assured when sewing corners.
Furthermore, the engagement and disengagement of the needle bars of a multineedle sewing machine, which may be provided by a ball-detent mechanism, is known, for example, from Federal Republic of Germany Pat. No. 955,023, expressly incorporated by reference herein. Since in this device too, the needle bars are locked at the top dead center, the aforementioned disadvantages are also present in this multineedle sewing machine.
SUMMARY OF THE INVENTION
The object of the invention is to avoid the above-mentioned disadvantages, by providing a servo device which, after the disengaging, as well as after the engaging, of one of the needle bars, permits repeated penetration of the sewing needle, guided by the nondisengaged needle bar, into the needle-penetration hole of the sewing stitch last produced.
This object is achieved by a servo device comprising control means including a pair of electrical switch means which respectively correspond to said needle bars, for controlling the engagement and disengagement of said needle bars relative to said driving and stop means; first setting means associated with said control means, for selectively interrupting the transport by said feed dog of the material being sewn; and second setting means associated with said control means, for temporarily increasing a thread tensioning force exerted on said needle thread by said thread tensioning device.
In the servo device according to an embodiment of the invention, at the same time the disengagement or the engagement of a needle bar begins, the length of advance of the feed dog is set to zero and the thread tension acting on the needle threads is increased. This results in a sewing stitch formed with a feed length of zero, which may be referred to as a "zero stitch." This provides a firm looping--and thus a proper attachment to the part being sewn--of the respective loop thread around the needle thread. In this way, dependable efficient corner sewing of two seams extending parallel to each other is made possible. With the servo device of the invention, for the first time it is possible to economically produce so-called "fashion corners," which are employed in sports jackets, coats and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will be understood from the following detailed description of embodiments thereof, with reference to the drawings, in which:
FIG. 1 is a schematic end view, taken from the left of the arm head as shown in FIG. 2, of a multineedle sewing machine having a servo device for the engagement and disengagement of the needle bars, the servo device having setting devices which include pressure-fluid-actuated cylinders;
FIG. 2 is a schematic side view of a multineedle sewing machine which includes a thread tensioning device on its arm, the feed foot and the holding foot not being shown in order to clarify the drawing;
FIG. 3 is a schematic end view of the multineedle sewing machine having a servo device for the engagement and disengagement of the needle bars, the servo device having electromagnetic setting devices; and
FIG. 4 is a diagram showing two seams produced by a multineedle sewing machine, for use in explaining the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 2 shows a machine arm 1 of a multineedle sewing machine. According to the embodiments shown in FIGS. 1 and 3, the machine arm 1 has both bottom and top feed. The top feed has been described in detail in German Pat. Nos. 23 37 966 and 26 20 209, expressly incorporated by reference herein, so that further description may be dispensed with here. The machine arm 1 is provided at its front end with an arm head 2 in which--as can be noted from the above-mentioned prior patents--a frame 3 is pivotally mounted. Two optionally engageable and disengageable hollow needle bars 4, 5, which are associated with appropriate interior driving means and stop means, and a feed foot bar 6, are supported on the frame 3 for upward and downward movement. The driving means and stop means, for the engagement or disengagement of the needle bars 4, 5, and the engagement or disengagement operations for switching the needle bars, are described in detail in Federal Republic of Germany Pat. No. 955,023, expressly incorporated by reference herein, so their detailed description may be dispensed with here.
As disclosed therein, the needle bars 4, 5 are engaged and disengaged by a remotely controllable switch device 7, including a mechanism which comprises two electromagnets, two pivotally mounted lever mechanisms, and two switch bars which can be moved up and down by the lever mechanisms.
The switch bars are received by the hollow needle bars 4, 5 for engaging and disengaging the latter. The electromagnets, lever mechanisms and switch bars which have just been mentioned, as well as the operation of the switch device 7, need not be described here since they have been described in German Utility Model No. 83 35 949, expressly incorporated by reference herein.
The feed-foot bar 6 supports a feed foot 8 which is movable in a skipping fashion. An upwardly and downwardly movable holding-foot bar 9, which supports a holding foot 10, is mounted in the arm head in a known manner. As disclosed in German Pat. Nos. 23 7 966 and 26 20 209, expressly incorporated by reference herein, the feed foot 8 and the holding foot 10 cooperate for alternately feeding and holding the workpiece being sewn.
In order to assure precise transport of the material being sewn, which may be a part 11 consisting of several layers, the skipping feed foot 8 engages the top side of the sewing material 11 between a throat plate 12 and the holding foot 10, as shown in FIGS. 1 and 3, and a skipping feed dog 13 engages the bottom side. The feed foot 8 and feed dog 13 operate completely synchronously with each other.
The feed dog 13 is mounted on a support 14. At the right side of the support 14, as shown in FIG. 1, a lever mechanism 15 engages the support 14 and causes a lifting movement of the feed dog 13. At the left side of the support 14, another lever mechanism 16 engages the support 14 and causes a pushing movement of the feed dog 13. The lever mechanisms 15 and 16 are pivotally mounted in a known manner on a base plate 17 to which, inter alia, the machine arm 1 and the throat plate 12 are connected.
In order to change the length (the stitch length) of a transport step by which the sewing material is advanced, the multineedle sewing machine has a feed-length adjusting device 18, known per se, which comprises the lever mechanism 16 and a slot guide 19 which is pivotally mounted in the base plate 17. In order to change the feed action exerted on the part 11 being sewn, the slot guide 19 is pivoted by a connecting rod 21 in response to the pivoting of a stitch-setting lever 20. The stitch-setting lever 20 extends out of a machine stand 22 in which it is pivotally mounted. The pivoting of the stitch-setting lever 20 is limited by two stops 23, 24 with adjustable position which are arranged on the machine stand 22.
The stitch-setting lever 20 is pulled by a tension spring 25 against the stop 23. In this position, for forward sewing, the feed dog 13, in cooperation with the feed foot 8, moves the part 11 being sewn with a maximum length of feed. If, however, the stitch-setting lever 20 is pressed against the stop 24 in opposition to the action of the tension spring 25, then the sewing material 11 is moved with a maximum length of feed for performing rearward sewing. During the pivoting of the stitch-setting lever 20 which has just been described, it passes through the so-called zero position of the slot guide 19, wherein neither the feed dog 13 nor the feed foot 8 carries out any feeding movement on the part 11 being sewn.
By activating a setting member 28, which is fastened to the base plate 17, a ram 27 can be moved against an extension arm 26 which is firmly connected to the slot guide 19. The setting member 28 can be a single-acting cylinder 29 which is actuated by pressure fluid and which, as shown in FIG. 1, may be controlled via a 3/2-way solenoid valve 30. Alternatively, as shown in FIG. 3, the setting member 28 may have an electromagnet or solenoid 31 for actuation thereof.
On the machine arm 1 there is fastened a thread tensioning device 32, known per se, which comprises a plate 33 with thread tensioning elements 34 to 37 mounted therein. The thread tensioning elements consist in each case of two correspondingly shaped discs 38 which are pressed against each other in known manner by a compression spring with adjustable spring force. In this way, a definite thread tensioning force is imposed upon a needle thread 59 which is passed between the two discs 38 A single-arm lever 40 is mounted pivotally on a pivot point 39 in the plate 33, projections 41, 42 being provided on said lever. The lever 40 has a tongue 43 against which a ram 44 can be applied by activation of a setting member 45. The setting member 45 can be a single-acting cylinder 46 actuatable by pressure fluid which, as shown in FIG. 1, is controlled by a 3/2-way solenoid valve 47, or it can be an electromagnet or solenoid 48 (FIG. 3).
Since in this embodiment both cylinders 29, 6 are activated simultaneously, they may alternatively be controlled via a single 3/2-way solenoid valve, for instance 30. The solenoid valves 30, 47 are connected in a known manner to a source 62 of pressure fluid.
The setting member 45 is firmly connected to the machine arm 1 by an angle plate 49. The pivoting of the lever 40 takes place against the action of a tension spring 50 which is provided between the angle plate 49 and the tongue 43.
An arm shaft 51 of the multineedle sewing machine is driven in known manner by a positioning drive 52. To the arm shaft 51 there is rigidly connected a position indicator 61 which, in known manner, regulates the speed of rotation and the positioning of the needle bars 4, 5 in predetermined positions.
The commands necessary for the engagement and/or disengagement of the needle bars 4, 5 are given via a control 53 which may suitably be integrated in a control device, not shown here, which is part of the positioning drive 52.
Arranged at an adjustable position on the arm head 2 is a light barrier which comprises a transmitter 54 and a receiver 55. The latter is preferably arranged in the throat plate 12 in such a manner that it does not interfere with the movement of the feed dog 13.
Two electric switch elements 56 for the engagement and disengagement of the needle bars 4 and 5 respectively are also provided on the arm head 2 and therefore in the vicinity of a sewing point 60. In the preferred embodiment, the switch elements 56 are push buttons 57, 58. As can be noted from FIGS. 1 and 3, the transmitter 54, the receiver 55 and the push buttons 57, 58 are connected in a circuit with the control 53. Thus, either interrogation of the light barrier (transmitter 54, receiver 55), or actuation of the push buttons 57, 58, will cause switch signals which will be supplied to the control 53.
The manner of operation of the servo device of the invention will now be described.
A multineedle sewing machine produces seams extending parallel to the edge K (FIG. 4) of a part 11 being sewn. As a rule, these seams follow an angular course at acute, obtuse, or right-angle corners of the part being sewn. However, in the case of sewing seams as shown in FIG. 4, the sewing process is interrupted upon reaching the needle-penetration holes A and B, the positioning drive 52 positioning both sewing needles in their lowest position. The penetration holes A and B must be at such a distance from the edge K' of the part 11 being sewn that the following penetration hole H is at the same distance from both the edges K and K'. The interruption of the sewing process at A and B is brought about by transmitter 54 and receiver 55, which sense the edge K' of the part 11 being sewn.
Upon the interruption of the sewing process, in which the sewing needles are positioned in lowest position at A and B, the disengagement of the needle bars 4, 5 is effected by depressing the switch elements 56. With the seam shown in FIG. 4, the needle bar 4 must be disengaged by pressing the push button 57 for sewing the corner. In this way the following operations are simultaneously brought about:
(a) The arm shaft 51 carries out a further revolution.
(b) The activated setting member 28 pivots the slot guide 19 into its "zero position" in which no feed action is exerted on the part 11 being sewn.
(c) The activated setting member 45 pivots the lever 40 in the counter-clockwise direction, as a result of which additional thread tensioning forces are imposed on the needle threads 59 by the thread tensioning elements 34 and 36.
(d) The corresponding electromagnet which is in the switch device 7 is energized and effects the disengagement of the corresponding needle bar 4.
After the completion of the revolution carried out by the arm shaft 51, the needle bar 4 is locked in its highest position (top dead center), i.e., disengaged, while the sewing needle borne by the nondisengaged needle bar 5 again enters into the penetration hole B of the last sewing stitch produced, and is positioned in its lowest position. In order for the sewing needle borne by the needle bar 5 to then proceed to the corner of the part 11 being sewn at a predetermined place, it must carry out at least one additional sewing stitch. With the seam shown in FIG. 4, two additional sewing stitches must be produced, having the penetration holes C and D. These individual sewing stitches are produced either with the pedal or by depressing a third push button, not shown here.
To locate the corner penetration hole E with precision, it is necessary for the last sewing stitch DE to be produced with a stitch length which differs from that of the sewing stitches previously made. The necessary stitch length is estimated by the operator of the sewing machine and is either set on the stitchsetting lever 20, or else an adjustably set partial stitch length is carried out by depressing a further push button, not shown here. The sewing needle 5 is now located in the penetration hole E and in its lowest position. This makes it possible, after lifting the holding foot 10, for the part 11 being sewn to turn around the sewing needle of the needle bar 5, whereby the part 11 is positioned for the following sewing process, in which both seams will extend parallel to the edge K'.
After the part 11 has been turned around the needle at E as previously described, at least one further sewing stitch is produced with the needle bar 4 still disconnected. If the stitch length is, for instance, half as large as the distance between the two seams, then after the turn around E, two sewing stitches must be carried out. In this connection it is noted that the penetration hole G should lie on the alignment line of the inner seam (see FIG. 4). In this connection also, the necessary stitch length must be estimated by the operator of the machine and be carried out by adjustment of the stitch setting lever 20 or by depressing the aforementioned fourth push button (not shown).
After the completion of the sewing stitch FG the sewing needle borne by the non-disconnected needle bar 5 is within the penetration hole G and in its lowest position. Now, by again depressing the push button 57, the needle bar 4 is again engaged, and the functions (a) to (d) described previously take place again in a similar manner. The sewing needle of the needle bar 4 is then within the penetration hole H. Thus, the sewing stitch AH has been formed while the sewing needle of the needle bar 5 was penetrated into the penetration hole G of the sewing stitch last produced. Thereupon, the needle bars 4, 5 are again engaged and in their lowest position, so both of the seams illustrated along side K' in FIG. 4 can continue to be produced in the normal manner, starting with the penetration holes G and H.
The preceding discussion of embodiments of the invention has been illustrative rather than limiting. Therefore, the appended claims should not be so limited, but should be construed to include modifications and variations thereof which may occur to those of ordinary skill in the art, within the spirit and scope of the invention disclosed herein. | A servo device for a multineedle sewing machine which includes two needle bars; driving and steop devices for said needle bars; devices for engaging and disengaging the two needle bars relative to the driving and stop devices; a feed-length adjustment device associated with at least one feed dog for the transport of the material being sewn; an adjustable thread tensioning device for the needle threads; devices for locking each needle bar selectively in its highest position; a positioning drive for the multineedle sewing machine; and a device including a position indicator attached to an arm shaft of the multineedle sewing machine, for adjusting the speed of rotation and positioning of the needle bars in predetermined positions. The servo device comprises a control system including a pair of electrical switches which respectively correspond to the needle bars, for controlling the engagement and disengagement of the needle bars relative to the driving and stop devices; a first setting device associated with the control system, for selectively interrupting the transport by the feed dog of the material being sewn; and a second setting device associated with the control system, for temporarily increasing a thread tensioning force exerted on the needle thread by the thread tensioning device. | 3 |
FIELD OF THE INVENTION
The present invention relates to an improved process for the hydrogenation of organic compounds, The process is applicable for the hydrogenation of organic compounds consisting of one or more functional groups of the type alkyne, alkene, carbonyl (aldehydic, keto), nitro, nitroso, nitrile, nitrene etc. Specifically, the invention relates to a process for the hydrogenation of organic compounds using water soluble metal complex catalysts in the presence of a promoter in a water immiscible phase. The improved process results in the enhancement of the rate of hydrogenation by interfacial catalysis induced by the presence of a ligand (promoter) in a catalyst imscible phase.
The reaction system comprises of two phases viz--Organic phase and Aqueous phase. The organic phase consists of a substrate and an N- or P- containing water insoluble ligand with or without water immiscible solvent. The aqueous phase consists of a metal complex catalyst comprising of group VIII element such as Rh, Ru, Pd, Pt, Ir, Ni, Co, Fe, Os and a water soluble ligand of the type triphenylphosphine monosulfonate-sodium salt (TPPMS), triphenylphosphine disulfonate-sodium salt (TPPDS), triphenylphosphine trisulfonate-sodium salt (TPPTS), [2 (diphenyl phosphino) ethyl]trimethyl ammonium salt (amphos), [2 (diphenyl phosphino) ethyl]trimethyl phosphonium salt (phosphos) dissolved in water.
BACKGROUND OF THE INVENTION
The hydrogenated products have wide ranging applications in fine chemicals, pharmaceuticals and pertrochemical industries and this invention relates to a significant improvement in the catalytic process by interfacial catalysis, as illustrated by a variety of substrates with different functional groups.
Hydrogenation reactions are industrially important for the manufacture of a wide range of compounds. These products find applications in fine chemicals as well as intermediates in pharmaceutical and petrochemical industries. Hydrogenation reactions using homogeneous catalysis are well known in which addition of hydrogen to a substrate in the presence of a catalyst soluble in the reaction medium is involved. Although, this route has been applied commercially only in a few cases, it is of potential importance for systems where selectivity as well as activity are of prime importance. The major disadvantage in the use of homogeneous catalysis in hydrogenation is the difficulty in separation and isolation of the product from the catalyst solution and recycle/recovery processes.
To overcome these disdvantages various attempts were made to heterogenize these catalysts by binding the metal complex on supports like silica, polymer etc. These methods have so far not provided a commercially viable heterogeneous catalyst since loss of activity, selectivity, leaching, deactivation and decomposition of the catalyst is observed on repeated use (Kalck and Monteil in Adv. Organomet. chem 34, 219-284, 1992 and Bailey and Langer in Chem. Rev. 81, 109, 1981).
A major breakthrough in this direction has been the synthesis of water soluble phosphine ligands (E. Kuntz U.S. Pat. No. 4,248,802, 1981). These water soluble phosphine ligands are generally synthesized by introducing a hydrophilic group on the ligands. These phosphines generally occur in two major classes (1) Phosphines containing quarternized salt as the hydrophilic component e.g. (i) [2 (diphenyl phosphino) ethyl]trimethyl ammonium salt (amphos) (Smith & Baird in Inorg. Chim. Acta. 62,135, 1982) (ii) [2 (diphenyl phosphino) ethyl]trimethyl phosphonium salt (phosphos) (Renaud et. al. in J. organomet. chem. 419, 403, 1991) (2) Phosphines containing sulphonated groups as the hydrophilic component. Triphenyl phosphine monosulphonate sodium salt (TPPMS) and triphenyl phosphine trisulphonate sodium salt (TPPTS).
Besides these major classes, other modifications of phosphines find limited applications (Kalck and Monteil in Adv. Organomet. chem 34, 219-284, 1992 and reference cited therein). These ligands have been used for-the formation of water soluble complexes of transition metals. Such complexes are used as hydrogenation catalysts in two phase (aqueous/organic) systems. The system consists of an aqueous phase, comprising of the metal complex along with the water soluble ligand. The organic phase consists of a reactant with or without water immscible solvent. The reaction occurs in the aqueous phase with dissolved reactants. The products (usually water insoluble) separate out into the organic phase thus making product separation and catalyst recycle/recovery easy. The application of this methodology is, however, restricted to the substrates having marginal solubility in water. Due to a very low solubility of most of the organic compounds in the aqueous catalytic phase, the rates of reaction using these catalyst are significantly lower than the conventional homogeneously catalysed systems.
Use of a co-solvent has been advocated to overcome such limitations (I. Hablot Chem. Engg. Sci. 47, 2689 1992). This approach, however, does not prove to be very useful because of complications involving (i) reactivity of co-solvent (ii) enhanced solubility of water in the organic phase causing leaching of the catalyst (iii) large volumes of co-solvent required.
European patent EP 362037, 1990 deals with the preparation of saturated aldehydes from a, b-unsaturated aldehydes in a biphasic system using Rh catalyst and a water soluble ligand--TPPTS. The organic phase comprises of toluene alongwith the substrate.
Complexes of group VIIA VIIIA and IB elements with TPPTS and optional additional water soluble ligand were utilised for hydrogenation of different substrates in EP 372313, 1990. A Co 2 (CO) 8 /TPPTS catalyst system has been reported for hydrogenation of substrates like cyclohexene etc. in the same patent.
Complexes of group VIIIA elements with TPPTS ligand as hydrogenation catalyst are reported in German Patent DE 3840600, wherein Rh(NO)(TPPTS) 3 complex was used to hydrogenate cyclohexene and cyclooctene.
The hydrogenation catalysts described in the prior art using a biphasic system have a drawback of lower rates due to reactants solubility limitations in the aqueous phase.
SUMMARY OF THE INVENTION
The main objective of the present invention is to provide an improved process for the hydrogenation of organic compounds using a biphasic medium, to obtain higher rates of reaction. Another objective of present invention is to provide an improved process for the hydrogenation of organic compounds. Yet another objective of the present invention is to provide process for the hydrogenations of organic compounds in biphasic media, using water soluble catalysts comprising of group VIII metal complexes and substrates containing functional group like alkyne, alkene, carbonyl, (aldehydic, keto) nitro, nitroso, nitrile.
Still another objective of the present invention is to provide a hydrogenation process having enhanced rate of reaction without causing significant losses of the catalysts into the organic phase thereby retaining the activity and selectivity of the water soluble catalyst.
The main findings underlying the inventions can be summerized as follows:
It is observed that introduction of water ,insoluble ligand like tertiary aryl as well alkyl phosphines and phosphites into the organic phase causes significant enhancement in reaction rate in a biphasic catalytic hydrogenation. The presence of a ligand in the organic phase having negligible solubility in the aqueous phase results in substantial enriching the catalyst concentration at the liquid-liquid interface and hence results in dramatic enhancement in the rate of reaction.
The enhancement in the rate is obtained without affecting the liquid-liquid equilibria in significant way.
The improved process in the present invention has the following advantages over the processes described in the prior art:
Significant enhancement (2-100 times) in the rate of reaction of a biphasic catalytic hydrogenation as a result of interfacial catalysis.
Negligible or no loss of catalyst to organic phase by leaching.
Effective in absence or presence of aliphatic or aromatic solvents.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is concerned with the modification of the conventional catalytic system for biphasic hydrogenation reactions.
The reaction system consists of two phases, Aqueous and organic (water immiscible). The organic phase comprises of a substrate with or without solvent (water immiscible) and water insoluble ligand. The aqueous phase consists of a catalyst containing group VIIIA metal along with water soluble ligand dissolved in the aqueous phase. The reaction is carried out by contacting hydrogen with the substrate and the catalyst in the aqueous-organic dispersion.
Examples of substrates that can be used as starting material consist of aliphatic or aromatic compounds containing one or more of the following functional groups alkyne, alkene, carbonyl, (aldehydic, keto) nitro, nitroso, nitriles (eg. butynediol diacetate, phenylacetylene, cyclohexene, octene, decene, tetradecene, hexadecene, heptaldehyde, valeraldehyde, benzaldehyde, benzophenone, acetophenone, methyl isobutyl ketone, cyclohexanone, nitrobenzene, o-nitrophenol, p-nitrophenol, o-nitroaniline, nitrosobenzene, nitrosophenol, adiponitrile, benzonitrile, crotonaldehyde, butyraldehyde, hexenal, 2-ethylhexenal, acrylonitrile, polybutadiene, etc.).
Examples of solvents immiscible in water which may be used in this invention include aliphatic and aromatic hydrocarbon solvents like hexane, heptane, octane, decane, benzene, toluene, o-, m-, p- xylene, cyclohexane, methylene chloride, ethylene chloride, ethyl acetate, diethyl ether, etc. However it is not a prerequisite for solvent to be utilised in the process of present invention.
Examples of water insoluble ligands added in the organic phase include N- or P- containing ligands of the type triphenyl phosphine, triphenyl phosphite, tributyl phosphine, tributyl phosphite, triethyl phosphine, triaryl and trialkyl phosphine, triaryl and trialkyl phosphites, and mixed phosphines i.e. alkyl-aryl-phosphines, trialkyl amines, triaryl amines, diphosphines, N- containing compounds like tertiary, secondary or primary amines, heterocycles, quinolines, substituted quinolines, pyridines etc.
The catalysts used in the process of present invention consist of water soluble metal complexes prepared from group VIIIA metals (eg. nickel, iron, cobalt, palladium, rhodium, platinum, ruthenium, iridium and osmium) or complexes of the said elements or compounds containing group VIII elements (eg. platinum metal carbonates, halides, sulphates, hydroxides, chlorates).
Examples of water soluble ligands which can be employed in the process of the invention can be of the type PPh n (C 6 H 4 SO 3 M) 3-n (M=alkali metal, alkaline earth metal/2, quaternary ammonium group); n=0, 1 or 2. Water soluble phosphines containing qarternary ammonium group eg. amphos and phosphines containing phosphonium or acetate, hydroxyl groups.
The reaction may be carried out in the temperature range of 50°-150° C., preferably in the range of 80°-120° C. The hydrogen partial pressure used may vary between 5-2000 psig, most preferably between 100-600, psig. The hydrogen gas employed may be pure hydrogen as available commercially or may be contaminated with inert gases like nitrogen upto 10%. The molar ratio of group VIII element used as the catalyst to the water soluble ligands employed can be between 0.5 to 100 preferably between 1 to 20. The ratio of group VIII element used as the catalyst to the water insoluble ligand may vary between 0.01 to 50, Preferably between 0.1 to 5. The agitation speed employed for the reaction may vary between 300 to 2000, rpm. The phase holdup ratio employed may vary between 0.1 to 10 (aqueous to total liquid volume). The molar ratio of catalyst to substrate may vary between 1:5 to 1:8000 mol, preferably between 1:20 to 1:1000.
No process is hitherto known for the hydrogenation of organic compounds in which a dramatic increase in the rate of a biphasic catalytic reaction is reported through a interfacial catalysis.
The present invention is not limited to hydrogenation reactions as it can be extended for application to other similar biphasic catalytic reactions like hydroformylation, carbonylation, telomerization, metathesis, polymerization etc.
The process of the invention is described in detail in the examples given below that are presented by way of illustration only and should not be confined to limit the scope of the invention.
EXAMPLE 1
The following charge consisting of aqueous and organic phases was introduced in a 50 cc microclave equipped with magnetic drive type agitation system and connected to a reservior of hydrogen under pressure.
The aqueous phase consisted of 0.025 g (0.05 mmol) of dirhodium dicyclooctadienyl dichloride [Rh(C 8 H 12 )Cl] 2 , representing 0.0001 g atom of Rh, was dissolved in deaerated water containing 500 mg of the trisodium salt of tris(sulfophenyl) phosphine (TPPTS) (0.664,mmol), and diluted to 10,cm 3 with deaerated water. The TPPTS was used from a stock solution of 50% w/w concentration in deaerated water. The molar ratio of Rh:TPPTS was 1:6. The organic phase consisted of 1-octene 10 cm3 (63.7 mmol) in the absence of any solvent along with triphenylphosphine 26 mg (0.1 mmol). The molar ratio of Rh:P was 1:1. The contents were heated upto 100° C. and the reaction was carried out at pH 2 of 400 psi and a stirring speed of 900 rpm. The reaction was carried out to completion. The reaction was over in 26 minutes. The activity moles of product form per grams of Rh per s of this reaction was found to be 1.63×10 -3 mol/s/g. The analysis of the reaction showed 99.8% conversion and 99.5% selectivity towards n-octane which is final product. In comparision the reaction taken in the absence of triphenyl phosphine in the organic phase (other charge is same as above) took 154 min for completion. This shows activity of 2.76×10 -4 mol/s/g. Conversion of this reaction was found to be 98.6% and selectivity of 99.0% towards final product i.e. n-octane.
EXAMPLE 2
The charge similar to that given in example 1 was taken except that 1-tetradecene 10 cm 3 (40.0 mmol) was taken instead of 1-octene. The reaction was completed in 26 minutes. The activity of this reaction was found to be 4.83×10 -4 mol/s/g. Conversion of this reaction was found to be 99.6% and selectivity of 98.2% towards final product tetradecane. A similar reaction taken in absence of triphenylphosphine took 90 minutes to go to completion, which shows the activity of 2.85×10 -4 mol/s/g. Conversion of this reaction was found to be 98.9% and selectivity of 97.4% towards final product n-tetradecane.
EXAMPLE 3
The charge similar to that given in example 2 was taken except that the tri-t-butylphosphine was used instead of triphenylphosphine in the same ratio of metal to phosphine. The reaction was completed in 9 minutes. This shows the activity of 3.90×10 -3 mol/s/g. Conversion of this reaction was found to 98.8% and selectivity of 99.1% towards final product n-tetradecane.
EXAMPLE 4
The charge similar to that given in example 2 was taken except that the tri-t-butylphosphite was used instead of triphenylphosphine in the same ratio of metal to phosphine. The reaction was completed in 23 minutes. The activity of this reaction was found to be 1.13×10 -3 mol/s/g. Conversion of this reaction was found to be 99.6% and selectivity of 98.3% towards final product n-tetradecane.
EXAMPLE 5
The charge similar to that given in example 2 was taken except that the tri-t-phenylphosphite was used instead of triphenylphosphine in the same ratio of metal to phosphine. The reaction was completed in 12 minutes. This shows the activity of 2.18×10 -3 mol/s/g. Conversion of thi reaction was found to be 99.1% and selectivity of 99.2% towards final product n-tetradecane.
EXAMPLE 6
A procedure similar to that indicated in example 1 was used. The following charge was taken. The aqueous phase consisted of RuCl 3 .xH 2 O 10.4 mg (0.1 mmol) equivalent of 0.0001 g atom of Ru dissolved in TPPTS solution containing 500 mg (0.664, mmol) of TPPTS, diluted to 10, cm 3 using deareated water. The organic phase consisted of 1-tetradecene 10, cm 3 (40.0, mmol) and tributylphosphine 0.05 mmol. The ratio of metal to phosphine used was 1:0.5. The condition and monitoring methodology were the same as in example 1. The reaction was found to go to completion in 15 min. The activity of this reaction was found to be 4.17×10 -3 mol/s/g. Conversion of this reaction was found to be 98.6% and selectivity of 99.1% towards n-tetradecane.
In comparision the reaction in absence to tributylphosphine went to completion in 135 min with the activity of 4.61×10 -4 mol/s/g. Conversion of this reaction was found to be 98.2% and selectivity of 99.1% towards n-tetradecane.
EXAMPLE 7
The charge similar to that given in example 6 was taken except that benzaldehde 10 cm 3 (98.4 mmol) was used for the reaction instead of 1-tetradecene and triphenylphosphine instead of tributylphosphine with metal to phosphine ratio of 1:1. The reaction was carried out for 120 minutes. Analysis of the organic phase showed 72% conversion of benzaldehyde with the selectivity of 95.6% to benzyl alcohol. The activity of this reaction was found be 9.05×10 -4 mol/s/g. For the same time the reaction conducted in the absence of triphenylphosphine showed only 38% conversion with benzyl alcohol selectivity of 94.8%. The acivity of this reaction is 4.7×10 -4 mol/s/g.
EXAMPLE 8
The procedure and methodology of monitoring the reaction as given in example 1 were used. The organic phase consisted of nitrobenzene 2,cm 3 (19.4 mmol) in toluene (13 cm 3 ) as a solvent along with triphenylphosphine 26,mg (0.1 mmol ). The reaction was found to go to completion in a period of 39, minutes. The activity of this reaction is 3.28×10 -4 mol/s/g. Conversion of this reaction was found to be 99.8% and selectivity of 99.2% towards aniline. Whereas, the reaction in the absence of triphenylphosphine took 95, minutes for completion. Conversion of this reaction was found to be 98.2% and selectivity of 99.1% towards aniline. The activity of this reaction is 1.32×10 -4 mol/s/g.
It is evident from these examples that the addition of a ligand/promoter in the organic phase causes a significant enhancement in the rate of the reaction by inducing an interfacial reaction. Besides the process of the reaction can be used for the hydrogenation of varierty of substrates as indicated above. | A process for the hydrogenation of organic compounds using water soluble catalyst in a biphasic media by: (A) forming an organo-water dispersion of (i) an organic phase having (a) an organic compound and (b) an organic solvent, and (ii) an aqueous phase having a water soluble group VIII metal catalyst composition and a water soluble ligand; and (B) contacting said dispersion with hydrogen to provide an interfacial reaction between said organic compound and said hydrogen, giving significant enhancement in the rate of reaction to produce saturated organic compound as compared to a reaction carried out in the absence of said water immiscible ligand. | 2 |
This is a continuation of application Ser. No. 635,983, filed July 30, 1984 now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to a method of fabricating an optical component. The optical component consists of a large number of thin glassy layers of different refractive indices deposited from the vapor phase in a prescribed sequence on a solid substrate. Gratings made in this way are used, for example, in optical telecommunications.
European Patent Application No. 0,017,296 (corresponding to U.S. Pat. No. 4,296,143) describes the fabrication of rotationally symmetric lenses by depositing, from vapor phase, a large number of thin glassy layers of different refractive indices into grooves in a glass plate. The thickness of the coated glass plate is reduced, after the glass deposition, to its original value. There remain in the grooves the halves of so-called Luneberg lenses, which consist of superimposed semispherical layers.
In the known method, good results depend on the accuracy with which the grooves are produced in the glass plate and on the precision in the mechanical treatment of the glass layers left after reduction.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method of fabricating versatile diffraction gratings and other optical components by depositing glass layers from the vapor phase in only a few process steps.
According to the invention, a large number of layers with a prescribed refractive index profile are deposited one after the other. By cutting the multilayer structure in prescribed ways, different optical components can be produced. The particular advantage of this method is the many optical structural components which can be fabricated by providing different sequences of layers.
In a preferred embodiment of the invention, sequences of layers are deposited in such a way as to produce a parabolic refractive index profile. Parts are cut from the stack of layers whereby the cut faces are separated by integral multiples of one quarter pitch. A further advantage is that the substrate on which the layers are deposited does not have to be of any optical significance.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is perspective views of various stages of manufacture of structural components fabricated by the method according to the invention.
FIG. 2 is a perspective view of details of an optical grating according to the invention.
FIG. 3 schematically shows various usable sequences of layers.
FIG. 4 is a perspective view of a group of optical gratings made by the method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The substrate 10 shown in FIG. 1 is coated by vapor deposition with a large number of thin layers of glass of different refractive indices. The dashed arrows represent glass being deposited. In order to obtain parallel, planar layers, the substrate surface must be smooth.
The deposition process is a CVD process described in European Patent Application No. 0,017,296. As compared to the fabrication of Luneberg lenses described therein, according to the invention the stack of layers is cut across the layers, based on optical calculations, into portions 11 that form independent optical components.
In the case of the optical component shown enlarged in FIG. 2, the optical properties depend on distance between the cut faces (that is, the faces cut across the layers) and the sequence of the deposition. In a practical example, the layers are considerably thinner and there is a much larger number of them than shown in the drawing.
The component shown in FIG. 2 can be used as two different gradient cylindrical lenses. The distance between the faces is calculated based on the desired pitch. Dotted lines indicate that when light passes through the component from left to right, or vice versa, the component behaves as a gradient cylindrical lens with a pitch of 0.5. When light passes through the component from front to rear, the component behaves as a gradient cylindrical lens with 0.25 pitch. A component of this type is particularly advantageous as optical systems that are operated in both senders and receivers of light signals.
In the component shown in FIG. 2, the substrate has been removed. A glass substrate is used in another embodiment, not shown in the drawing, in which the rays pass through the component vertically and the layers act as plane-parallel plates.
The parts of the component can be based on any given selectable refractive index profile and can be fabricated accordingly. Diagrams of some refractive index profiles are shown in FIG. 3. In one case, layers of two different refractive indices are deposited alternately with differences of thickness. Alternating layers of different refractive index can be given a fine structure.
The possible sequences of layers indicated in FIG. 3 illustrate the many different optical components that can be made by the method. For example, Fresnel cylinder lenses can be made by the method. (Applied Optics, Vol. 21, No. 11, June '82, pages 1967).
Components made by the method described need not have only rectangular external shapes. They can also have curved surfaces which can be cut out of a stack of layers, and they can also be given a shape where the surfaces have to be finished by subsequent polishing.
FIG. 4 shows an assembly of components made by the method described. By reason of their smooth surfaces, the components made according to the invention can very easily be combined, for example, by cementing them together. In combination, these components produce an optical system equivalent in quality to traditional groups of lenses and prisms. However, by virtue of their shapes which depend on the method of fabrication, these components can be assembled at exceptionally low costs.
The invention can, in addition, be used with the known method of manufacturing Luneberg lenses by the CVD process. Before grinding off the remaining layers, pieces can be removed from the plate in the manner described above, especially from the edge. This results in even better utilization of the deposited material. | Glass layers are deposited according to a prescribed refractive index profile. The multilayer component is divided into precalculated parts, which are rectangular in shape and which have the optical properties of cylinder lenses. The optical properties of such structural components can be determined within wide limits by the nature of the deposition. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrically erasable and programmable ROM (referred to as an EEPROM hereinafter), and more particularly, to an EEPROM in which a negative voltage is applied to the control gate for erasure.
2. Description of the Prior Art
A conventional EEPROM is constituted of a peripheral circuit that includes memory cells arranged in matrix form along word lines and bit lines, a row decoder, and a column decoder. Level shifters are arranged between the row decoder and the word lines and between the column decoder and the bit lines, respectively. The write or read or erase operation for each selected memory cell is carried out as in the following. Namely, by virtue of a designation signal of write or read or erase and address signals, a row output and a column output from the row decoder and the column decoder are input to the respective level shifters, and a row signal having a voltage corresponding to the write or read or erase operation and a column signal having a voltage corresponding to the write or read or erase operation are output from the respective level shifters to a designated word line and a designated bit line.
The conventional EEPROM memory cell is constituted of a select transistor consisting of an N-channel MOS transistor and an N-channel MOS transistor having a stacked gate type structure (a laminated structure of a floating gate and a control gate). In order to avoid possible confusion as to the definition of write and erase operations, it will tentatively be defined here that the write operation is one in which electron injection to the floating gate takes place while the erase operation is one in which electron emission from the floating gate takes place, analogous to the case for an EEPROM. In such an EEPROM it is necessary to carry out the erase operation for every memory cell so that the length of the erase time will become of importance when an erase operation for a large number of memory cells is to be carried out. For such a reason, when the connection of the memory cells is of the NOR type, for example, there has been proposed the flash type EEPROM (abbreviated as a flash memory hereinafter) which has at least the function of erasing simultaneously and in a lump all the data written on the memory cells that belong to the same word line (in particular, erasure for each unit, with one row or a plurality of rows as a unit, is called sector erasure). Because of this, the flash memory has an advantage of reducing the cell size due to the reduction in the erasure time in comparison to the conventional EEPROM and the elimination of the necessity for the select transistors.
Such a flash memory is reported, for example, in IEEE Journal of Solid-State Circuits, Vol. 23, No. 5, pp. 1157-1162. According to the report, the memory cell is constituted of a first gate insulating film (thickness of about 10 nm) provided on the surface of a P-type silicon substrate, a floating gate consisting of N + -type polycrystalline silicon provided on the gate insulating film, a second gate insulating film (thickness of about 25 nm) provided on the top face of the floating gate, a control gate provided on the gate insulating film, and an N + -type source and drain provided on the surface of the silicon substrate in self-alignment with these gates.
The operation of a memory cell with the above-mentioned structure can generally be described as follows. For writing to the memory cell, voltages of 7 V, for example, to the drain, 0 V (ground potential) to the silicon substrate and the source, and 12 V, for example, to the control gate, are applied. Since the floating gate is not connected to an external power supply, its potential is uniquely determined by the ratio of the electrostatic capacities due to the first gate insulating film and the second gate insulating film, and the potentials of the control gate, the source, the drain, and the silicon substrate. Ordinarily, by setting the potential of the control gate to be comparable to the potential of the drain, the injected quantity of the hot electrons (electrons having energies that exceed the energy barrier height of the first gate insulating film) generated by the current that flows between the source and the drain to the floating gate is maximum, so that the aforementioned potential setting is prevalent. As a result, electrons are injected to the floating gate pushing down the potential of the floating gate even to a negative level, and shifts the threshold of the memory cell to the positive direction. Ordinarily, the threshold of the memory cell at this time is set to be about 7 V.
Focusing the attention on one memory cell, the erasure of the memory cell (that is, the erasure of a written data) is to draw the electrons that were injected to the floating gate as in the above from the floating gate. For this purpose, the following method is frequently adopted. That is, a voltage of 12 V, for example, is applied to the source, 0 V (ground potential) is applied to the silicon substrate and the control gate, and the drain is left in the open state. Although the potential of the floating gate is determined uniquely as mentioned above, the floating gate is at a negative potential in the state where the the memory cell is written, so that a potential difference corresponding to this component is added further and a fairly strong electric field (greater than 10 MV/cm at this time) is applied to the first gate insulating film between the source and the floating gate. Under such a strong electric field the Fowler-Nordheim current based on the quantum mechanical tunnel effect flows in the first gate insulating film. Utilizing this effect, electrons are drawn from the floating gate to the source, performing the erasure of the memory cell. For example, in a device of the NOR type, the sources of the memory cells connected to the same word line have a common potential so that when one memory cell is erased, at least the remaining memory cells belonging to the same word line will also be erased.
In the conventional flash memory, the erasure method that draws electrons to the source as described in the above has certain problems which deteriorate the reliability of the cell. At this time, a high voltage in the reverse direction of about 12 V with respect to the P-N junction of the source is applied to the source, which was found to create two problems. A first problem is the junction breakdown and a second problem is the generation of hot holes (holes having energies that exceed the energy barrier height of the first gate insulating film) and their injection into the floating gate which takes place prior to the occurrence of the junction breakdown.
To cope with these problems there have been proposed methods for drawing the electrons from the floating gate without applying a high reverse voltage to the source. According to a first method reported in IEDM Technical Digest, 1990, pp. 111-114, erasure is carried out by applying voltages of 5 V to the source and -12 V to the control gate while leaving the drain in the open state. In this method the voltage applied to the source is low so that the junction breakdown would not be generated. The key point of this method is to push out the electrons accumulated in the floating gate to the source side by the application of a negative voltage to the control gate. On the other hand, according to a second method as reported in IEDM Technical Digest, 1990, pp. 115-118, erasure is carried out by applying 0 V (ground potential) to the control gate and applying positive voltages to the source, the drain, and the silicon substrate. The write operation in this method is realized by applying 0 V (ground potential) to the source, the drain, and the silicon substrate, and applying a positive voltage to the control gate alone. The advantage of this method resides in the fact that the application of a high local electric field to the source can be avoided at the time of write or erase, thereby enhancing the reliability of the memory cell.
Both of the above-mentioned methods do have respective features in enhancing the reliability of the memory cell. Note that the contents of these reports place the emphasis on the memory cells, and make no reference to the peripheral circuits. However, when one considers these reports by including up to the peripheral circuits, the presence of different kinds of problem surfaces up. Thus, in the first method, it becomes necessary to pay attention to the constitution of the elements of the circuit that outputs the voltage of -12 V. For example, in an N-channel MOS transistor that constitutes a level shifter connected to the row decoder, a voltage in the forward direction is to be applied to the source or the drain of the transistor which causes a serious problem. Furthermore, a positive voltage is applied to the source, in this method, at the time of erasure, so that it is necessary to isolate the sources that belong to the adjacent word line in order to carry out the sector erasure, which causes an increase in the cell size. On the other hand, the second method has a drawback in that it is applicable to the NAND type EEPROM alone and is not applicable to the NOR type EEPROM.
BRIEF SUMMARY OF THE INVENTION
Objects of the Invention
It is an object of the invention to provide an EEPROM which includes highly reliable memory cells and a highly reliable peripheral circuit.
It is an object of the invention to provide an EEPROM which includes highly reliable stacked memory cells and a highly reliable peripheral circuit.
It is an object of the invention to provide a flash EEPROM which includes highly reliable stacked memory cells and a highly reliable peripheral circuit.
It is an object of the invention to provide a flash EEPROM facilitating the sector erasure which includes highly reliable stacked memory cells and a highly reliable peripheral circuit.
It is an object of the invention to provide a flash EEPROM which includes highly reliable stacked memory cells with small cell size and a highly reliable peripheral circuit.
It is an object of the invention to provide a flash EEPROM facilitating the sector erasure which includes highly reliable stacked memory cells with small cell size and a highly reliable peripheral circuit.
It is an object of the invention to provide a NOR type or a NAND type flash EEPROM which includes highly reliable stacked memory cells with small cell size and a highly reliable peripheral circuit.
It is an object of the invention to provide a NOR type or a NAND type flash EEPROM facilitating the sector erasure which includes highly reliable stacked memory cells with small cell size and a highly reliable peripheral circuit.
SUMMARY OF THE INVENTION
In a flash memory which has on the surface of a P-type silicon substrate stacked gate type memory cells arrayed in matrix form along bit lines and word lines served also as control gates, and a peripheral circuit which includes at least first level shifters connected respectively to one end of the respective word lines and a row decoder connected to the first level shifters, and carriers out erasure by applying a predetermined substrate voltage to the silicon substrate and applying an erase voltage which is negative with respect to the substrate potential to a control gate, the EEPROM according to the invention includes a first N well formed on the surface of the P-type silicon substrate and is applied a first voltage higher than the voltage potential, has on the surface of the first N well first P-channel MOS transistors in number corresponding to the number of word lines, with one of the source and the drain of the respective transistors being connected to the respective word lines and the other of the source and the drain of them being connected to the respective first level shifters, has a first P well formed on the surface and enfolded by the first N well with the erase voltage being applied to it, provided with first N-channel MOS transistors in number corresponding to the number of word lines formed on the surface of the first P well, with one of the source and the drain of the respective transistors being connected to the first P well and the other of the source and the drain of them being connected to the respective second level shifters, has an input terminal which inputs an input signal consisting of the substrate potential or the first voltage and an output terminal which outputs a second voltage with value greater than the substrate potential or an erase voltage, and has at least one of second level shifter, with its output being connected to the gate of at least one of the first N-channel MOS transistor and its input terminal being connected at least to the gate of a first P-channel MOS transistor connected to the first N-channel MOS transistor.
Preferably, the EEPROM has a sector decoder, second level shifters are provided corresponding to the respective word lines, and the outputs of the sector decoder are input to the input terminals of the respective second level shifters.
Preferably, the EEPROM has a second N well formed on the P-type silicon substrate and is given the second voltage, and a second P well formed on the surface and enfolded by the second N well and is given the erase voltage, provided with a second and a third P-channel MOS transistors formed on the surface of the second N well with their respective sources connected to the second N well, provided with a second and a third N-channel MOS transistors formed on the surface of the second P well with their respective sources connected to the second P well, and has the second level shifter constructed by the flip-flop connection of a first CMOS inverter having the second N-channel MOS transistor as a driver and the second P-channel MOS transistor as a load, and a second CMOS inverter having the third N-channel MOS transistor as a driver and the third P-channel MOS transistor as a load, wherein the inputs to the first and the second inverters are mutually in the opposite phases.
Preferably, the EEPROM is a NOR type or a NAND type flash memory.
In the EEPROM according to this invention, when the input signal to the second level shifter is the substrate potential or the first voltage, the output signal is the second voltage or the erase voltage. Because of this, when the memory cells belonging to a certain word line are erased simultaneously, the input signal to the second level shifter is the first voltage, and the first P-channel MOS transistor is turned off so that the word line and the first level shifter connected thereto are disconnected. On the other hand, the output signal from the second level shifter at this time is the second voltage, and the first N-channel MOS transistor is turned on and the erase voltage is applied to this word line. At this time, other first P-channel MOS transistors are turned on, other first N-channel MOS transistors are turned off, the word lines connected to these transistors are not given the erase voltage, and are connected to the respective first level shifters.
Because of this, in the EEPROM of the invention, in spite of the fact that erasure is executed by the erasure voltage which has a negative value with respect to the substrate potential, even if the erase voltage with this negative value is applied to the source and the drain of a first N-channel MOS transistor, there will be generated no forward voltage in the transistor because the transistor is formed on the first P well which is given the erase voltage. Similar circumstances applied also to a first P-channel MOS transistor. Moreover, the separation of potentials is easy because there is interposed the first N well between the P well and the P-type silicon substrate.
Furthermore, in the EEPROM according to the invention it is not necessary to apply a voltage higher than the substrate potential to the sources of the memory cells in order to carry out erasure. Because of this, the memory cells can be given a high reliability, and memory cells with small cell size can be obtained since no isolation between the memory cells belonging to the adjacent word lines is required.
In addition, the EEPROM of this invention makes it possible to carry out the sector erasure because of the aforementioned constitution, and the invention can be applied without any limitation to the EEPROM of the NOR type or the NAND type.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other objects, features, and advantages of this invention will become more apparent by reference to the following detailed description of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a circuit diagram for describing the circuit constitution of a first embodiment of the invention;
FIG. 2 is a schematic plan view for describing the first embodiment from the device aspect;
FIGS. 3A to 3C are schematic sectional views of the first embodiment along the line A--A, the line B--B, and the line C--C in FIG. 2;
FIGS. 4A to 4E are schematic sectional views for the part corresponding to the line B--B in FIG. 2 arranged in the order of processes for describing the fabrication of the first embodiment;
FIG. 5 is a circuit diagram for the second level shifter in the first embodiment; and
FIG. 6 is a circuit diagram for describing the outline of the circuit constitution for a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Next, referring to the drawings, this invention will be described.
Referring to FIG. 1 which shows the principal part of the circuit constitution of a flash memory formed on the surface of a P-type silicon substrate, the first embodiment of the invention is a flash memory with 16-bit constitution, and memory cells (M11, M12, M21, M22, and the like) are arrayed in matrix form and in NOR type along word lines (W1, W2, and the like) and bit lines (B1, B2, and the like). The sources of M11, M12, M21, M22, and the like are maintained for all time at 0 V which is the substrate potential. The lines W1, W2, and the like are connected to a pair of switching transistors, namely, a first N-channel MOS transistor T11 and a first P-channel MOS transistor T21, a first N-channel MOS transistor T12 and a first P-channel MOS transistor T22, and the like, respectively.
The first P-channel MOS transistors (T21, T22, and the like) are formed on the surface of a first P well (not shown, but will be described in more detail later) kept at 5 V which is a first voltage (being equal to a source voltage Vcc of this flash memory). One of the source and the drain of each of T21, T22, and the like is connected to each of W1, W2, and the like, and the other of the source and drain of each of T21, T22, and the like is connected to each of first level shifters (LS1, LS2, and the like). Because of this, T21, T22, and the like are turned on at 0 V, for example, and are turned off at 5 V, for example, functioning as the switching transistors between W1, W2, and the like and LS1, LS2, and the like. Here, the first voltage has to have a value (namely, a value greater than 0 V) for which the first N well does not correspond to the application of a forward voltage with respect to the P-type silicon substrate. Considering the input voltages to the gates of T21, T22, and the like it is preferable to have these first P-channel transistors turned on and off at 0 V (substrate potential) and at 5 V (Vcc). (For example, if the first voltage is chosen to be 0 V, then a voltage lower than -1 V is required to turn on these transistors, requiring a voltage generation circuit exclusively for this purpose.)
The first N-channel MOS transistors (T11, T12, and the like) are formed on a first P well (not shown here, but will be described in detail later on) which is given a potential of -16 V which is an erase voltage. One of the source and the drain of each of T11, T12, and the like is connected to W1, W2, and the like, respectively, and the other of the source and the drain is connected to the first P well. Because of this arrangement, T11, T12, and the like are turned on at 0 V, for example, and are turned off at -16 V, for example, and thus function as switching transistors whether or not to apply the erase voltage to W1, W2, and the like. The first P well is formed on the surface of the first N well, and because of this it is possible to apply the erase voltage to the first P well.
It should be mentioned that if it is desired to connect T11, T12, and the like to the end parts of W1, W2, and the like on the side where W1, W2, and the like are connected to LS1, LS2, and the like, T11, T12, and the like have to be provided respectively between T21, T22, and the like and M11, M12, and the like. Note, however, that T11, T12, and the like may also be provided at the other respective end parts of W1, W2, and the like.
The address signals are input to a row decoder (RD) and a sector decoder (SD) via the respective 4-bit address signal input terminals A1, A2, A3, and A4. The sector decoder is connected to 16 of second level shifters LS1a, LS2a, LS3a, . . . , and LS16a. A sector active signal which is an erase instruction is input to SD from an input terminal SA. The sector active signal is at 0 V when a write or read instruction is given or when the system is at standby whereas it is at 5 V when a write or read instruction is not given and an erase instruction is given.
The output signals (LS1a, LS2a, LS3a, . . . , and LS16a) from SD are input to the gates of T21, T22, and the like to determine the on (0 V) or the off (5 V) of T21, T22, and the like. For this purpose, SD has to have the following function. When the sector active signal is at 0 V, the output signals from SD are all at 0 V regardless of the address signals, and when the sector active signal is at 5 V, the output signal (or signals) from SD is (or are) 5 V only for a sector (or sectors) selected by the address signals, and the output signals from SD at nonselected sectors are 0 V. An SD with such a function is easily realizable by the use of well-known technology.
The output signals from the second level shifters (LS1a, LS2a, and the like) are input to the gates of T11, T12, and the like to determine the on (0 V) or the off (-16 V) of T11, T12, and the like. For this purpose, LS1a and the like have to have a function to have output signals of -16 V, and 0 V which is the second voltage for the input signals of 0 V and 5 V. A circuit constitution with such a function can readily be obtainable based on the well-known technology. The expedients from the viewpoint of device design and the second voltage will be described in more detail later.
Sixteen first level shifters (LS1, LS2, LS3, . . . , and LS16) are connected to RD. Upon inputting of a write or a read instruction signal (the input terminal for this signal is not shown) and address signals to RD a specified row is selected. Since all of T21, T22, and the like are turned on and all of T11, T12, and the like are turned off, a voltage (15 V, for example) corresponding to the write operation or a voltage (5 V, for example) corresponding to the read operation from the selected first level shifter LS1, for example, is applied to W1. Simultaneously, a voltage (7 V, for example) corresponding to the write operation or a voltage (1 V or so) corresponding to the read operation is output from a column decoder (not shown) and level shifters (not shown) connected thereto to a selected bit line (B2, for example). With this arrangement, write or read to M21, for example is carried out. Note that 0 V is applied at this time to all of the nonselected word lines and nonselected bit lines. Moreover, at the time of standby or an erase instruction, the output voltages from LS1, LS2, LS3, . . . , and LS16 and the output voltages from all of the level shifters connected to the column decoder are all at 0 V.
On the other hand, if there is no read instruction and an erase instruction is given, this signal is combined with the address signals from A1, A2, A3, and A4 in response to the input of a 5 V sector signal to SD from SA, and a sector (or sectors) is selected. For example, when the first row alone is selected, 5 V is applied to the gate of T21 alone, out of the first P-channel MOS transistors, to turn off T21 alone. As a result, W1 alone is disconnected from the first level shifter (LS1). On the other hand, when 0 V is applied to the gate of T11 alone, output of the first N-channel MOS transistors, T11 alone is turned off. Because of this, the erase voltage is applied via T11 to only W1 which is disconnected from LS1, and only M11, M21, and the like of the memory cells that belong to W1 are sector erased. At this time, there will occur no erroneous erasure since 0 V is applied to other nonselected word lines such as W2, and since 0 V (the substrate potential) is applied also the drains of all of the memory cells including the selected memory cells. Moreover, it becomes possible to select a plurality of word lines (could also be all of the word lines) by contriving the address signals that are input to A1, A2, A3, and A4.
Referring also to FIG. 2 which is the principal part of the flash memory and FIGS. 3A to 3C which are schematic sectional views along the line A--A, line B--B, and line C--C in FIG. 2, the first embodiment of the flash memory has a constitution as described below.
The memory cells M11, M12, M21, M22, and the like are formed on the surface of the P-type silicon substrate 101 (impurity concentration of 10 16 to 10 17 cm -3 ), have respectively a source 106a and a drain 106b each consisting of an N + -type diffused layer, and have respectively a floating gate 105a consisting of a first gate insulating film 104 (a silicon oxide film with thickness of about 10 nm formed by thermal oxidation) and an N + -type polycrystalline silicon film (with thickness of about 0.15 μm), and a second gate insulating film 114 (with film thickness of about 20 nm when converted to an equivalent silicon oxide film). The memory cells M11 and M12 have a control gate 115a that serves also as W1, and M21 and M22 have a control gate 115b that serves also as W2. Further, W1 is constituted of the control gate 115a and a second aluminum wiring 120ba (with thickness of about 1.0 μm) that is connected to the control gate 115a via a contact hole 119ba, and W2 is constituted of the control gate 115b and a second aluminum wiring 120bb connected to the control gate 115b via a contact hole 119bb. The drains 106b of the memory cells M11 and M12, and M21 and M22 are connected via contact holes 109aa and 109ab respectively to a bit line B1 consisting of a second aluminum wiring 120aa and a bit line B2 consisting of a second aluminum wiring 120ab. Here, the contact holes 109, 119, and the like are formed by etching a first interlayer insulating film 108 (a silicon oxide film with thickness of about 0.1 μm) and a second interlayer insulating film 118 (a filicon oxide film with thickness of about 1.0 μm) [FIGS. 1, 2, and 3A].
On the surface of the P-type silicon substrate 101 there is provided a first N well 111 (with impurity concentration of about 10 17 cm -3 ), and a first P well 121 (with impurity concentration of about 10 18 cm -3 and junction depth of 0.5-1.0 μm). The transistors T11, T12, and the like are formed on the surface of the P well 121. The transistors T11, T12, and the like have a source/drain 116 consisting of an N + -type diffused layer and a second gate insulating film 124, and respectively have gates 135a and 125b. On the surface of the P well 121 there are formed P + -type diffused layers 117 and 127l One of the source/drains 116 is provided at a position adjacent to the diffused layer 117, and is connected to the diffused layer 117 by means of an aluminum wiring 110ac provided via a contact hole 109ac. The other of the source/drains 116 of T11 and T12 are connected to the second aluminum wiring 120ba (W1) and the second aluminum wiring 120bb (W2). The respective gates 125a and 125b are connected via contact holes 109ba and 109bb to a first aluminum wiring 110ba which is the output signal line of LS1a and a first aluminum wiring 110bb which is the output signal line of LS1b, respectively. The P + -type diffused layer 127 is connected to a first aluminum wiring 110ab to which is applied the erasure voltage via a contact hole 109ab FIGS. 1, 2, and 3B.
When one considers solely the energization of T11 and T12, the output signal from the second level shifters for this purpose suffices if it is higher than the value of -14 V. As will be described later the second level shifters in this embodiment will be constituted of a CMOS transistor. In that case, the output signal depends on the voltage (second voltage) applied to a second N well that forms the CMOS transistor. In order to avoid the forward voltage application for the second N well and the P-type silicon substrate the voltage has to be given a value higher than 0 V. When T11 and T12 are de-energized, the maximum potential difference between the source/drain on the side making connection with W1 and the like and the N well is on the order of 28 V. Because of this, it is desirable to adopt such structures as the DDD structure, an offset structure with respect to 125a, and the like for this source/drain 116. It is also effective to increase the thickness of the second gate insulating film 124 and to increase the gate length. Since the first N well 111 is given a voltage of 5 V, the potential difference between the N well and the P well is 21 V. As this is a voltage application in the opposite direction, and the junction breakdown voltage between the P well and the N well is several tens of volts the above-mentioned application of the voltage will cause no problems. Further, it is preferable that the junction depth of the N well 111 be greater than the junction depth of the P well 121 by more than 1 μm.
The transistors T21, T22, and the like are formed on the surface of the first N well 111. The transistors T21, T22, and the like have a source/drain 107 consisting of P + -type diffused layer, second gate insulating film 124, and have gates 135a and 135b, respectively. Further, an N + -type diffused layer 126 is formed on the surface of the N well 111. One of the source/drains 107 for the respective members of T21 and T22 is connected to a second aluminum wiring 120ba (W1) and a second aluminum wiring (W2) via contact holes 119ca and 119cb, respectively. The other of the source/drains 107 for T21 and T22 are connected respectively to the first level shifters LS1 and LS2 via a contact hole 119ea and a second aluminum wiring 120ca, and a contact hole 119eb and a second aluminum wiring 120cb. The respective gates 135a and 135b are connected to the input terminals of the second level shifters LS1a and LS2a, respectively, via a contact hole 109ca and a first aluminum wiring 110ca, and a contact hole 109cb and a first aluminum wiring 110cb. An N + -type diffused layer 126 is connected to a first aluminum wiring 110aa having the first voltage via a contact hole 109aa [FIGS. 1, 2, and 3C].
Since the flash memory according to this embodiment is given a circuit constitution and a device structure as described in the above, the deterioration in the reliability of the memory cells at the time of erase operation can be suppressed. Further, in the peripheral circuit, there will be given no voltage application to the P-N junction in the forward direction, and even in parts where the voltage application in the reverse direction amounts to large values it is possible to suppress the generation of the hot holes by the adoption of well-known technology, enabling to obtain peripheral circuits with high reliability. Moreover, at the time of erase or write, there is no need to apply specified voltages only to the sources of specified memory cells so that the reduction of the cell size can be facilitated. Furthermore, there exist no restrictions to the sector erasure, and there are no restrictions either as to the adoption not only of the NOR type but also the NAND type.
Referring also to FIGS. 4A to 4E which show schematic sectional views arranged in the order of processes, for the part indicated by the line B--B in FIG. 2, in the flash memory of the first embodiment described in the above, first, the silicon oxide film 102 is formed on the surface of the P-type silicon substrate, and N wells such as the first N well 111 and the like are formed by ion implantation and heat treatment. Next, P wells such as the first P well 121 and the like are formed by ion implantation and heat treatment. At this time, the first P well 121 is formed on the surface of the first N well 111 [FIG. 4A].
After removal of the silicon oxide film 102, a field oxide film 103 is formed, and the first gate insulating film 104 consisting of a silicon oxide film is formed by thermal oxidation. Next, an N + -type polycrystalline silicon film 105 is formed allover the surface [FIG. 4B].
An etching which leaves the polycrystalline silicon film 105 in island form only for the parts that cover sufficiently the channel parts of the memory cells is carried out, then only the peripheral circuit formation part of the first gate insulating film 104 is removed by etching. Next, the second gate insulating films 114 and 124 are formed allover the surface including the parts of the surface of the polycrystalline silicon film 105 left in island forms. The second gate insulating films 141 and 124 include the silicon oxide films due to the thermal oxidation, and these films may be made into laminated films of a silicon oxide film, a silicon nitride film, and a silicon oxide film as needed [FIGS. 3A to 3C, and 4C].
After depositing a conductor film allover the surface, etching for the formation of gates, including the parts for the memory cells, is carried out. In the parts for the memory cells, as a result of the etching, formation of the control gates 115a and 115b, shaping of the second gate insulating film, and formation of the floating gate 105a by the shaping of the polycrystalline silicon film 105 that was left in island form are carried out. On the other hand, in the parts for the memory cells, there are formed the gates 125a, 125b, 135a, 135b, and the like as a result of this etching. Next, the N + -type source 106a, the drain 106b, the source/drain 116, and the N + -type diffused layer 126 are formed by means of ion implantation of arsenic that uses a photoresist film 130 as the mask [FIGS. 3A to 3C, and 4D].
After removal of the photoresist film 130, p + -type source/drain 107, the P + -type diffused layers 117, 127, and the like are formed by ion implantation of boron, for example, that uses a photoresist film 131 as the mask [FIGS. 3A to 3C, and 4E].
The fabrication processes hereafter rely on the well-known technology so that they will not be reproduced here.
Referring to FIG. 5 which shows a circuit diagram for the level shifter, it can be seen that the second level shifters employed in this embodiment is constituted of a positive feedback circuit. A CMOS inverter consisting of a second N-channel MOS transistor T3 and a second P-channel MOS transistor T5, and a CMOS inverter consisting of a third N-channel MOS transistor T4 and a third P-channel MOS transistor T6 are connected to form a flip-flop, and a voltage of -16 V is applied to the sources of T3 or T4, and a voltage of 0 V is applied to the sources of T5 and T6, with the input signals to T3 and T4 being in the opposite phase. For example, when 5 V and 0 V are input to the input terminal IN, the output terminal OUT outputs 0 V and -16 V, respectively.
The second fabrication method will be described briefly. The second N well is formed at the same time as the first N well 111 is formed. The second P well is formed on the surface of the second N well at the same time as the first P well 121 is formed. The N-channel MOS transistors T3 and T4 are formed on the surface of the second P well at the same time as the first N-channel MOS transistors T11, T12, and the like are formed. Similarly, the P-channel MOS transistors T5 and T6 are formed on the surface of the second N well at the same time as the formation of the first P-channel MOS transistors T21, T22, and the like. A voltage of -16 V is applied to the second P well, and the sources of T3 and T4 are respectively short-circuited to the second P well. A voltage of 0 V is applied to the second N well, and the sources of T5 and T6 are respectively short-circuited to the second N well.
Referring to FIG. 6 showing the principal part of the circuit structure of the flash memory, the second embodiment of the invention is not of sector flash type but is a flash memory which erases all the memory cells simultaneously. Because of this, the sector decoder provided in the first embodiment can be obviated, and a single level shifter LSb alone suffices as the second level shifter. The constitution of LSb is the same as that of the level shifter in the first embodiment. In this embodiment, an erase signal of 5 V or 0 V is input to a terminal ES. This erase signal is input directly to the gates of all of the first P-channel MOS transistors T21, T22, and the like. Similarly, the output signal of 0 V or -16 V from LSb is input to the gates of all of the first N-channel MOS transistors T11, T12, and the like.
The signal wirings that are connected to the gates of the first N-channel MOS transistors T11, T12, and the like, and the signal wirings that are connected to the gates of the first P-channel MOS transistors T21, T22, and the like can be made to require smaller occupation areas. Because of this, it becomes easy to place the connecting terminal for T11 and W1, for example, to be a terminal on the opposite side to the terminal of W1 where T21 is connected, as shown in the figure. The reduction of the area in this embodiment can be made easier compared with the first embodiment for the reason just mentioned, and for the fact that the sector decoder is made unnecessary and that only one of the second level shifter suffices for the required operation.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as other embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover any modifications or embodiments as fall within the true scope of the invention. | A flash EEPROM with sector erasure, carries out the erasure by applying a negative voltage to a selected word line through an N-channel MOS transistor. P-channel MOS transistors are respectively inserted between row decoder level shifters and each of their respective word lines to which they are respectively connected. The turning-on and -off of the respective word lines and first level shifters is controlled by the turning-on and -off of the associated P-channel MOS transistor. An erase voltage is applied to one end of the source/drain path of the respective N-channel MOS transistor of the selected cord line, the other end to the respective word lines. The turning-on and -off of the N-channel MOS transistor is synchronized with the turning-on and -off of the P-channel MOS transistor connected to the same word line. The P-channel MOS transistor is formed on an N well biased to, for example, 5 V and the N-channel MOS transistor is formed on a P well biased to, for example, the erase voltage. The P well is formed on the surface of the N well. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to earth boring, especially to improvements to bits having cutters rotatively secured to bearing shafts, with air passages through the interior of the bit and bearings to enable air or gas cooling of the bearings.
2. Background Information
Earth boring bits of the rolling cutter type consist of three general types: (1) Those having sealed bearings that are lubricated with a liquid lubricant confined in the bearing area, (2) those having open bearings where the fluid in the well bore is free to enter the bearings, and (3) the air or gas cooled, unsealed bit that has unsealed bearings cooled by the flow of fluid through passages in the body and the bearing of each leg.
Inevitably, it seems, there are some liquid and particles of dust or other debris pumped through the drill pipe supporting the bit. Often there is particle contaminated water on the bottom of the hole that flows backwardly into the bit when the air supply is stopped. All too frequently these ingredients form obstructions in one or more of the passages leading to the bearings, block the flow of cooling fluid and cause excessive heating and failure of one of the bearings.
Since the so called "air bit" is often used to drill repeatedly shallow holes in the mining industry, the accumulation of detritus in the passages of the bit is manually removed by the workers. This task is difficult since access to the internal air passages is limited, and may involve the removal from inside the shank of the screening tubes used over the cooling passages. Then, water is flushed through the passages, and a rod used to dislodge the blockage. These cleaning efforts are time consuming and difficult, partly because access to the passages is restricted.
SUMMARY OF THE INVENTION
The general object of the invention is to provide, in an earth boring bit, improved means to access the cooling passages used to direct air or gas to the bearings between the rotatable cutter and shaft. To accomplish this object each leg of the bit has a generally vertical segment with an opening on the exterior of the body. A removable plug is inserted into this opening, and may be removed to permit access to the interior passages to remove obstructions. The preferred plug has an expandable, elastomeric portion used to seal the opening, and the body of the plug comprises an upper and lower plate to confine and expand the elastomeric portion by means of a threaded fastener extending through the assembly.
The above as well as additional objects, features and advantages of the invention will become apparent in the following description.
DESCRIPTION OF THE DRAWING
FIG. 1 of the drawing is a perspective view, partially in longitudinal section, to expose the interior of one leg of the body of an earth boring drill bit and the rotatable cutter which the leg supports. The cooling passages are shown, as is the access system of the invention.
FIG. 2 is a view of the preferred, removable plug, partially in longitudinal section to show the components of the assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The numeral 11 in FIG. 1 of the drawing designates an earth boring bit having a threaded upper end 13 and shoulder 14 formed on a body which consists in this instance of three head sections 15, each with a leg 17 to support a cantilevered bearing shaft 19. The bearing shaft 19 supports a rotatable cutter 21 having earth disintegrating teeth 23 to dislodge cuttings from bottom of a bore hole in the earth's geological formations. Bearing elements include in this instance roller bearings 25, ball bearings 27, bushing 29 and a thrust bottom 31.
The cutter 21 is retained on the bearing shaft 19 by the ball bearings 27 which, during assembly of the components of the bits, are inserted into a plug hole 33 which receives a ball plug retainer 35, welded at 37 to the leg 17.
The ball plug 35 has, in this instance, a pair of annular grooves 39 and 41. These grooves permit the flow of air on other gas from a drill rig (not shown) at the surface of the earth through: a vortex separator 43, the shank cavity 45 of the bit into a central tube 47 having a valve 49, transverse passage 51, a generally vertical passage 53, and a bearing shaft passage 55.
The bit also includes a plurality of nozzles 57 that communicate with the shank cavity 45, each nozzle having in this instance a back flow valve 59. The vertical passage 53 has an opening 61 at an upper, exterior portion of the leg 17, to receive a removable plug 63. The preferred form of this plug is as shown in FIG. 2, comprising upper and lower plates 65, 67 which confine an elastomeric core 69, having an opening 71 to receive the body of a threaded fastener 73 which is in this instance a bolt with a socket head 75, with a threaded end 77 to engage a mating threaded portion 79 of the lower plate 67.
In operation the threaded upper end 13 of bit 11 is secured to a drill string member that is raised, lowered and rotated by a drill rig at the surface of the earth. A pump associated with the drill rig forces air or gas through the vortex separator 43 and into the shank cavity 45 of the bit. (None of the surface equipment is shown in the drawing--only the bit.) Liquid and solid particles entrained in the air are forced by the vortex toward the outside of the shank cavity 45 and through nozzles 57 and back flow valves 59, which are opened by the downward flow of gas and associated pressure differential.
Some of the air or gas entering shank cavity 45 passes through the opened valve 49 and enters the passages 51, 53 and 55, into and through the clearances and passages between the bearing member of the shaft 19 and cutter 21.
Since some amount of dust and other particles are contained in the air, the passages leading to the bearings may become clogged. When this occurs, the pump is turned off, the valves 49 and 59 become shut because of the bias of springs (not shown) associated with them, to prevent back flow into the bit of water that may be in drilled hole. The removable plug 63 may be taken from the opening 61. This is accomplished by rotating the fastener 73 in a counterclockwise direction (as seen from above), separating the upper and lower plates 65, 67, and allowing a radial contraction of the elastomeric core 69. Then, a rod may be inserted into the vertical passage 53, while simultaneously water is flushed through this passage, to assist in removal of any blockage. After removal of the blockage, the removable plug 63 is reinserted into the opening 61, the fastener 73 rotated clockwise direction (as seen from above) to force the upper and lower plates 65, 67 together and raise or expand the elastomeric core 69 to form an excellent seal with the wall of the passage 53. The bit may then be lowered into the hole, with the assurance that relatively unobstructed flow of air or gas reaches and cools the bearings of the bit.
It should be apparent from the foregoing description that the invention has significant advantages. A convenient access is provided to the passages inside an air bit, due to the orientation and location of the vertical passage 53 and the construction of the removable plug 63. The construction of the removable plug enables convenient removal and replacement in a manner to achieve excellent sealing against the walls of the vertical passage 59, without necessity for having surface finishes other than those obtained by drilling, eliminating the necessity for reaming or grinding. The construction of the removable plug is rugged and can withstand repeated removal and insertion, without loss of sealing effectiveness. The orientation of the drill hole also permits convenient access with a rod or other cleaning implement, in addition to access by cleaning water or other fluids. It is not necessary, for example in the embodiment shown, that the bit be removed from the drill pipe in order for the passages to be accessed and cleaned.
While I have shown my invention in only one of it forms, it should be apparent to those skilled in the art that it is not thus limited, but is susceptible to various changes and modifications without departing from the principles which it embodies. | An earth boring bit of the "air cooled" type that includes an air passage access system, including a generally vertical passage with an opening on the exterior of the leg or in the shank cavity that forms part of the body of the bit. This vertical passage is accessible through the opening by removal of a core that expands or retracts by altering the pressure exerted against it by two plates and a threaded fastener. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of Ser. No. 11/928,515, filed Oct. 30, 2007 now U.S. Pat. No. 7,835,794, entitled “Electronics Package Suitable for Implantation”, which is a divisional application of application Ser. No. 11/517,859, entitled “Electronics Package Suitable for Implantation”, filed Sep. 7, 2006 now U.S. Pat. No. 7,645,262, which claims benefit of U.S. Provisional Application No. 60/778,833, filed Mar. 3, 2006, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation,” and which is a continuation in part of U.S. patent application Ser. No. 10/236,396, filed Sep. 6, 2002 now U.S. Pat. No. 7,142,909, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation” which is a continuation-in-part of U.S. patent application Ser. No. 10/174,349, filed on Jun. 17, 2002 now U.S. Pat. No. 7,211,103, entitled “Biocompatible Bonding Method and Electronics Package Suitable for Implantation,” and which claims benefit of U.S. Provisional Application No. 60/372,062, filed on Apr. 11, 2002, entitled “Platinum Deposition for Electrodes,” the disclosures of all are incorporated herein by reference.
FEDERALLY SPONSORED RESEARCH
This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
This invention relates to an electrode array or flexible circuit, electronics package and a method of bonding a flexible circuit or electrode array to an integrated circuit or electronics package.
BACKGROUND OF THE INVENTION
Arrays of electrodes for neural stimulation are commonly used for a variety of purposes. Some examples include U.S. Pat. No. 3,699,970 to Brindley, which describes an array of cortical electrodes for visual stimulation. Each electrode is attached to a separate inductive coil for signal and power. U.S. Pat. No. 4,573,481 to Bullara describes a helical electrode to be wrapped around an individual nerve fiber. U.S. Pat. No. 4,837,049 to Byers describes spike electrodes for neural stimulation. Each spike electrode pierces neural tissue for better electrical contact. U.S. Pat. No. 5,215,088 to Norman describes an array of spike electrodes for cortical stimulation. U.S. Pat. No. 5,109,844 to de Juan describes a flat electrode array placed against the retina for visual stimulation. U.S. Pat. No. 5,935,155 to Humayun describes a retinal prosthesis for use with a flat retinal array.
Packaging of a biomedical device intended for implantation in the eye, and more specifically for physical contact with the retina, presents a unique interconnection challenge. The consistency of the retina is comparable to that of wet tissue paper and the biological media inside the eye is a corrosive saline liquid environment.
Thus, the device to be placed against the retina, in addition to being comprised of biocompatible, electrochemically stable materials, must appropriately conform to the curvature of the eye, being sufficiently flexible and gentle in contact with the retina to avoid tissue damage, as discussed by Schneider, et al. It is also desirable that this device, an electrode array, provides a maximum density of stimulation electrodes. A commonly accepted design for an electrode array is a very thin, flexible conductor cable. It is possible to fabricate a suitable electrode array using discrete wires, but with this approach, a high number of stimulation electrodes cannot be achieved without sacrificing cable flexibility (to a maximum of about 16 electrodes).
A lithographically fabricated thin film flex circuit electrode array overcomes such limitations. A thin film flex circuit electrode array can be made as thin as 10 um (<0.0005 inches) while accommodating about 60 electrodes in a single circuit routing layer. The flex circuit electrode array is essentially a passive conductor ribbon that is an array of electrode pads, on one end, that contact the retina and on the other end an array of bond pads that must individually mate electrically and mechanically to the electrical contacts of a hermetically sealed electronics package. These contacts may emerge on the outside of the hermetic package as an array of protruding pins or as vias flush to a package surface. A suitable interconnection method must not only serve as the interface between the two components, but must also provide electrical insulation between neighboring pathways and mechanical fastening between the two components.
Many methods exist in the electronics industry for attaching an integrated circuit to a flexible circuit. Commonly used methods include wire-bonding, anisotropic-conductive films, and “flip-chip” bumping. However, none of these methods results in a biocompatible connection. Common materials used in these connections are tin-lead solder, indium and gold. Each of these materials has limitations on its use as an implant. Lead is a known neurotoxin. Indium corrodes when placed in a saline environment. Gold, although relatively inert and biocompatible, migrates in a saline solution, when electric current is passed through it, resulting in unreliable connections.
In many implantable devices, the package contacts are feedthrough pins to which discrete wires are welded and subsequently encapsulated with polymer materials. Such is the case in heart pacemaker and cochlear implant devices. Flexible circuits are not commonly used, if at all, as external components of proven implant designs. The inventor is unaware of prior art describing the welding of contacts to flex circuits.
Attachment by gold ball bumping has been demonstrated by the Fraunhofer group (Hansjoerg Beutel, Thomas Stieglitz, Joerg Uwe Meyer, “Versatile ‘Microflex’-Based Interconnection Technique,” Proc. SPIE Conf on Smart Electronics and MEMS, San Diego, Cal., March 1998, vol. 3328, pp 174-82.) to rivet a flex circuit onto an integrated circuit. A robust bond can be achieved in this way. However, encapsulation proves difficult to effectively implement with this method. Because the gap between the chip and the flex circuit is not uniform, underfill with epoxy is not practical. Thus, electrical insulation cannot be achieved with conventional underfill technology. Further, as briefly discussed earlier, gold, while biocompatible, is not completely stable under the conditions present in an implant device since it “dissolves” by electromigration when implanted in living tissue and subject to an electric current (see M. Pourbaix, Atlas of Electrochemical Equilibria in Aqueous Solutions, National Association of Corrosion Engineers, Houston, 1974, pp 399-405.).
Widespread use of flexible circuits can be found in high volume consumer electronics and automotive applications, such as stereos. These applications are not constrained by a biological environment. Component assembly onto flex circuits is commonly achieved by solder attachment. These flex circuits are also much more robust and bulkier than a typical implantable device. The standard flex circuit on the market is no less than 0.002 inches in total thickness. The trace metallization is etched copper foil, rather than thin film metal. Chip-scale package (CSP) assembly onto these flex circuits is done in ball-grid array (BGA) format, which uses solder balls attached to input-output contacts on the package base as the interconnect structures. The CSP is aligned to a corresponding metal pad array on the flex circuit and subjected to a solder reflow to create the interconnection. A metallurgical interconnect is achieved by solder wetting. The CSP assembly is then underfilled with an epoxy material to insulate the solder bumps and to provide a pre-load force from the shrinkage of the epoxy.
Direct chip attach methods are referred to as chip-on-flex (COF) and chip-on-board (COB). There have been some assemblies that utilize gold wirebonding to interconnect bare, integrated circuits to flexible circuits. The flipchip process is becoming a reliable interconnect method. Flipchip technology originates from IBM's Controlled Collapse Chip Connection (C4) process, which evolved to solder reflow technique. Flipchip enables minimization of the package footprint, saving valuable space on the circuit, since it does not require a fan out of wirebonds. While there are a variety of flipchip configurations available, solder ball attach is the most common method of forming an interconnect. A less developed approach to flipchip bonding is the use of conductive adhesive, such as epoxy or polyimide, bumps to replace solder balls. These bumps are typically silver-filled epoxy or polyimide, although electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form, may alternatively be used. This method does not achieve a metallurgical bond, but relies on adhesion. Polymer bump flip chip also requires underfill encapsulation. Conceivably, polymer bump attachment could be used on a chip scale package as well. COB flipchip attach can also be achieved by using gold stud bumps, as an alternative to solder balls. The gold bumps of the chip are bonded to gold contacts on the hard substrate by heat and pressure. A recent development in chip-to-package attachment was introduced by Intel Corporation as Bumpless Build Up Layer (BBUL) technology. In this approach, the package is grown (built up) around the die rather than assembling the die into a pre-made package. BBUL presents numerous advantages in reliability and performance over flipchip.
Known technologies for achieving a bond between a flexible circuit and an electronics package suffer from biocompatibility issues. Novel applications of a biomedical implant that utilize a flexible circuit attached to a rigid electronics package require excellent biocompatibility coupled with long term mechanical attachment stability, to assure long lived reliable electrical interconnection.
Known deposition techniques for a bond, such as an electrically conductive metal bond or “rivet” are limited to thin layers. Plating is one such known method that does not result in an acceptable bond. It is not known how to plate shiny platinum in layers greater than approximately 1 to 5 microns because the dense platinum layer peels off, probably due to internal stresses. Black platinum lacks the strength to be a good mechanical attachment, and also lack good electrical conductivity.
Known techniques for bonding an electronic package to a flex circuit do not result in a hermetic package that is suitable for implantation in living tissue. Therefore, it is desired to have a method of attaching a substrate to a flexible circuit that ensures that the bonded electronic package and flex circuit will function for long-term implant applications in living tissue.
SUMMARY OF THE INVENTION
An implantable electronic device comprising a hermetic electronics control unit that is typically mounted on a substrate that is bonded to a flexible circuit by an electroplated platinum or gold rivet-shaped connection. The resulting electronics assembly is biocompatible and long-lived when implanted in living tissue, such as in an eye or ear.
The novel features of the invention are set forth with particularity in the appended claims. The invention will be best understood from the following description when read in conjunction with the accompanying drawings.
OBJECTS OF THE INVENTION
It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached to a flexible circuit.
It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue.
It is an object of the invention to attach a hermetically sealed electronics package to a flexible circuit for implantation in living tissue to transmit electrical signals to living tissue, such as the retina.
It is an object of the invention to provide a hermetic, biocompatible electronics package that is attached directly to a substrate.
It is an object of the invention to provide a method of bonding a flexible circuit to a substrate with an electroplated rivet-shaped connection.
It is an object of the invention to provide a method of plating platinum as a rivet-shaped connection.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective cutaway view of an eye containing a flexible circuit electrode array.
FIG. 2 is a side view of an electronics package.
FIG. 3 illustrates a cutaway side view of an electronics package.
FIG. 4 is a top view of a flex circuit without the electronics package.
FIG. 5 presents a side view of a flex circuit with the electronics package.
FIG. 6A-FIG . 6 E is a series of illustrations showing the steps of bonding of the hybrid substrate to the flexible circuit with adhesive underfill.
FIG. 7A-FIG . 7 E is a series of illustrations showing the steps of bonding the hybrid substrate to the flexible circuit with adhesive underfill.
FIG. 8A-FIG . 8 F is a series of illustrations showing the steps of bonding the hybrid substrate to flexible circuit by weld staple bonding.
FIG. 9A-FIG . 9 D is a series of illustrations showing the steps of bonding the hybrid substrate to flexible circuit.
FIG. 10A-FIG . 10 L is a series of illustrations showing the steps of electrically and adhesively bonding the flexible circuit to a hermetic rigid electronics package.
FIG. 11 is a side view of a flexible circuit bonded to a rigid array.
FIG. 12 is a side view of an electronics control unit bonded to an array.
FIG. 13A-FIG . 13 C is a series of illustrations showing the steps of bonding the hybrid substrate with rivets to flexible circuit.
FIG. 14 is an electroplating equipment schema.
FIG. 15 is a three-electrode electroplating cell schema.
FIG. 16 is a plot of showing the plating current density decrease with hole size.
FIG. 17 a is a scanning electron micrograph of a polyimide surface before plating magnified 850 times.
FIG. 17 b is a scanning electron micrograph of electrochemically deposited rivets magnified 850 times.
FIG. 18A-FIG . 18 E is a series of illustrations showing the steps of bonding of the hybrid substrate to the flexible circuit with adhesive underfill.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
The present invention provides a flexible circuit electronics package and a method of bonding a flexible circuit to a hermetic integrated circuit which is useful for a number of applications, including implantation in living tissue as a neural interface, such as a retinal electrode array or an electrical sensor. The tissue paper thin flexible circuit 18 , FIG. 1 , transmits electrical signals to the eye 2 by means of electrodes that are located in a stimulating electrode array 10 , that are in contact with the retina 14 . It is obvious that in addition to a stimulating electrode array or sensing electrode, the electrodes may be contacts connecting to remote electrodes. FIG. 1 illustrates the electronics control unit 20 in a perspective cutaway view of an eye 2 containing a flexible circuit electrode array 18 . The electronics control unit 20 is hermetically sealed. The electronics control unit 20 may be a hermetic ceramic case with electronics inside, or it may be a hermetically sealed integrated circuit, or any other environmentally sealed electronics package. The stimulating electrode array 10 is implanted on the retina 14 . Flexible circuit ribbon 24 connects the stimulating electrode array 10 to the electronics control unit 20 .
The flexible circuit ribbon 24 preferably passes through the sclera 16 of the eye 2 at incision 12 . Another embodiment of the invention is the flexible circuit ribbon 24 replaced by alternative means of electrical interconnection, such as fine wires or thin cable. The lens 4 of the eye 2 is located opposite the retina 14 . A coil 28 , which detects electronic signals such as of images or to charge the electronics control unit 20 power supply, located outside the eye 2 , near the lens 4 , is connected to the electronics control unit 20 by wire 30 .
FIG. 2 illustrates a side view of the hermetic electronics control unit 20 and the input/output contacts 22 that are located on the bottom of the unit 20 . The input/output contacts 22 are bonded in the completed assembly to the flexible circuit 18 . Thick film pad 23 is formed by known thick film technology, such as silk screening or plating.
FIG. 3 illustrates a cutaway side view of the hermetic electronics control unit 20 . The pad 23 facilitates attachment of wire 30 , and is preferably comprised of a biocompatible material such as platinum, iridium, or alloys thereof, and is preferably comprised of platinum paste. Wire 30 is preferably bonded to pad 23 by welding. The microelectronics assembly 48 is mounted on the hybrid substrate 44 . Vias 46 pass through the substrate 44 to input/output contacts 22 . Electrical signals arrive by wire 30 and exit the electronics control unit 20 by input/output contacts 22 .
A top view of the flexible circuit 18 is illustrated in FIG. 4 . Electrical signals from the electronics control unit 20 (see FIG. 3 ) pass into bond pads 32 , which are mounted in bond pad end 33 . Flexible electrically insulating substrate 38 is preferably comprised of polyimide. The signals pass from the bond pads 32 along traces 34 , which pass along flexible circuit ribbon 24 to the stimulating electrode array 10 . The array 10 contains the electrodes 36 , which are implanted to make electrical contact with the retina 14 of the eye 2 , illustrated in FIG. 1 . An alternative bed of nails embodiment for the electrodes 36 is disclosed by Byers, et al. in U.S. Pat. No. 4,837,049.
In FIG. 5 , the hermetic electronics control unit 20 is illustrated mounted to flexible circuit 18 . In order to assure electrical continuity between the electronics control unit 20 and the flexible circuit 18 , the electrical control unit 20 must be intimately bonded to the flexible circuit 18 on the bond pad end 33 . A cutaway of the electronics control unit 20 ( FIG. 5 ) illustrates a bonded connection 42 . The flexible electrically insulating substrate 38 is very thin and flexible and is able to conform to the curvature of the retina 14 ( FIG. 1 ), when implanted thereon.
Methods of bonding the flexible insulating substrate 18 to the hermetic electronics control unit 20 are discussed next.
Platinum Conductor in Polymer Adhesive
A preferred embodiment of the invention, illustrated in FIG. 6A-6E , shows the method of bonding the hybrid substrate 244 to the flexible circuit 218 using electrically conductive adhesive 281 , such as a polymer, which may include polystyrene, epoxy, or polyimide, which contains electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form.
In FIG. 6A , step a, the hybrid substrate 244 , which may alternatively be an integrated circuit or electronic array, and the input/output contacts 222 are prepared for bonding by placing conductive adhesive 281 on the input/output contacts 222 . The rigid integrated circuit 244 is preferably comprised of a ceramic, such as alumina or silicon. In step b, FIG. 6B , the flexible circuit 218 is preferably .prepared for bonding to the hybrid substrate 244 by placing conductive adhesive 281 on bond pads 232 . Alternatively, the adhesive 281 may be coated with an electrically conductive biocompatible metal. The flexible circuit 218 contains the flexible electrically insulating substrate 238 , which is preferably comprised of polyimide. The bond pads 232 are preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue, and are preferably platinum or a platinum alloy, such as platinum-iridium.
FIG. 6C , step c illustrates the cross-sectional view A-A of step b. The conductive adhesive 281 is shown in contact with and resting on the bond pads 232 . Step d, FIG. 6D , shows the hybrid substrate 244 in position to be bonded to the flexible circuit 218 . The conductive adhesive 281 provides an electrical path between the input/output contacts 222 and the bond pads 232 . Step c illustrates the completed bonded assembly wherein the flexible circuit 218 is bonded to the hybrid substrate 144 , thereby providing a path for electrical signals to pass to the living tissue from the electronics control unit (not illustrated). The assembly has been electrically isolated and hermetically sealed with adhesive underfill 280 , which is preferably epoxy. Studbump Bonding.
FIGS. 7A-7E illustrates the steps of an alternative embodiment to bond the hybrid substrate 244 to flexible circuit 218 by studbumping the hybrid substrate 244 and flexible electrically insulating substrate 238 prior to bonding the two components together by a combination of heat and/or pressure, such as ultrasonic energy. In FIG. 7A , step a, the hybrid substrate 244 is prepared for bonding by forming a studbump 260 on the input/output contacts 222 . The studbump is formed by known methods and is preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue if exposed to a saline environment. It is preferably comprised of metal, preferably biocompatible metal, or gold or of gold alloys. If gold is selected, then it must be protected with a water resistant adhesive or underfill 280 .
Alternatively, the studbump 260 may be comprised of an insulating material, such as an adhesive or a polymer, which is coated with an electrically conductive coating of a material that is biocompatible and stable when implanted in living tissue, while an electric current is passed through the studbump 260 . One such material coating may preferably be platinum or alloys of platinum, such as platinum-iridium; where the coating may be deposited by vapor deposition, such as by ion-beam assisted deposition, or electrochemical means.
FIG. 7B , step b presents the flexible circuit 218 , which comprises the flexible electrically insulating substrate 238 and bond pads 232 . The flexible circuit 218 is prepared for bonding by the plating bond pads 232 with an electrically conductive material that is biocompatible when implanted in living tissue, such as with a coating of platinum or a platinum alloy. Studbumps 260 are then formed on the plated pad 270 by known methods. FIG. 7C step c illustrates cross-section A-A of step b, wherein the flexible circuit 218 is ready to be mated with the hybrid substrate 244 .
FIG. 7D , step d illustrates the assembly of hybrid substrate 244 flipped and ready to be bonded to flexible circuit 218 . Prior to bonding, the studbumps 260 on either side may be flattened by known techniques such as coining. Pressure is applied to urge the mated studbumps 260 together as heat is applied to cause the studbumps to bond by a diffusion or a melting process. The bond may preferably be achieved by thermosonic or thermocompression bonding, yielding a strong, electrically conductive bonded connection 242 , as illustrated in FIG. 7E , step e. An example of a thermosonic bonding method is ultrasound. The bonded assembly is completed by placing an adhesive underfill 280 between the flexible circuit 218 and the hybrid substrate 244 , also increasing the strength of the bonded assembly and electrically isolating each bonded connection. The adhesive underfill 280 is preferably epoxy.
Weld Staple Interconnect
FIGS. 8A-8F illustrates the steps of a further alternative embodiment to bond the hybrid substrate 44 to flexible circuit 18 by weld staple bonding the substrate 244 and flexible electrically insulating substrate 38 together. In FIG. 8A step a, a top view of the flexible circuit 18 is shown. Flexible circuit 18 is comprised of flexible electrically insulating substrate 38 , which is preferably polyimide, and bond pads 32 having a through hole 58 therethrough each bond pad 32 and through the top and bottom surfaces of flexible circuit 18 . The bond pads 32 are comprised of an electrically conductive and biocompatible material which is stable when implanted in living tissue, and which is preferably platinum or a platinum alloy; such as platinum-iridium.
FIG. 8B , step b presents section A-A, which is shown in the illustration of step a. The through holes 58 pass completely through each bond pad 58 , preferably in the center of the bond pad 58 . They are preferably formed by plasma etching. The bond. pads 58 are not. covered on the top surface of flexible circuit 18 by flexible electrically insulating substrate 38 , thereby creating bond pad voids 56 .
FIG. 8C , step c shows the side view of hybrid substrate 44 with input/output contacts 22 on one surface thereof. The hybrid substrate 44 is positioned, in FIG. 8D . step d; to be bonded to the flexible circuit 18 by placing the parts together such that the input/output contacts 22 are aligned with the bond pads 32 . Then wire 52 , which is preferably a wire, but may equally well be a ribbon or sheet of weldable material that is also preferably electrically conductive and biocompatible when implanted in living tissue, is attached to input/output contact 22 and bond pad 32 to bond each aligned pair together. The wire 52 is preferably comprised of platinum, or alloys of platinum, such as platinum-iridium. The bond is preferably formed by welding using the parallel gap welder 50 , which moves up and down to force the wire 52 into the through hole 58 and into contact with input/output contact 22 . This process is repeated for each aligned set of input/output contacts 22 and bond pads 32 , as shown in FIG. 8B , step e.
The weld staple interconnect bonding process is completed, as shown in FIG. 8F , step f, by cutting the wire 54 , leaving each aligned set of input/output contacts 22 and bond pads 32 electrically connected and mechanically bonded together by staple 54 .
Tail-Latch Interconnect
FIGS. 9A-9D illustrates yet another embodiment for attaching the hybrid substrate 244 to a flexible circuit 218 by using a tail-ball 282 component, as shown in FIG. 9A , step a. The hybrid substrate 244 is preferably comprised of a ceramic material, such as alumina or silicon. In one embodiment, a wire, preferably made of platinum or another electrically conductive, biocompatible material, is fabricated to have a ball on one end, like the preferred tail-ball 282 illustrated in step a. The tail-ball 282 has tail 284 attached thereto, as shown in the side view of step a. The tail-ball 282 is aligned with input/output contact 222 on hybrid substrate 244 , in preparation to being bonded to flexible circuit 218 , illustrated in FIG. 98 . step b.
The top view of step b illustrates flexible electrically insulating substrate 238 , which is preferably comprised of polyimide, having the through hole 237 passing completely thorough the thickness and aligned with the tail 284 . The bond pads 232 are exposed on both the top and bottom surfaces of the flexible circuit 218 , by voids 234 , enabling electrical contact to be made with input/output contacts 222 of the hybrid substrate 244 . The voids are preferably formed by plasma etching.
The side view of FIG. 9C , step c, which illustrates section A-A of step b, shows the hybrid substrate 244 in position to be bonded to and aligned with flexible circuit 218 . The tails 284 are each placed in through hole 237 . Pressure is applied and the tail-balls 282 are placed in intimate contact with bond pads 232 and input/output contacts 222 . FIG. 9D . Step e-d illustrates that each of the tails 284 is bent to make contact with the bond pads 232 . The bonding process is completed by bonding, preferably by welding, each of the tails 284 , bond pads 232 , tail-balls 282 , and input/output contacts 222 together, thus forming a mechanical and electrical bond. Locking wire 262 is an optional addition to assure that physical contact is achieved in the bonded component. The process is completed by underfilling the gap with an electrically insulating and biocompatible material (not illustrated), such as epoxy.
Integrated Interconnect by Vapor Deposition
FIGS. 10-10L illustrates a further alternative embodiment to creating a flexible circuit that is electrically and adhesively bonded to a hermetic rigid electronics package. In this approach, the flexible circuit is fabricated directly on the rigid substrate. Step a, FIG. 10A shows the hybrid substrate 44 , which is preferably a ceramic, such as alumina or silicon, having a total thickness of about 0.012 inches, with patterned vias 46 therethrough. The vias 46 are preferably comprised of frit containing platinum.
In step b, FIG. 10B , the routing 35 is patterned on one side of the hybrid substrate 44 by known techniques, such as photolithography or masked deposition. It is equally possible to form routing 35 on both sides of the substrate 44 . The hybrid substrate 44 has an inside surface 45 and an outside surface 49 . The routing 35 will carry electrical signals from the integrated circuit, that is to be added, to the vias 46 , and ultimately will stimulate the retina (not illustrated). The routing 35 is patterned by know processes, such as by masking during deposition or by post-deposition photolithography. The routing 35 is comprised of a biocompatible, electrically conductive, patternable material, such at platinum.
Step c, FIG. 10C , illustrates formation of the release coat 47 on the outside surface 49 of the hybrid substrate 44 . The release coat 47 is deposited by known techniques, such as physical vapor deposition. The release coat 47 is removable by know processes such as etching. It is preferably comprised of an etchable material, such as aluminum.
Step d, FIG. 10D , illustrates the formation of the traces 34 on the outside surface 49 of the hybrid substrate 44 . The traces 34 are deposited by a known process, such as physical vapor deposition or ion-beam assisted deposition. They may be patterned by a known process, such as by masking during deposition or by post-deposition photolithography. The traces 34 are comprised of an electrically conductive, biocompatible material, such as platinum, platinum alloys, such as platinum-iridium, or titanium-platinum. The traces 34 conduct electrical signals along the flexible circuit 18 and to the stimulating electrode array 10 , which were previously discussed and are illustrated in FIG. 4 .
Step e, FIG. 10 a , illustrates formation of the flexible electrically insulating substrate 38 by known techniques, preferably liquid precursor spinning. The flexible electrically insulating substrate 38 is preferably comprised of polyimide. The flexible electrically insulating substrate electrically insulates the traces 34 . It is also biocompatible when implanted in living tissue. The coating is about 5 um thick. The liquid precursor is spun coated over the traces 34 and the entire outside surface 49 of the hybrid substrate 44 , thereby forming the flexible electrically insulating substrate 38 . The spun coating is cured by known techniques.
Step f, 10 F, illustrates the formation of voids in the flexible electrically insulating substrate 38 thereby revealing the traces 34 . The flexible electrically insulating substrate is preferably patterned by known techniques, such as photolithography with etching.
Step g, FIG. 10G , illustrates the rivets 51 having been formed over and in intimate contact with traces 34 . The rivets 51 are formed by known processes, and are preferably formed by electrochemical deposition of a biocompatible, electrically conductive material, such as platinum or platinum alloys, such as platinum-iridium.
Step h, FIG. 10H , illustrates formation of the metal layer 53 over the rivets 51 in a controlled pattern, preferably by photolithographic methods, on the outside surface 49 . The rivets 51 and the metal layer 53 are in intimate electrical contact. The metal layer 53 may be deposited by known techniques, such as physical vapor deposition, over the entire surface followed by photolithographic patterning, or it may be deposited by masked deposition. The metal layer 53 is formed of an electrically conductive, biocompatible material, which in a preferred embodiment is platinum. The patterned metal layer 53 forms traces 34 and electrodes 36 , which conduct electrical signals from the electronics control unit 20 and the electrodes 36 (see FIGS. 4 and 5 ).
Step i, FIG. 10I , illustrates the flexible electrically insulating substrate 38 applied over the outside surface 49 of the rigid substrate 44 , as in step e. The flexible electrically insulating substrate 38 covers the rivets 51 and the metal layer 53 .
Step j, FIG. 10J , illustrates the hybrid substrate 44 having been cut by known means, preferably by a laser or, in an alternative embodiment, by a diamond wheel, thereby creating cut 55 . The portion of hybrid substrate 44 that will be removed is called the carrier 60 . The flexible electrically insulating substrate 38 is patterned by known methods, such as photolithographic patterning, or it may be deposited by masked deposition, to yield voids that define the electrodes 36 . The electrodes 36 transmit electrical signals directly to the retina of the implanted eye (see FIG. 4 )
Step k, FIG. 10J , illustrates flexible circuit 18 attached to the hybrid substrate 44 . The carrier 60 is removed by utilizing release coat 47 . In a preferred embodiment, release coat 47 is etched by known means to release carrier 60 , leaving behind flexible circuit 18 .
Step l, FIG. 10L , illustrates the implantable electronic device of a flexible circuit 18 and an intimately bonded hermetic electronics control unit 20 . The electronics control unit 20 , which contains the microelectronics assembly 48 , is hermetically sealed with header 62 bonded to rigid circuit substrate 44 . The header 62 is comprised of a material that is biocompatible when implanted in living tissue and that is capable of being hermetically sealed to protect the integrated circuit electronics from the environment.
FIG. 11 illustrates an electronics control unit 320 attached to flexible electrically insulating substrate 338 , which is preferably comprised of polyimide, by bonded connections 342 . The electronics control unit 320 is preferably a hermetically sealed integrated circuit, although in an alternative embodiment it may be a hermetically sealed hybrid assembly. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps The bond area is underfilled with an adhesive 380 . Rigid stimulating electrode array 310 is attached to the flexible electrically insulating substrate 338 by bonded connections 342 .
FIG. 12 illustrates an electronics control unit 320 attached to rigid stimulating electrode array 310 by bonded connections 342 . The bond area is then underfilled with an adhesive 380 , preferably epoxy. Bonded connections 342 are preferably conductive adhesive, although they may alternatively be solder bumps.
The bonding steps are illustrated in FIG. 13 for a flex circuit assembly that is bonded with rivets 61 that are created in situ by a deposition process, preferably by electroplating. The rivets 61 are rivet-shaped electrical connections. The substrate 68 is shown generally in FIG. 13 . It is comprised of the hybrid substrate 44 , which is preferably a ceramic, such as alumina or silicon. The silicon would preferably be coated with a biocompatible material to achieve biocompatibility of the silicon, which is well known to slowly dissolve when implanted in living tissue.
The hybrid substrate 44 preferably contains vias 46 that pass through the thickness of the hybrid substrate 44 , see FIG. 13 , step (a). Vias 46 are not required to enable this invention, and are not present in alternative embodiments. It is preferred that the hybrid substrate 44 be rigid, although alternative embodiments utilize a non-rigid substrate. The vias 46 are integral with electrically conductive routing 35 that has been placed on the surface of the hybrid substrate 44 by known techniques. The routing is preferably comprised of a stable biocompatible material, such as platinum, a platinum alloy, or gold, most preferably platinum.
A flexible electrically insulating substrate 38 is preferably comprised of two layers of an electrically insulating material, such as a polymer. Known preferred polymer materials are polyimide or Parylene. Parylene refers to polyparaxylylene, a known polymer that has excellent implant characteristics. For example, Parylene, manufactured by Specialty Coating Systems (SCS), a division of Cookson Electronic Equipment Group, located in Indianapolis, Ind., is a preferred material. Parylene is available in various forms, such as Parylene C, Parylene D, and Parylene N, each having different properties. The preferred form is Parylene C.
The flexible electrically insulating substrate layers 38 are preferably of approximately equal thicknesses, as illustrated in FIG. 13 , step (a). A trace 65 is also illustrated in FIG. 13 , step (a), where trace 65 may be at least one, but preferably more than one, trace 65 that is electrically conductive. The traces 65 are integrally bonded to bond pads 63 . The bond pads 63 each have a bond pad hole 64 therethrough, which is in approximate alignment with first hole 57 in first electrically insulating substrate 37 and second hole 59 in the second flexible electrically insulating substrates 38 , such that there is a hole, with centers approximately aligned, through the thickness of the flexible assembly 66 .
The flexible assembly 66 is placed next to the hybrid substrate in preparation for bonding, FIG. 13 , step (b). The flexible assembly aligned holes that are formed by first substrate holes 57 , bond pad holes 64 , and second substrate holes 59 are aligned with the routing 35 . In a preferred embodiment, there is at least one via 46 , although no via 46 is required. In a preferred embodiment, an adhesive layer 39 is applied to adhesively bond the assembly together. The adhesive is preferably epoxy, silicone, or polyimide. In alternative embodiments, the assembly is not adhesively bonded.
As illustrated in FIG. 13 , step (c), a rivet 61 is formed in each flexible substrate hole to bond the assembly together. The rivets 61 are preferably formed by a deposition process, most preferably electroplating. The rivets 61 are comprised of a biocompatible, electrically conductive material, preferably platinum, although alternative embodiments may utilize platinum alloys (e.g. platinum-iridium or platinum-rhodium), iridium, gold, palladium, or palladium alloys. It is most preferred that rivet 61 be comprised of electroplated platinum, called “plated platinum” herein.
Referring to FIGS. 14 and 15 , a method to produce plated platinum according to the present invention is described comprising connecting a common electrode 402 , the anode, and a bonded assembly 70 , the cathode, to a voltage to current converter 406 with a wave form generator 430 and monitor 428 , preferably an oscilloscope. The common electrode 402 , bonded assembly 70 , a reference electrode 410 , for use as a reference in controlling the power source, which is comprised of a voltage to current converter 406 and a waveform generator 430 , and an electroplating solution are placed in a electroplating cell 400 having a means for mixing 414 the electroplating solution. Power may be supplied to the electrodes with constant voltage, constant current, pulsed voltage, scanned voltage or pulsed current to drive the electroplating process. The waveform generator 430 and voltage to current converter 406 is set such that the rate of deposition will cause the platinum to deposit as plated platinum, the rate being greater than the deposition rate necessary to form shiny platinum and less than the deposition rate necessary to form platinum black.
Because no impurities or other additives, such as lead, which is a neurotoxin and cannot be used in an implantable device, need to be introduced during the plating process to produce plated platinum, the plated material can be pure platinum. Alternatively, other materials can be introduced during the plating process, if so desired, but these materials are not necessary to the formation of plated platinum.
Referring to FIGS. 14 and 15 , the electroplating cell 400 , is preferably a 50 ml to 150 ml four neck glass flask or beaker, the common electrode 402 , or anode, is preferably a large surface area platinum wire or platinum sheet, the reference electrode 410 is preferably a Ag/AgCl electrode (silver, silver chloride electrode), the bonded assembly 70 , or cathode, can be any suitable material depending on the application and can be readily chosen by one skilled in the art. Preferable examples of the bonded assembly 70 include, but are not limited to, platinum, iridium, rhodium, gold, tantalum, titanium or niobium, preferably platinum.
The means for mixing 414 is preferably a magnetic stirrer ( FIG. 15 ). The plating solution is preferably 3 to 30 millimoles ammonium hexachloroplatinate in 0.4 moles of disodium hydrogen phosphate, but may be derived from any chloroplatinic acid or bromoplatinic acid or other electroplating solution. The preferable plating temperature is approximately 24°-26° C.
The electroplating system for pulsed current control is shown in FIGS. 14 and 15 . While constant voltage, constant current, pulsed voltage or pulsed current can be used to control the electroplating process, pulsed current control of the plating process is preferable for plating rivets 61 , which have a height that approximates their diameter. The preferable current range to produce plated platinum, which varies from about 50 to 2000 mA/cm 2 , is dependent on the whole dimensions, FIG. 16 , where the response voltage ranges from about −0.45 volts to −0.85 volts. Applying power in this range with the above solution yields a plating rate in the range of about 0.05 um per minute to 1.0 um per minute, the preferred range for the plating rate of plated platinum. The average current density may be determined by the equation y=19572x −1.46 , where y is the average current density in mA/cm 2 and x is the hole diameter in microns. Pulsed current control also allows an array of rivets to be plated simultaneously achieving uniform rivet properties.
As plating conditions, including but not limited to the plating solution, surface area of the electrodes, pH, platinum concentration and the presence of additives, are changed the optimal control parameters will change according to basic electroplating principles. Plated platinum will be formed so long as the rate of deposition of the platinum particles is slower than that for the formation of platinum gray and faster than that for the formation of shiny platinum.
It has been found that because of the physical strength of plated platinum, it is possible to plate rivets of thickness greater than 30 microns. It is very difficult to plate shiny platinum in layers greater than approximately several microns because the internal stress of the dense platinum layer cause the plated layer to peel off.
On a hybrid substrate 44 , a thin-layer routing 35 , preferably platinum, is sputtered and then covered with about 6 um thick flexible assembly 66 , preferably polyimide, with holes in the range from 5 um to 50 um. On each sample, preferably about 100 to 700 or more such holes are exposed for plating of rivets 61 , see FIG. 17 a.
SEM micrographs record the rivet surface appearance before plating. The surface is chemically and electrochemically cleaned before plating.
The electrodes in the test cell are arranged, so that the bonded assembly 70 (cathode) is physically parallel with the common electrode 402 (anode). The reference electrode 410 is positioned beside the bonded assembly 70 . The plating solution is added to electroplating solution level 411 . The solution is comprised of about 18 millimoles ammonium hexachloroplatinate in about 0.4 moles phosphate buffer solution. The amount of solution used depends on the number of rivets 61 to be plated. The means for mixing 414 , preferably a magnetic stirrer, is activated.
A voltage waveform is generated, preferably with a 1 msec pulse width as a 500 Hz square wave, which is converted to a current signal through a voltage to current converter 406 .
The pulse current is applied to the plating electrode versus anode. The electrode voltage versus Ag/AgCl reference electrode is monitored using an oscilloscope (Tektronix TDS220 Oscilloscope). The current amplitude is adjusted so that the cathodic peak voltage reaches about −0.6 v versus the Ag/AgCl reference electrode 410 . During plating, the electrode voltage tends to decrease with plating time. The current amplitude is frequently adjusted so that the electrode voltage is kept within −0.5 to −0.7 v range versus Ag/AgCl reference electrode 410 . When the specified plating time is reached, he current is eliminated. The cathode is rinsed in deionized water thoroughly. Typical plating time is in the range of about 5 to 60 minutes, preferably 15 to 25 minutes.
The plated surface is examined under an optical microscope. Optical photomicrographs are taken at both low and high magnifications to record the image of the surface. The plated samples are profiled with a surface profilometer to measure the dimensions of the plated rivet. The total plated rivet has a total height of about 8 to 16 um.
After plating, the pulsing current amplitudes are averaged for the total plating time and recorded. It is has been demonstrated that the current density increases exponentially with sample hole decrease. The smaller the sample holes, the higher the current density required (see FIG. 16 ).
An illustrative example of a plated platinum rivet according to the present invention are micrographs produced on a Scanning Electron Microscope (SEM) at 850× taken by a JEOL JSM5910 microscope, FIGS. 17 a and 17 b.
A further preferred embodiment of the invention, illustrated in FIG. 18 , shows the method of bonding the hybrid substrate 244 to the flexible circuit 218 using electrically conductive adhesive 281 , such as a polymer, which may include polystyrene, epoxy, or polyimide, which contains electrically conductive particulate of select biocompatible metal, such as platinum, iridium, titanium, platinum alloys, iridium alloys, or titanium alloys in dust, flake, or powder form.
In FIG. 18 , step a, the hybrid substrate 244 , which may alternatively be an integrated circuit or electronic array, and the input/output contacts 222 are prepared for bonding by placing conductive adhesive 281 on the input/output contacts 222 . The conductive adhesive 281 , which includes at least one bump, is cured to become hard. A second conductive adhesive 281 a is applied on top of the first cured conductive adhesive 281 . Preferably on each bump of conductive adhesive 281 an additional bump is applied to raise the bumps of conductive adhesive. The rigid integrated circuit 244 is preferably comprised of a ceramic, such as alumina or silicon. In step b, the flexible circuit 218 is preferably prepared for bonding to the hybrid substrate 244 by placing conductive adhesive 281 on bond pads 232 . Alternatively, the adhesive 281 may be coated with an electrically conductive biocompatible metal. The flexible circuit 218 contains the flexible electrically insulating substrate 238 , which is preferably comprised of polyimide. The bond pads 232 are preferably comprised of an electrically conductive material that is biocompatible when implanted in living tissue, and are preferably platinum or a platinum alloy, such as platinum-iridium.
FIG. 18 , step c illustrates the cross-sectional view A-A of step b. The conductive adhesive 281 is shown in contact with and resting on the bond pads 232 . Step d shows the hybrid substrate 244 in position being bonded to the flexible circuit 218 . The conductive adhesive 281 resting on the bond pads 232 and the conductive adhesive 281 a resting on the cured conductive adhesive 281 resting on the contacts 222 , are cured to yield one conductive adhesive 281 / 281 a / 281 . The conductive adhesive 281 / 281 a / 281 provides an electrical path between the input/output contacts 222 and the bond pads 232 . Step c illustrates the completed bonded assembly wherein the flexible circuit 218 is bonded to the hybrid substrate 244 , thereby providing a path for electrical signals to pass to the living tissue from the electronics control unit (not illustrated). The conductive adhesive 281 / 281 a / 281 is higher than in the embodiment shown in FIG. 6 and the distance between the hybrid substrate 244 and flexible circuit 218 is larger. In step e the assembly has been electrically isolated and hermetically sealed with adhesive underfill 280 , which is preferably epoxy. Since the distance between the hybrid substrate 244 and flexible circuit 218 is larger the underfill 280 is higher in this embodiment.
The method of manufacturing an implantable electronic device comprises the following steps:
a) applying conductive adhesive 281 on one or more contacts 222 on a substrate 244 , and curing the conductive adhesive 281 ;
b) applying one or more layers of conductive adhesive 281 a on the cured conductive adhesive 281 ;
c) applying conductive adhesive 281 on one or more bond pads 232 on a flexible assembly 218 ;
d) aligning the contacts 222 on the substrate with the bond pads 232 on the flexible assembly;
e) curing the conductive adhesive 281 connecting the contacts 232 on the substrate 244 with the bond pads 232 on the flexible assembly 218 ; and
f) filling the remaining space between the substrate and the flexible assembly with adhesive underfill 280 , and curing the underfill 280 .
Each layer of conductive adhesive applied on the substrate is preferably cured prior to aligning with the conductive adhesive applied on the flexible assembly. A biocompatible non-conductive adhesive underfill is preferably applied between the substrate and the flexible assembly.
The adhesive connecting the contacts on the substrate with the bond pads on the flexible assembly contains epoxy or polyimide filled with electrically conductive biocompatible metal in dust, flake, or powder form. The electrically conductive biocompatible metal preferably comprises silver, gold, platinum, iridium, titanium, platinum alloys, iridium alloys, titanium alloys in, or mixtures thereof. The adhesive connecting the contacts on the substrate with the bond pads on the flexible assembly can alternatively be coated with an electrically conductive biocompatible metal.
The adhesive underfill is cured at a pressure of 50 PSI to 100 PSI. The adhesive underfill is preferably cured at a pressure of 60 PSI to 90 PSI. The adhesive underfill is more preferably cured at a pressure of 70 PSI to 85 PSI. The curing process carried out under pressure yields an adhesive with very limited amount of gas bubbles and improved adhesion. The adhesive underfill is cured under pressure at a temperature of 20° C. to 30° C. for 3 h to 50 h. The adhesive underfill is alternatively cured at a temperature of 70° C. to 100° C. for a time of 10 min to 2 h.
The height of one or more conductive adhesives on the substrate determines the distance between the substrate and the flexible assembly. The conductive adhesive on the substrate which comprises one or more layer and is preferably in the form of bumps is preferably cured before being aligned with the uncured bumps on the flexible assembly. The hard bumps of conductive adhesives on the substrate push into the soft bumps of the flexible assembly as deep as possible prior to the final curing process. Therefore, the higher the hard bumps on the substrate are the larger is the distance between the substrate and the flexible assembly.
The implantable electronic device comprises:
a) a substrate 244 having one or more contacts 222 and two or more layers of conductive adhesive 281 / 281 a on the contacts 222 ;
b) a flexible assembly 218 having one or more bond pads 232 and one or more layers of conductive adhesive 281 on the bond pads 232 ;
c) the conductive adhesive 281 connecting the contacts 222 on the substrate 244 with the bond pads 232 on the flexible assembly 218 ; and
d) adhesive underfill 280 in the remaining space between the substrate 244 and the flexible assembly 218 .
The substrate comprises a biocompatible ceramic. The biocompatible ceramic comprises alumina. The substrate is rigid and is an electrically insulated substrate circuit. The flexible assembly is a thin substrate circuit. The conductive adhesive provides an electrical path between the input/output contacts and the bond pads. The adhesive underfill is nonconductive and contains epoxy.
Furthermore, it has been found that because of the physical strength of plated platinum, it is possible to plate rivets 61 of thickness greater than 16 um. It is very difficult to plate shiny platinum in layers greater than approximately 1 to 5 um because the internal stress of the dense platinum layer which will cause plated layer to peel off.
The following example is illustrative of electroplating platinum as a rivet 61 , according to the present invention.
EXAMPLE
A flexible electrically insulating substrate comprised of a first substrate 37 and a second substrate 38 of polyimide having a total thickness of 6 um. It had 700 first substrate holes 57 , an equal number of matching bond pad holes 64 , and an equal number of matching second substrate holes 59 , all in alignment so as to create a continuous hole through flexible assembly 66 that terminates on routing 35 , arranged in 100 groups of seven on about 40 um centers, FIG. 4 a . The hybrid substrate 44 was alumina and the routing 35 was platinum. The bond pad 63 was platinum.
The assembly was cleaned by rinsing three times in 10% HCl. It was further prepared by bubbling for 10 seconds at +/−5V at 1 Hz in phosphate buffered saline. Finally, it was rinsed in deionized water.
The electroplating set up according to FIGS. 14 and 15 was comprised of an electroplating cell 400 that was a 100 ml beaker with an electroplating solution level 411 at about the 75 ml level. The solution was 18 millimoles of ammonium hexachloroplatinate in 0.4 moles phosphate buffer solution.
The means for mixing 414 was a magnetic stirrer, which was activated. The voltage waveform of 1 msec pulse width as a square wave was generated by an HP 33120A waveform generator, which is converted to current signal through a voltage to current converter 406 . The pulse current was 1 msec in pulse width at 500 Hz square wave.
The pulse current was applied on the plating electrode bonded assembly 70 versus common electrode 402 . The electrode voltage versus Ag/AgCl reference electrode 410 was monitored using as a monitor 428 a Tektronix model TDS220 oscilloscope. The current amplitude was increased so that the bonded assembly 70 (cathode) peak voltage reached −0.6 v versus the Ag/AgCl reference electrode 410 . During plating, the electrode voltage decreased with plating time.
The average current density was 660 mA/cm 2 , which generated response voltages of −0.5 to −0.7 volts, where the voltage was controlled by the current. A 1 msec pulse width square wave was generated by an HP 33120A Arbitrary Waveform Generator. The pulse was converted to a current signal through a voltage to current converter 406 . The pulse current was typically about 1 msec in pulse width as a 500 Hz square wave. The resulting plated platinum rivet 61 was about 32 um diameter on the button end and about 15 um tall, with about 9 um of the height extending above the polyimide substrate. The plated platinum rivet was dense, strong, and electrically conductive.
Scanning Electron Microscope (SEM)/energy dispersive analysis (EDAX™) analysis were performed on the rivets 61 . SEM micrographs of the plated surface were taken showing its as-plated surface, FIG. 17 b . Energy dispersed analysis demonstrated that the rivet 61 was pure platinum, with no detectable oxygen.
The above described is the preferred embodiment of the current invention, however the platinum electrodeposition described in co-pending application “Platinum Electrode and Method for Manufacturing the Same,” application Ser. No. 10/226,976, filed on Aug. 23, 2002, now U.S. Pat. No. 6,974,533, and incorporated herein by reference, is also effective for forming electrochemically deposited rivets.
The rivet 61 ( FIG. 13 ) forms an electrically conductive bond with the routing 35 and with the bond pad 63 . It is obvious that the bonded assembly may be stacked with other bonded assemblies forming multiple stacked assemblies with increased stacking density.
Accordingly, what has been shown is an improved flexible circuit with an electronics control unit attached thereto, which is suitable for implantation in living tissue and to transmit electrical impulses to the living tissue. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described. | The invention is directed to a method of bonding a hermetically sealed electronics package to an electrode or a flexible circuit and the resulting electronics package that is suitable for implantation in living tissue, such as for a retinal or cortical electrode array to enable restoration of sight to certain non-sighted individuals. The hermetically sealed electronics package is directly bonded to the flex circuit or electrode by electroplating a biocompatible material, such as platinum or gold, effectively forming a plated rivet-shaped connection, which bonds the flex circuit to the electronics package. The resulting electronic device is biocompatible and is suitable for long-term implantation in living tissue. | 7 |
FIELD OF THE INVENTION
The present invention relates to an apparatus for treating wood chips, to enhance liquor penetration and subsequent pulping operations, and relates more particularly to destructuring apparatus in which chips are passed between closely operating rolls with compressive forces being exerted on the chips by the rolls.
BACKGROUND OF THE INVENTION
In a typical paper making process, logs are debarked and chipped, and individual cellulose fibers are then freed or liberated from the chip for subsequent treatment and ultimate paper web formation. A common way to liberate the cellulose fibers is by cooking the wood chips with chemicals at elevated temperatures and pressures in digesters to remove lignen from the chips, which holds the fibers together. For the subsequent paper making process, it is desirable that the delignified fibers obtained exhibit substantially similar characteristics. To minimize the production of undercooked or overcooked chips in the digester, it is necessary that the cooking liquor penetration into the chips is substantially similar for all chips, so that the effects of temperature, pressure, and time are similar for all chips. Therefore, it has been found desirable in the past to utilize chip screening apparatus which removes both undersized and oversized chips, so that the undersized can be treated separately and the oversized passed through chip size reducing apparatus prior to digesting.
A commonly used apparatus for reducing the size of oversized chips separated from a chip stream by screens is a chip slicer. The basic operation of a chip slicer includes a rotor operating within a drum, wherein the oversized chips are forced against knives and are thereby sliced to acceptable thickness. An example of a chip slicer can be found in U.S. Pat. No. 4,235,382 issued to William C. Smith for a "Method and Apparatus for Rechipping Wood Chips". While chip slicers such as that taught in U.S. Pat. No. 4,235,382 work effectively to reduce the size of oversized chips, thereby substantially reducing the occurrence of undercooked chips in a digesting process, chip slicers which are not working within optimum design parameters, such as when knives are dull, or improper speed or loading occurs, tend to generate fines while reducing oversized chips. Thus, while minimizing the problem associated with oversized chips, chip slicers tend to increase the problem of undersized chips or fines. Therefore, it is desirable to develop an apparatus for treating oversized wood chips which does not compound the problems associated with fines or undersized chips.
Closely operating rolls have been utilized in the past for treating oversized chips by compression, and thereby affecting liquor penetration into the chips. For example, U.S. Pat. No. 4,050,980 issued Sept. 27, 1977 to Fred L. Schmidt and Frank J. Steffes for "Selective Delamination of Wood Chips". This patent teaches screening a chip stream and passing the oversized chips through closely operating rolls for selective delamination by compression.
U.S Pat. 3,393,634 issued July 23, 1968 to John M. Blackford for a "Method and Apparatus for Loosening Fibers of Wood Chips". This patent teaches closely operating rolls with an apparatus for directing chips edgewise into the crotch between the rolls, with the rolls compressing the chips transversely of their thickness to at least about one-fifth of their original thickness, but not more than about one-tenth of their original thickness. Thereafter, the chips are allowed to expand to their original shape, with the fibers therein having been loosened and the porosity of the chips having been increased.
In each of the two above-mentioned patents, the opposed, closely operating rolls, or delamination rolls compress the chips for loosening the fibers therein. The rolls are smooth, so that the only action on the chips is compressive, whereby the chip structure is not substantially changed other than for a loosening of the fibers.
A problem associated with the use of delamination rolls is that throughput is low. Chips tend to stay in the pocket above the rolls, and, particularly the larger chips which are most in need of delamination, tend to ride between the rolls in the upper portion of the roll couple, without being drawn through the rolls.
A typical structure for a chip destructuring apparatus is disclosed in an article entitled "A Machine For Destructuring Wood Chips by Rolling" by John A. Oldham in the July 1983 issue of APPITA, Volume 37, Number 1. In the last paragraph of the first column on Page 65, the destructuring machine is described as having "smooth, chrome surfaced, very rigid rollers". The aforedescribed problem of passing larger chips through the nip is discussed in the first paragraph on Page 66. The larger chips "often would not enter between the smooth rollers; the surface of the rollers slipped over the chips". It is then described that the chips remaining above the rolls obstructed feeding of succeeding chips causing clotting or bridging. In the third paragraph on Page 66, a solution is discussed wherein small grooves, only one millimeter deep were cut parallel to the roll axis at approximately 10 millimeter spacings. Harsher roll surfaces are not deemed appropriate, since an unacceptable amount of fiber damage would be created. General roughening of the roll surface is also described as being likely to improve feed reliability.
An analysis of the effects of chip destructuring or delamination was presented at the 1984 TAPPI Pulping Conference by D. Lachenal, P. Monzie, and C. deChoudens in a paper entitled "Chip Destructuring Improves Kraft Pulping", TAPPI November 1984, Book 1, Pages 13-17. In the apparatus used for the pulping trials discussed in the article, again the rollers were smooth, and the chips were compressed.
Destructuring or delamination as known previously has not been accepted as a standard process in pulping operations, largely, it is believed, due to the low capacities of delamination devices and inconsistent results and subsequent effects on digesting operations.
It is therefore one of the principal objects of the present invention to provide an apparatus for treating oversized chips in a manner to reduce the necessary cooking time therefore, to achieve in the treated oversize chips delignification levels similar to that for smaller chips during identical delignification processes, with resultant pulps having similar characteristics and properties.
It is another object of the present invention to provide an apparatus for treating oversized chips quickly and efficiently with rapid throughput, while minimizing plugging or blinding of the apparatus.
It is yet another object of the present invention to provide a wood chip treating apparatus which cracks or fractures oversized chips without generating additional fines or pin chips, and which is simple in operation, requiring minimal adjustment for optimal operation.
A still further object of the present invention is to provide an apparatus for treating wood chips to increase the rate of liquor impregnation particularly of large chips and for providing an apparatus to destructure wood chips which is not dependent on a particular chip orientation between the closely operating rolls.
SUMMARY OF THE INVENTION
These and other objects are achieved in the present invention by providing closely operating, oppositely rotating rolls having highly aggressive surfaces. In a preferred design, the rolls have matrices of pyramid shaped projections machined into their surfaces. In a preferred embodiment, the peaks of the pyramids are spaced one-half inch apart, and the depth of the machining from the peak to the base of an individual pyramid is approximately one-quarter inch. In operation, the peaks of the rolls may be placed in peak-to-peak orientation or in peak-to-valley orientation. In use, the chips are fractured along the direction of fiber orientation, and with the present apparatus, the chips will crack there along regardless of how the chip enters the nip between the rolls.
The present invention differs from conventional thinking for destructuring or delamination devices, in that a highly aggressive surface is used, not merely to compress the chips, but to actually break or fracture the chip, generally through the thickness dimension of the chip previously such chip cracking has been believed undesirable.
Additional objects and advantages of the present invention will become apparent from the following detailed description and the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional, end view of a wood chip cracking apparatus embodying the present invention.
FIG. 2 is a vertical cross-sectional view of the wood chip cracking apparatus shown in FIG. 1, taken generally along line II--II of FIG. 1.
FIG. 3 is a perspective view of a portion of the roll surface for one of the rolls of a wood chip cracking apparatus embodying the present invention.
FIG. 4 is a fragmentary end view of one of the roll couples in a wood chip cracking apparatus embodying the present invention, showing one manner of adjacent roll orientation.
FIG. 5 is a fragmentary end view similar to that of FIG. 4, but showing another manner of roll orientation.
FIG. 6 is yet another fragmentary end view similar to that of FIGS. 4 and 5, but showing yet another manner of roll orientation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawing, and to FIG. 1 in particular, numeral 10 designates a wood chip cracking apparatus embodying the present invention. The apparatus 10 receives wood chips from a distributing device 12 which supplies an even flow of wood chips generally indicated by numeral 14 to top and bottom roll couples 16 and 18. The roll couples 16 and 18 are disposed in a housing 20 having a top opening 22 through which the wood chips 14 enter, and a bottom opening 24 through which the treated wood chips flow from the apparatus. The incoming flow of chips 14 is directed by baffles 26 and 28 to the upper roll couple 16, and the chips passing through the upper roll couple are directed by baffles 30 and 32 to the bottom roll couple 18. A suitable conveying apparatus, not shown, carries the treated chips from the apparatus 10 to subsequent process steps.
Top roll couple 16 includes rolls 40 and 42 closely spaced and oppositely driven, so that in the upper pocket between the rolls, the surfaces are running toward a narrow region formed by the closely spaced rolls 40 and 42, as indicated by the arrows 44 and 46.
The bottom roll couple 18 includes rolls 50 and 52 closely spaced and oppositely driven, so that in the upper pocket between the rolls, the surfaces are running toward a narrow region formed by the closely spaced rolls 50 and 52, as indicated by the arrows 54 and 56.
Each of the rolls 40, 42, 50, and 52 is suitably journalled in bearings generally indicated at numeral 60 in housing 20, and a drive mechanism 62 is provided for turning the rolls. The drive mechanism 62 may include a motor 64, or other source of power, and a drive train 66. The drive train 66 may drive each of the rolls; however, it has been found that in some applications of the present invention, it is necessary to drive only one roll of each roll couple. The mating roll in each roll couple opposite the driven roll can merely idle, and, in this manner, the energy requirements for operating the machine are reduced, in that when chips are not flowing to the apparatus, only one roll of each couple is being driven. As chips enter the apparatus and wedge between the driven and non-driven rolls, the non-driven roll will rotate, aiding in the cracking operation and in the passing through of wood chips.
The distributing device 12 includes a housing 70 having an opening 72 for receiving chips from a chip supply apparatus not shown, a distributing screw 74 for evening the flow of chips along the distributing device, and a distributing grid 76 through which chips pass from the distributing device 12 to the first roll couple 16. The distributing screw 74 is driven at 78 by a suitable source of power and is journalled in bearings 80 in the housing 70.
It should be understood by those skilled in the art that the arrangement shown in FIGS. 1 and 2 for the wood chip cracking apparatus of the present invention is merely one example of a suitable arrangement. In some installations, it may be desirable to use only one roll couple or to use more than two roll couples, and the apparatus for supplying chips to the roll couple or couples may be of types other than the distributing device 12 described above.
The surfaces of the rolls used in the present invention differ from that of rolls used for delaminating chips previously, in that the roll surfaces of the present invention are aggressively contoured. In the embodiment shown in FIG. 3, the roll surface comprises a matrix of pyramid shaped projections 100 which are formed by machining into the roll surface circumferential v-shaped valleys 102 and axial v-shaped valleys 104 in the roll at right angles. By machining such intersecting valleys, four-sided pyramids are formed extending radially outward on the roll surface. Each of the projections 100 has a peak 106 formed by the remaining material from the outer portions of the machined roll surface, and a base 108 defined by the depth of the intersecting valleys 102 and 104 in the machined material zone. Normally both rolls of the roll couples have similar surface configuration; however, it may be desirable to have one roll of each roll couple be smooth or otherwise have a more aggressively or less aggressively contoured surface than that of the other roll in the roll couple.
In one structure found to work advantageously, the roll surface was formed wherein the peaks 106 were spaced one-half inch apart, and each peak comprised a flattened surface approximately one-sixteenth inch square. The depth of each pyramid, from peak 106 to base 108 was six millimeters.
In the use and operation of an apparatus for destructuring wood chips as depicted in the aforedescribed drawings, chips are supplied to the distributing device 12, and from the distributing device 12 are supplied evenly along the axial extent of the first roll couple 16. The chips entering the distributing device 12 can be from a previous screening step, and comprise only the oversize chips separated at a previous screening step, or the entire chip flow to a pulping operation can be processed through the apparatus of the present invention. In yet other applications, it may be desirable to separate from the total chip stream only the under size chips, and then process both oversize and acceptable size chips through the present apparatus.
One significant advantage of the present invention is that the highly aggressive surface on the rolls significantly minimizes, virtually eliminating the heretofore recognized problem of chips not being pulled between the rolls, but instead, particularly with overlarge chips, riding above the rolls, with rolls sliding there along. Thus, a high volume of chips can be passed through the present apparatus, making it possible to process the entire chip flow in the pulp mill, potentially even eliminating the need for screening out oversized chips. If acceptable and oversized chips all can be passed through the apparatus, it is unnecessary to separate the overlarge for separate treatment. The small and acceptable chips, through proper roll spacing, will pass through the device substantially untreated, while only the oversize will be cracked. However, after treatment, the acceptable and treated oversize chips will respond similarly to pulping.
From the distributing device 12, the chips enter the region above the roll couple. The rolls may be separately driven, and positions controlled such that they are aligned in a peak to valley orientation such as shown in FIG. 4. Alternatively, in some processes and for some types of wood chips, it is desirable to control the roll's orientation in a peak-to-peak orientation as shown in FIG. 5. In yet other processes wherein a substantial compression in addition to cracking is desired, or wherein the acceptable chip thickness is quite thin, a closely intermeshed peak-to-valley relationship, as shown in FIG. 6, may be desirable. In yet other operations, particularly when the power input to the apparatus is to be minimized as much as possible, only one roll of each roll couple is driven, and the other merely idles. As chips approach the rolls and are pinched therebetween, the idle roll is driven by the driven roll through the driving connection formed by the wood chips compressed therebetween.
As chips are passed between the roll couples, regardless of the chip orientation, the chips tend to crack or split parallel to the fiber orientation in the chip. This is true whether the chip passes between the rolls lengthwise or endwise.
When the peak-to-valley orientation, as shown in FIGS. 4 or 6, is used, together with pyramid-shaped projections spaced one-half inch from each other, and being approximately six millimeters high, the cracks created in the chips occur approximately every one-fourth inch. This spacing of the cracks formed generally corresponds to the typically acceptable chip thickness in pulping operations. By cracking the chips, openings are created in the larger surfaces of the chips to aid liquor penetration. In addition to any fiber loosening which may result from compression, liquor penetration into the chip is aided by the actual physical openings created by the cracks. Displacement of the material near the crack is generally greater for thicker chips than for thinner chips, and thus, the opening for liquor penetration is less obstructed for thicker chips than thinner chips, thereby equalizing liquor penetration rates in the thicker and thinner chips. Because the rolls are spaced apart, the core of the chip is not displaced, and even with very thick chips, although surface displacement near the cracks may be significant and the general shape of the chip may be slightly changed, the integrity of the chip is not compromised, and the chip remains whole without the generation of pins, fines, or broken chips.
When a plurality of vertically arranged roll couples are used, as shown in FIGS. 1 and 2, it may be advantageous to provide progressively decreasing roll spacing on the lower roll couples. In this way, the largely oversized will be compressed and/or fractured by the upper rolls, with the acceptable and minimally oversized passing therethrough. Subsequent roll couples will further process the greatly oversized and process the minimally oversized.
Laboratory pulping studies have been conducted on chips processed through a single roll couple of the present invention wherein the projections of the adjacent rolls were intermeshed, as shown in FIG. 6. As a control, one sample was not treated, and other samples were sliced by conventional chip thickness slicing techniques.
Several different samples were treated in a wood chip cracking apparatus of the present invention. Several samples were treated in what is termed a "mild treatment" and others were treated in a "harsh treatment". In the mild treatment, the spacing between the projections in the region where projections from each roll are at their closest was six millimeters. In the harsh treatment, the spacing at the closest point of spacing between projections on separate rolls was three millimeters. Table 1 hereinafter summarizes the characteristics of the various samples on which pulping studies were conducted.
TABLE 1______________________________________(Sample Characteristics)Sample Species Treatment______________________________________1 Pine Not Treated2 Pine Mild3 Pine Harsh4 Pine Sliced5 Pine/Fir Sliced6 Pine/Fir Harsh______________________________________
The samples were fractionated in a Rader Companies CC2000 Chip Classifier. Samples were divided into fines, which would pass through a 3 millimeter round hole; pins which were between 0 and 2 millimeters thick; accepts, which were between 2 and 8 millimeters thick; total over thick greater than 8 millimeter; and highly over thick greater than 14 millimeter. Table 2 summarizes the thickness characteristics of each sample.
TABLE 2______________________________________(Thickness Classification in Percentage)Sample 14 mm 8 mm 2-8 mm 0-2 mm Fines______________________________________1 46.2 82.4 17.5 0 02 16.0 50.0 33.0 0.7 0.33 8.8 53.6 44.8 0.8 0.84 0 4.5 91.5 3.1 0.95 0.4 7.1 84.8 5.4 2.76 29.2 84.8 15.2 0 0______________________________________
In all of the samples except those in which the overthick chips were sliced, fifty percent or more of the chips in each sample were greater than the maximum established acceptable thickness of 8 millimeters. Several samples included high percentages of overly thick chips greater than 14 millimeters.
The samples were cooked in a laboratory batch digester using kraft digesting processes. Several samples were cooked in separate batches under two separate cooking conditions. One batch was cooked using a 15%/85% blend of chips from samples 3 and 4. The pulping conditions used for each batch and the chip sample type are described below in Table 3.
TABLE 3______________________________________(Pulping Conditions) Eff Alkali % Yield Max Pressure %/Resid. Total/Rej./ KappaSample Min./P.S.I. Wood/(g/e) Screened Number______________________________________1 50/105 15.8/14.3 52.5/16.5/36.0 48.42 50/105 15.8/14.3 46.3/0.8/45.5 44.72 70/112 16.1/13.8 44.1/0.4/43.7 30.14 70/112 16.1/13.6 44.9/0.9/44.0 32.83 50/112 16.2/13.9 45.3/0.5/44.8 40.63 60/105 15.8/13.7 47.0/0.7/46.3 44.64 60/105 15.8/13.7 49.2/2.7/46.9 48.33/4 50/112 16.4/14.3 45.8/1.6/44.2 38.05 50/112 15.9/12.6 46.3/4.5/41.8 46.86 50/112 15.9/12.6 49.2/5.0/44.2 45.2______________________________________
Pulp strength properties were calculated after refining the cooked pulps at 3000 revolutions, Table 4 shows these results.
TABLE 4______________________________________(Unbleached Strength Properties) Break Freeness Length %Sample (CSF) Porosity (Km) Stretch Tear Mullen______________________________________1 600 606 7.7 3.7 246 1382 600 655 7.7 3.9 195 1202 534 312 7.9 3.8 200 1214 543 262 7.9 3.8 230 1343 540 264 7.8 3.5 187 1213 540 264 7.8 3.5 187 1204 570 307 7.6 3.1 217 1353/4 572 336 7.9 3.8 238 1345 543 141 9.8 3.8 189 1616 581 192 9.1 3.8 172 148______________________________________
As seen in Table 4, the break length and stretch were substantially unaffected by the current chip cracking process of the present invention. Both sliced and cracked chips yielded similar strength characteristics. Tear, strength, and mullen, were, however, lower for the cracked chips. The decreased tear was realized at the entire freeness range examined, with the lowest tear from the harshly treated chips. However, when mixed with sliced chips, the resultant tear from pulps combining samples 3 and 4 was higher than that for the sliced chips (sample 4). Hence, mixtures of cracked chips with regular chips for pulping should be acceptable.
In terms of yield, pulps from chips treated by an apparatus according to the present invention contained minimal reject levels and substantially less rejects than pulp from the sliced chips. The overall yield out of the digester was, however, somewhat lower for the chips processed according to the present invention; however, this is believed to be less significant when the percent yield of acceptable fibers is compared.
It can be seen that the present invention provides a means for treating oversize chips which yields acceptable, usable pulp having characteristics similar to pulps obtained from acceptable size chips. At the same time, the apparatus of the present invention substantially reduces fines generation and reject fibers when compared to chips processed by conventional slicing techniques or pulps obtained from untreated chips. The simplicity of operation of the present invention makes it advantageous over chip slicers which require more frequent adjustment for proper operation.
While an apparatus for destructuring wood chips has been shown and described in detail herein, various changes may be made without departing from the scope of the present invention. | An apparatus for improving the pulping characteristics of wood chips in which a pair of closely operating rolls are provided for supplying compressive force to chips passed therebetween, at least one roll having an aggressively contoured surface for causing chips to crack in the thickness dimension of the chip as compressive force is applied to the chip. | 3 |
BACKGROUND
The invention relates to decision-making, and more particularly, to systems and methods of negotiation support.
Electronic negotiations (e-negotiations) are becoming an important research subject in the area of electronic commerce (e-commerce). The Agent-Mediated Electronic Commerce (AMEC) laboratory of MIT, for instance, puts e-negotiations at the center of its Consumer Buying Behavior (CBB) model for e-commerce. The model identifies six steps in an e-commerce transaction, identification of the need, product brokering, merchant brokering, negotiation, purchase and delivery and service evaluation. Auctions are at present the most visible type of e-negotiations on the Internet as conducted by eBay. Application of e-negotiations is not limited to e-commerce but also exists in various decision support systems.
E-negotiations can take a complex form called bargaining. It involves making proposals and counter-proposals until an agreement is reached. Bargaining can be bilateral and multi-lateral negotiation depending on whether there are two parties (one-to-one bargaining) or many parties (many-to-many bargaining) involved in the negotiation. Negotiations are further classified as distributive or integrative. In distributive negotiations, only one issue (e.g. price) is negotiable. The parties have opposing interests. One party (e.g. buyer) tries to minimize and the other party (e.g. seller) tries to maximize the price. In integrative negotiations, multiple issues (e.g. price, quality, delivery date or others) are negotiable. If all issues are negotiable then a customer may hope to get a cheap price if she can live with a poorer quality and/or can stand a long delivery time. In this case, parties do not necessarily have opposing interests since they try to optimize different issues. Integrative negotiation, however, is time-consuming and difficult to achieve optimize satisfactions among parties.
SUMMARY
Systems for negotiation support are provided. An exemplary embodiment comprises a first negotiation agent module, a second negotiation agent module and a negotiation management module. The first negotiation agent module receives multiple first proposals, calculates a first preference score (PS) for each first proposal using a first utility model and selects a portion of the first proposals as second proposals in descending order according to the first PSs therewith. The second negotiation agent module receives the first proposals, calculates a second preference score (PS) for each first proposal using a second utility model and selects a portion of the first proposals as third proposals in descending order according to the second PSs therewith. The negotiation management module receives the second proposals from the first negotiation module and the third proposals from the second negotiation module, and generates the fourth proposals according to the second proposals and the third proposals. The first negotiation agent module receives the fourth proposals generated by the negotiation management module, calculates a third PS for each fourth proposal using the first utility model, and arranges the fourth proposals in descending order according to third PSs therewith to generate a first voting result. The second negotiation agent module receives the fourth proposals generated by the negotiation management module, calculating a fourth PS for each fourth proposal using the second utility model, and arranging the fourth proposals in descending order according to the fourth PSs therewith to generate a second voting result. The negotiation management module receives the first voting result from the first negotiation module and the second voting result from the second negotiation module, and generates a final agreement according to the first voting result and the second result.
Negotiation support methods are further provided. An exemplary method generates multiple first proposals, receives multiple second proposals being a portion of the first proposals, and third proposals being a portion of the first proposals, generates multiple fourth proposals according to the second proposals and the third proposals, receives a first voting result corresponding to a portion of the fourth proposals, and a second voting result corresponding to a portion of the fourth proposals, and determines one of the fourth proposals as a final agreement according to the first voting result and the second voting result.
A machine-readable storage medium storing a computer program which, when executed, performs the method of negotiation support is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Negotiation support systems and methods will become apparent by referring to the following detailed description of embodiments with reference to the accompanying drawings, wherein:
FIG. 1 is a diagram of an embodiment of a negotiation support system;
FIG. 2 is a diagram of a hardware environment applicable to negotiation server and computers in an embodiment of a negotiation support system;
FIG. 3 is a software architecture diagram of an embodiment of a negotiation support system;
FIG. 4 is a flowchart of an embodiment of a method for negotiation support;
FIG. 5 is a diagram of a storage medium storing a computer program providing an embodiment of a method of negotiation support.
DESCRIPTION
FIG. 1 is a diagram of an embodiment of a negotiation support system, comprising negotiation server 21 , computers 22 and 23 , operating in a network (preferably Internet or intranet) using logical connections to each other. Those skilled in the art will recognize that the negotiation server 21 , computers 22 and 23 may be connected in different types of networking environments, and communicate between different types of networking environments through various types of transmission devices such as routers, gateways, access points, base station systems or others.
FIG. 2 is a diagram of a hardware environment applicable to negotiation server and computers in an embodiment of a negotiation support system, comprising a processing unit 11 , a memory 12 , a storage device 13 , an input device 14 , an output device 15 and a communication device 16 . The processing unit 11 is connected by buses 17 to the memory 12 , storage device 13 , input device 14 , output device 15 and communication device 16 based on Von Neumann architecture. There may be one or more processing units 11 , such that the processor of the computer comprises a single central processing unit (CPU), a micro processing unit (MPU) or multiple processing units, commonly referred to as a parallel processing environment. The memory 12 is preferably a random access memory (RAM), but may also include read-only memory (ROM) or flash ROM. The memory 12 preferably stores program modules executed by the processing unit 11 to perform Web link management functions. Generally, program modules include routines, programs, objects, components, scripts, Web pages, or others, that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will understand that some embodiments may be practiced with other computer system configurations, including hand-held devices, multiprocessor-based, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like. Some embodiments may also be practiced in distributed computing environments where tasks are performed by remote processing devices linked through a communication network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices based on various remote access architecture such as DCOM, CORBA, Web objects, Web Services or other similar architectures. The storage device 13 may be a hard drive, magnetic drive, optical drive, portable drive, or nonvolatile memory drive. The drives and associated computer-readable media thereof (if required) provide nonvolatile storage of computer-readable instructions, data structures and program modules. The processing unit 11 , controlled by program modules received from the memory 12 and from an operator through the input device, directs negotiation support functions.
FIG. 3 is a software architecture diagram of an embodiment of a negotiation support system. Computers 22 and 23 individually comprise a negotiation agent module 221 and 231 , and the negotiation server 21 comprises a negotiation management module 211 communicating with the negotiation agent modules 221 and 231 . The negotiation agent modules 221 and 231 are individually stored in memories 12 of computers 22 and 23 , and individually loaded and executed by processing units 11 of computer 22 and 23 . The negotiation management module 211 is stored in memory 12 of negotiation server 21 , and loaded and executed by the processing unit 11 of negotiation server 21 . Note that the negotiation agent module 221 or 231 may be stored in the negotiation server 21 . Those skilled in the art will recognize that a negotiation system may comprise more than two negotiation agent modules. Negotiation content comprises multiple issues, with each issue associated with multiple items.
FIG. 4 is a flowchart of an embodiment of a method for negotiation support, divided into three sections, a left section showing steps performed by the negotiation agent module 221 , a middle section showing steps performed by the negotiation management module 221 , and a right section showing steps performed by the negotiation agent module 231 , separated by dashed lines for added clarity.
In step S 4111 , multiple initial proposals are generated by the negotiation management module 211 . Items for specific issues in each initial proposal are randomly selected. In step S 4221 , the initial proposals are transmitted to the negotiation agent modules 221 and 231 .
In step S 4221 , the proposals initially generated by the negotiation management module 211 are received by the negotiation agent module 221 . In step S 4223 , a preference score (PS) for each received proposal is calculated according to a predetermined utility model for the negotiation agent module 221 . The implementation of the utility model may utilize at least one mathematic equation. In step S 4225 , a number of received proposals are selected in descending order according to the PSs thereof. In step S 4227 , the selected proposals are transmitted to the negotiation management module 211 .
In step S 4321 , the proposals initially generated by the negotiation management module 211 are received by the negotiation agent module 231 . In step S 4323 , a PS for each received proposal is calculated according to a predetermined utility model for the negotiation agent module 231 . The implementation of the utility model may utilize at least one mathematic equation. In step S 4325 , a number of received proposals are selected in descending order according to the PSs thereof. In step S 4327 , the selected proposals are transmitted to the negotiation management module 211 .
In step S 4121 , proposals selected by the negotiation agent modules 221 and 231 are received by the negotiation management module 211 . In step S 4123 , new proposals are generated according to the received proposals, preferably in a number equaling to that of received proposals. Some embodiments may perform recombination processes of Genetic Algorithm (GA) to selectively combine more than two received proposals to generate new proposals. During the recombination process, two selected proposals may be split at a point randomly chosen to produce two “head” sub-proposals and two “tail” sub-proposals. The “head” sub-proposals of proposals are respectively combined with the “tail” sub-proposals of the other proposals to produce new proposals. Some embodiments may perform mutation processes of GA to selectively change item in at least one issue for each received proposals to generate new proposals. Some embodiments may first perform mutation processes of GA and subsequently perform recombination processes of genetic algorithm to generate new proposals. Some embodiments may first perform recombination processes of genetic algorithm and subsequently perform mutation processes of GA to generate new proposals. Some embodiments may perform other various well-known search algorithms or random optimization algorithms to generate new proposals. Preferably, if the number of generated proposals exceeds the number of received proposals, some generated proposals are randomly removed from the generated proposals to maintain the generated proposal size. In step S 4125 , it is determined whether the new proposals require further evolution or improvement. If so, the process proceeds to step S 4127 , and otherwise, the process proceeds to step S 4131 . Some embodiments may determine whether the rounds of new proposal generation exceeds to a predetermined threshold. Some embodiments may determine whether the new proposals are required to improve or evolve according to content thereof. In step S 4131 , the generated proposals are transmitted to the negotiation agent modules 221 and 231 . In step S 4131 , the generated proposals and voting notices are transmitted to the negotiation agent modules 221 and 231 .
In step S 4231 , the proposals and voting notice generated by the negotiation management module 211 are received by the negotiation agent module 221 . In step S 4233 , a PS for each received proposal is calculated according to the predetermined utility model for the negotiation agent module 221 . In step S 4235 , the proposal with the highest PS in the remaining proposals (i.e. proposals not yet voted on by the negotiation agent module 221 ) is selected. In step S 4237 , the selected proposal or proposal identity is transmitted as a voting result to the negotiation management module 211 .
In step S 4331 , the proposals and voting notice generated by the negotiation management module 211 are received by the negotiation agent module 231 . In step S 4333 , a PS for each received proposal is calculated according to the predetermined utility model for the negotiation agent module 231 . In step S 4335 , the proposal with the highest PS in the remaining proposals (i.e. proposals not yet voted on by the negotiation agent module 231 ) is selected. In step S 4337 , the selected proposal or proposal identity is transmitted as a voting result to the negotiation management module 211 .
In step S 4133 , proposals or proposal identities are received from the negotiation agent modules 221 and 231 . In step S 4133 , it is determined whether a proposal voted on by a specific number of negotiation agent modules is present. If so, the process proceeds to step S 4139 , and otherwise, the process proceeds to step S 4137 . In step S 4137 , a voting notice is transmitted to the negotiation agent modules 221 and 231 . In step S 4139 , a proposal voted on by a specific number of negotiation agent modules (i.e. final proposal) is transmitted as a final result to the negotiation agent modules 221 and 231 . Although a preferred embodiment discloses a voting procedure in rounds as steps S 4133 to S 4139 , those skilled in the art will recognize that the negotiation management module 211 may receive more than two proposals or proposal identities with priorities at one time and accordingly determine a final result, enabling reduced process time.
In step S 4239 , a voting notice or a final proposal generated by the negotiation management module 211 is received by the negotiation agent module 221 . In step S 4241 , it is determined whether a voting notice is received. If so, the process proceeds to step S 4235 , and otherwise, the process proceeds to step S 4243 . In step S 4243 , the received proposal is acquired as a final agreement.
In step S 4339 , a voting notice or a final proposal is received by the negotiation agent module 231 . In step S 4341 , it is determined whether a voting notice is received. If so, the process proceeds to step S 4335 , and otherwise, the process proceeds to step S 4343 . In step S 4343 , the received proposal is acquired as a final agreement.
Details of the method for negotiation support are illustrated in the following example. A travel proposal comprises multiple issues, such as activity, restaurant, hotel and the like. The activity comprises items A1, A2 and A3, the restaurant comprises items R1, R2, R3, R4 and R5, and the hotel comprises items H1, H2 and H3. In steps S 4111 and S 413 , multiple initial proposals, P1={A3,R2,H3}, P2={A1,R5,H2}, P3={A2,R4,H2}, P4={A2,R3,H2}, P5={A1,R1,H1}, P6={A3,R1,H1}, are generated by the negotiation management module 211 , and transmitted to the negotiation agent modules 221 and 231 .
In steps S 4221 and S 4223 , proposals initially generated by the negotiation management module 211 are received by the negotiation agent module 221 , and PSs for received proposals are calculated by formula 1:
PS = ∑ i = 1 n Wi ⋆ S ( i , j ) ,
where n represents the number of issues, Wi represents the ith weighted value, and S(i,j) represents the score of the jth item in the ith issue. Where Wpb 1 = 3 , W2=2, W3=1, S(1,1)=¼, S(1,2)=1, S(1,3)=½, S(2,1)=1, S(2,2)= 1/10, S(2,3)= 1/10, S(2,4)= 1/10, S(2,5)= 1/10, S(3,1)=1, S(3,2)=1 and S(3,3)=1, PSs for initial proposals P1 to P6 are 2.7, 1.95, 4.2, 4.2, 3.75 and 4.5. In steps S 4225 and S 4227 , three proposals P6, P3 and P4 are selected in descending order according to PSs therewith, and transmitted to the negotiation agent module 211 .
In steps S 4321 and S 4323 , proposals initially generated by the negotiation management module 211 are received by the negotiation agent module 231 , and PSs for received proposals are calculated by formula 2:
PS = ∑ i = 1 n S ( i , j ) ,
where n represents the number of issues, and S(i,j) represents the score of the jth item in the ith issue. Where S(1,1)=1, S(1,2)=3, S(1,3)=2, S(2,1)=5, S(2,2)=2, S(2,3)=4, S(2,4)=1, S(2,5)=3, S(3,1)=2, S(3,2)=3 and S(3,3)=1, PSs for initial proposals P1 to P6 are 5, 5, 7, 10, 8 and 9. In steps S 4325 and S 4327 , three proposals P4, P6 and P5 are selected in descending order according to PSs therewith, and transmitted to the negotiation agent module 211 .
In steps S 4121 to S 4127 , proposals P6, P3, P4, P4, P6 and P5 selected by the negotiation agent modules 221 and 231 are received by the negotiation management module 211 . New proposals, P7={A3,R1,H2}, P8={A2,R3,H1}, P9={A2,R1,H1}, P10={A3,R4,H2}, P11={A2,R3,H1} and P12={A1,R1,H2}, are generated by performing recombination processes of GA for pairs of received proposals {P6,P4}, {P3,P6} and {P4,P5}. The new generated proposals are transmitted to negotiation agent modules 221 and 231 .
In steps S 4221 and S 4223 , proposals generated by the negotiation management modules 211 are received by the negotiation agent module 221 . The PSs for received proposals are calculated by the utility module in formula 1. The resulting PSs are 4.5, 4.2, 6, 3.7, 4.2 and 3.75 for the received proposals, P7 to P12. In steps S 4225 and S 4227 , three proposals P9, P7 and P8, are selected in descending order according to PSs therewith, and transmitted to the negotiation management module 211 .
In steps S 4321 and S 4323 , proposals generated by the negotiation management modules 211 are received by the negotiation agent module 231 . The PSs for received proposals are calculated by the utility module in formula 2. The resulting PSs are 10, 9, 10, 6, 9 and 9 for the received proposals P7 to P12. In steps S 4325 and S 4327 , three proposals P7, P9 and P8 are selected in descending order according to PSs therewith, and transmitted to the negotiation management module 211 .
In steps S 4121 and S 4123 , proposals P9, P7, P8, P7, P9 and P8 selected by the negotiation agent modules 221 and 231 are received by the negotiation management module 211 . New proposals, P13={A3,R1,H1}, P14={A2,R3,H1}, P15={A2,R3,H1}, P16={A2,R1,H1}, P17={A3,R1,H1} and P18={A1,R1,H2}, are generated by performing recombination processes of GA for pairs of received proposals {P7,P8}, {P8,P9} and {P7,P9}. In steps S 4125 and S 4131 , the new generated proposals and voting notices are transmitted to negotiation agent modules 221 and 231 .
In steps S 4221 and S 4223 , proposals generated by the negotiation management modules 211 are received by the negotiation agent module 221 . The PSs for received proposals are calculated by the utility module in formula 1. The resulting PSs are 4.5, 4.2, 4.2, 6, 4.5 and 6 for the received proposals P13 to P18. In steps S 4321 and S 4323 , proposals generated by the negotiation management modules 211 are received by the negotiation agent module 231 . The PSs for received proposals are calculated by the utility module in formula 2. The resulting PSs are 9, 10, 9, 10, 9 and 11 for the received proposals P13 to P18.
During a first voting round, in steps S 4237 and S 4239 , the proposal P16 is selected and transmitted to the negotiation management module 211 . In steps S 4337 and S 4339 , the proposal P18 is selected and transmitted to the negotiation management module 211 . In steps 4135 and S 4137 , voting notices are transmitted to the negotiation agent modules 221 and 231 by the negotiation management module 211 .
During a second voting round, in steps S 4237 and S 4239 , the proposal P18 is selected and transmitted to the negotiation management module 211 . In steps S 4337 and S 4339 , the proposal P14 is selected and transmitted to the negotiation management module 211 . In steps 4135 and S 4137 , the proposal P18 is transmitted to the negotiation agent modules 221 and 231 by the negotiation management module 211 .
Finally, in step S 4243 , the proposal P18 is acquired as a final agreement by the negotiation agent module 221. In step S 4343 , the proposal P18 is acquired as a final agreement by the negotiation agent module 231 .
Also disclosed is a storage medium as shown in FIG. 5 storing a computer program 520 providing the disclosed method of negotiation support. The computer program product includes a storage medium 50 having computer readable program code embodied therein for use in a computer system. The computer readable program code comprises at least computer readable program code 521 generating initial proposals, computer readable program code 522 generating new proposals, computer readable program code 523 managing voting procedures, computer readable program code 524 calculating PSs, computer readable program code 525 generating voting proposals, and computer readable program code 526 voting proposals.
Negotiation support systems and methods, or certain aspects or portions thereof, may take the form of program code (i.e., instructions) embodied in tangible media, such as floppy diskettes, CD-ROMS, hard drives, or any other machine-readable storage medium, wherein, when the program code is loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. The disclosed methods and systems may also be embodied in the form of program code transmitted over some transmission medium, such as electrical wiring or cabling, through fiber optics, or via any other form of transmission, wherein, when the program code is received and loaded into and executed by a machine, such as a computer, the machine becomes an apparatus for practicing the invention. When implemented on a general-purpose processor, the program code combines with the processor to provide a unique apparatus that operates analogously to specific logic circuits.
Although the invention has been described in terms of preferred embodiment, it is not limited thereto. Those skilled in this technology can make various alterations and modifications without departing from the scope and spirit of the invention. Therefore, the scope of the invention shall be defined and protected by the following claims and their equivalents. | Systems for negotiation support. First and second negotiation agent modules respectively receive multiple first proposals, calculate preference scores (PSs) for each first proposal using utility models and select a portion of the first proposals as second proposals in descending order according to the calculated PSs therewith. The negotiation management module receives the second proposals from the first and second negotiation modules, and generates third proposals according to the received proposals. The first and second negotiation agent modules respectively receive the third proposals, calculate PSs for received proposals using utility models, and arrange the third proposals in descending order according to PSs therewith to generate voting results. The negotiation management module receives the voting results, and generates a final agreement according to the received voting results. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a reciprocating compressor, and in particular to a reciprocating compressor which is capable of constructing construction parts compactly, restraining collision noise occurrence by preventing collision of the construction parts in operation and stabilizing the operation.
BACKGROUND ART
[0002] Generally, a compressor is for compressing a fluid. The compressor can be divided into a rotation compressor, a reciprocating compressor and a scroll compressor, etc. according to fluid compression types.
[0003] In the rotation compressor, a rotational shaft rotates by receiving a driving force of a rotational motor, simultaneously an eccentric part combined with the rotational shaft performs an eccentric rotation in a cylindrical compression space of a cylinder, and accordingly gas is compressed.
[0004] In the scroll compressor, a rotational shaft rotates by receiving a driving force of a rotational motor, simultaneously a rotary scroll combined with the rotational shaft engaging with a fixed scroll performs a rotating motion, and accordingly gas is compressed.
[0005] In the reciprocating compressor, a rotational shaft rotates by receiving a driving force of a rotational motor, simultaneously a connecting rod combined with the rotational shaft converts the rotating motion into a linear reciprocating motion and transmits it to a piston, the piston performs the linear reciprocating motion in a cylinder, and accordingly gas is compressed.
[0006] In addition, in another type of the reciprocating compressor, a piston receiving a driving force of a reciprocating motor performs a linear reciprocating motion in a cylinder, and accordingly gas is compressed.
[0007] [0007]FIG. 1 illustrates a reciprocating compressor in accordance with the conventional art. As depicted in FIG. 1, the reciprocating compressor includes a container 100 having a suction pipe 10 in which gas is sucked; a frame unit installed inside the container 100 ; a reciprocating motor installed at the frame unit and generating a linear reciprocating driving force; a compression unit installed at the frame unit with a certain distance from the reciprocating motor, receiving the driving force of the reciprocating motor and compressing gas; a spring unit for elastically supporting the linear reciprocating driving force of the reciprocating motor; and a valve unit installed at the compression unit and opening/closing a compression space in which gas is compressed.
[0008] The container 100 is sealed to have a certain inner space, and the suction pipe 10 penetrates-combines with the container 100 so as to communicate with the container 100 .
[0009] The reciprocating motor consists of an outer stator 310 installed at a rear frame 210 of the frame unit; an inner stator 320 inserted into the outer stator 310 with a certain interval; a wound coil 330 inserted into an open groove 311 formed at the outer stator 310 ; and a mover 340 inserted between the outer stator 310 and the inner stator 320 to perform a linear reciprocating motion.
[0010] And, a middle frame 220 is fixedly combined with a certain side of the reciprocating motor to face the rear frame 210 .
[0011] The compression unit includes a cylinder 410 combined with a front frame 230 having a certain distance from the reciprocating motor and a piston 420 inserted into a compression space 411 of the cylinder 410 and connected to the mover 340 of the reciprocating motor.
[0012] And, in the front frame 230 , a protrusive supporting portion 232 extended from a certain side of a plate portion 231 is formed so as to have a certain length, and a through hole 233 in which the cylinder 410 is inserted is formed at the supporting portion 232 .
[0013] In the cylinder 410 , the compression space 411 penetrates through a cylinder body 412 having a certain length. And, the cylinder 410 is inserted into the through hole 233 of the front frame 230 .
[0014] Herein, the end surface of the supporting portion 232 of the front frame 230 is the same surface as the end surface of the cylinder body 412 .
[0015] The piston 420 includes a body unit 421 having a certain length and a flange portion 422 extended from a certain side of the body unit 421 so as to have a certain size and connected to the mover 340 .
[0016] In the piston 420 , the flange portion 422 is combined with the mover 340 , and the body unit 421 is inserted into he compression space 411 of the cylinder 410 .
[0017] The spring unit includes a certain-shaped spring supporting portion 510 in which a certain side is combined with the flange portion 422 of the piston 420 or the mover 340 so as to place between the front frame 230 and the middle frame 220 ; and a spring 520 respectively placed at both sides of the spring supporting portion 510 .
[0018] The valve unit includes a discharge cover 610 combined with the front frame 230 to cover the compression space 411 of the cylinder; a discharge valve 620 placed inside the discharge cover 610 and opening/closing the compression space 411 of the cylinder 410 ; a valve spring 630 for elastically supporting the discharge valve 620 ; and a suction valve 640 combined with the end of the piston 420 and opening/closing a suction channel 423 formed inside the piston 420 .
[0019] Unexplained reference numeral 20 is a discharge pipe, 240 is a connecting member of the frame unit, and 341 is a permanent magnet.
[0020] The operation of the conventional reciprocating compressor will be described.
[0021] When power is applied to the reciprocating motor, a current flows onto the wound coil 330 of the reciprocating motor, a flux is formed between the outer stator 310 and the inner stator 320 , by mutual operation of the flux between the outer stator 310 and the inner stator 320 with a flux by the permanent magnet 341 of the mover 340 , the mover 340 performs a linear reciprocating motion.
[0022] The linear reciprocating driving force of the mover 340 is transmitted to the piston 420 , and the piston 420 performs a linear reciprocating motion inside the cylinder compression space 411 .
[0023] The spring unit stores, discharges the linear reciprocating power of the reciprocating motor as elastic energy and causes a resonance motion.
[0024] With the linear reciprocating motion of the piston 420 in the compression space 411 of the cylinder 410 , the valve unit is operated, the gas sucked into the suction pipe 10 is sucked into the compression space 411 through the suction channel 423 of the piston 420 , compressed discharged, herein, the gas is discharged to the outside through the discharge pipe 20 of the discharge cover 610 .
[0025] In general, the compressor includes a cooling cycle apparatus and is installed to an air-conditioner, a refrigerator and a showcase, etc. In order to install the compressor to a system such as an air-conditioner, a refrigerator and a showcase, etc., the compressor has to have a simple structure and require a small installation space and operate stably.
[0026] In the meantime, unlike other compressors, in the reciprocating compressor, an output of the reciprocating motor as a driving power source is a linear reciprocating motion power, the piston 420 receives the linear reciprocating motion power of the reciprocating motor and performs the linear reciprocating motion in the compression space 411 to compress the gas, and accordingly constructing parts moving in the axial direction compactly is important object to simplify a structure of the compressor.
[0027] In the meantime, as depicted in FIG. 2, in a reciprocating compressor constructed by considering the above-mentioned object, in the linear reciprocating motion of the flange portion 422 of the piston (receiving the driving force of the reciprocating motor and performing the linear reciprocating motion in the compression space 411 of the cylinder), a distance between the inner stator 320 of the reciprocating motor respectively placed at both sides of the flange portion 422 and the front frame 230 corresponds to a reciprocating motion distance of the flange portion 422 .
[0028] And, the flange portion 422 of the piston 420 is placed between the inner stator 320 and the front frame 230 , a distance (a) between the end surface of the front frame 230 and the flange portion 422 is the same as a distance (b) between the inner stator 320 and the flange portion 422 .
[0029] And, as depicted in FIG. 3, in the cylinder 410 in which the piston 420 is inserted and the front frame 230 of the frame unit in which the cylinder 410 is inserted, the end surface (c) of the cylinder 410 is placed on the same surface as the end surface (d) of the supporting portion 232 .
[0030] In the above-mentioned construction, the piston 420 receives the linear reciprocating driving force of the reciprocating motor, sucks, compresses and discharges the gas while performing the linear reciprocating motion in the compression space 411 of the cylinder 410 , however, by the compressed gas force in the compression space 411 , the center of the reciprocating motion of the piston 420 may be moved from an initial position toward the reciprocating motor, due to that, the flange portion 422 of the piston 420 may collide against the inner stator 320 of the reciprocating motor during the linear reciprocating motion, and accordingly collision noise may occur and the operation may be unstable.
[0031] In addition, when the piston 420 performs the unstable reciprocating motion, the flange portion 422 of the piston 420 may collide against the end surface (d) of the supporting portion 232 of the front frame 230 and the end surface (C) of the piston 420 , impact may be applied to the piston 420 and the front frame 230 , and accordingly the assembly condition of the valve unit connected to the cylinder 410 may not be secured.
TECHNICAL GIST OF THE PESENT INVENTION
[0032] In order to solve the above-described problems, it is an object of the present invention to provide a reciprocating compressor which is capable of constructing construction parts compactly, restraining collision noise occurrence by preventing collision between the construction parts in operation and stabilizing the operation.
[0033] In order to achieve the above-mentioned object, in a reciprocating compressor comprising a container having a suction pipe in which gas is sucked; a frame unit installed inside the container; a reciprocating motor installed at the frame unit and generating a linear reciprocating driving force; a compression unit installed at the frame unit so as to have a certain distance from the reciprocating motor, receiving the driving force of the reciprocating motor and compressing gas; a spring unit for elastically supporting the linear reciprocating driving force of the reciprocating motor; and a valve unit installed at the compression unit and opening/closing the compression space in which gas is compressed, wherein the piston of the compression unit has a flange portion connected to a mover of the reciprocating motor, a distance (k) between a front frame of the frame unit and the flange portion of the piston is smaller than a distance (m) between the reciprocating motor and the flange portion of the piston.
BRIEF DESCRIPTION OF DRAWINGS
[0034] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0035] In the drawings:
[0036] [0036]FIG. 1 illustrates a reciprocating compressor in accordance with the conventional art;
[0037] [0037]FIG. 2 is a sectional view illustrating major parts of the reciprocating compressor;
[0038] [0038]FIG. 3 is a sectional view illustrating major parts of the reciprocating compressor;
[0039] [0039]FIG. 4 is a sectional illustrating a reciprocating compressor in accordance with the present invention;
[0040] [0040]FIG. 5 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention;
[0041] [0041]FIG. 6 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention;
[0042] [0042]FIG. 7 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention;
[0043] [0043]FIG. 8 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention;
[0044] [0044]FIG. 9 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention; and
[0045] [0045]FIG. 10 is a sectional view illustrating major parts of the reciprocating compressor in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0046] Hereinafter, the preferred embodiment of the present invention will be described with reference to accompanying drawings.
[0047] As depicted in FIG. 4, a reciprocating compressor in accordance with the present invention includes a container having a suction pipe in which gas is sucked; a frame unit installed inside the container; a reciprocating motor installed at the frame unit and generating a linear reciprocating driving force; a compression unit installed at the frame unit so as to have a certain distance from the reciprocating motor, receiving the driving force of the reciprocating motor and compressing gas; a spring unit for elastically supporting the linear reciprocating driving force of the reciprocating motor; and a valve unit installed at the compression unit and opening/closing the compression space in which gas is compressed.
[0048] The container 100 is sealed to have a certain inner space, and the suction pipe 10 penetrates-combines with the container 100 so as to communicate with the container 100 .
[0049] The compression unit includes a cylinder 410 combined with a front frame 230 having a certain distance from the reciprocating motor and a piston 420 inserted into a compression space 411 of the cylinder 410 and connected to the mover 340 of the reciprocating motor.
[0050] And, in the front frame 230 , a protrusive supporting portion 232 extended from a certain side of a plate portion 231 is formed so as to have a certain length, and a through hole 233 in which the cylinder 410 is inserted is formed at the supporting portion 232 .
[0051] And, the supporting portion 232 of the front frame 230 is projected toward the reciprocating motor.
[0052] In the cylinder 410 , the compression space 411 penetrates through a cylinder body 412 having a certain length. And, the cylinder 410 is inserted into the through hole 233 of the front frame 230 .
[0053] As depicted in FIG. 5, when the cylinder 410 is inserted into the through hole 233 of the front frame 230 , the end of the cylinder 410 is placed inside the through hole 233 of the supporting portion 232 of the front frame 230 .
[0054] In more detail, the end surface (d) of the supporting portion 232 of the front frame 230 is combined with the end surface (c) of the cylinder 410 as a step structure to make a distance (k) between the flange portion 422 of the piston 420 and the end surface (d) of the supporting portion 232 shorter than a distance (f) between the flange portion 422 of the piston 420 and the end surface (c) of the cylinder 410 .
[0055] The piston 420 includes a body unit 421 having a certain length; and a flange portion 422 extended from a certain side of the body unit 421 so as to have a certain size and connected to the mover 340 .
[0056] The reciprocating motor consists of an outer stator 310 installed at a rear frame 210 of the frame unit; an inner stator 320 inserted into the outer stator 310 with a certain interval; a wound coil 330 inserted into an open groove 311 formed at the outer stator 310 ; and a mover 340 inserted between the outer stator 310 and the inner stator 320 so as to perform a linear reciprocating motion.
[0057] When a current flows onto the wound coil 330 , the outer stator 310 and the inner stator 320 form a closed loop in which a flux flows, herein, both sides of the open groove 311 of the outer stator 310 are pole portions 312 respectively forming each pole.
[0058] As depicted in FIG. 6, the mover 340 includes a permanent magnet 341 having a certain length. The permanent magnet 341 has the same length as an added length of an inlet length (g) of the open groove 311 and the one pole portion length (h), places along the both pole portions 312 of the outer stator 310 and faces the open groove 311 . In addition, the center of the permanent magnet 341 and the open groove 311 are eccentric.
[0059] In more detail, on the basis of the center of the open groove 311 , the center of the permanent magnet 341 is placed so as to be eccentric as a certain amount toward the compression unit.
[0060] And, a middle frame 220 is fixedly combined with the reciprocating motor to combine the outer stator 310 of the reciprocating motor with the rear frame 210 .
[0061] In more detail, the middle frame 220 is placed between the front frame 230 and the rear frame 210 .
[0062] And, the frame unit includes the front, middle and rear frames 230 , 220 , 210 and a connecting member 240 placed between the front and middle frames 230 , 220 .
[0063] The mover 340 of the reciprocating motor is connected to the flange portion 422 of the piston 420 constructing the compression unit.
[0064] As depicted in FIG. 7, the flange portion 422 of the piston 420 is placed between the front frame 230 and the reciprocating motor, a distance (k) between the flange portion 422 and the front frame 230 is smaller than a distance (m) between the flange portion 422 and the reciprocating motor.
[0065] In more detail, the distance (k) between the end surface (d) of the supporting portion 232 and one side of the reciprocating motor facing the flange portion 422 is smaller than the distance (m) between the inner stator 320 of the reciprocating motor and the flange portion 422 .
[0066] As depicted in FIG. 8, the distance (m) between the flange portion 422 and the one side of the reciprocating motor facing the flange portion 422 is smaller than a distance (p) between the end surface (n) of the mover 34 b and the rear frame 210 facing the end surface (n).
[0067] As depicted in FIG. 9, the height of the pole portion 312 is smaller than an added distance ((k)+(m)) of the distance (k) between the end surface (d) of the supporting portion 232 and the flange portion 422 and the distance (m) between the flange portion 422 and the reciprocating motor facing the flange portion 422 .
[0068] The spring unit includes a certain-shaped spring supporting portion 510 in which a certain side is combined with the flange portion 422 of the piston 420 or the mover 340 so a to place between the front frame 230 and the middle frame 220 ; and a spring 520 respectively placed at both sides of the spring supporting portion 510 .
[0069] The valve unit includes a discharge cover 610 combined with the front frame 230 to cover the compression space 411 of the cylinder; a discharge valve 620 placed inside the discharge cover 610 and opening/closing the compression space 411 of the cylinder 410 ; a valve spring 630 for elastically supporting the discharge valve 620 ; and a suction valve 640 combined with the end of the piston 420 and opening/closing a suction channel 423 formed inside the piston 420 .
[0070] And, as depicted in FIG. 10, a distance (r) between the discharge valve 620 and the end of the piston 420 (the suction valve 640 combined with the end of the piston 420 ) is smaller than a distance (k) between the end surface (d) of the supporting portion 232 and the flange portion 422 of the piston 420 .
[0071] Hereinafter, advantages of the reciprocating compressor in accordance with the present invention will be described.
[0072] When power is applied to the reciprocating motor, a current flows onto the wound coil 330 of the reciprocating motor, a flux is formed between the outer stator 310 and the inner stator 320 , by mutual operation of the flux between the outer stator 310 and the inner stator 320 with a flux by the permanent magnet 341 of the mover 340 , the mover 340 performs a linear reciprocating motion.
[0073] Herein, a reciprocating motion distance of the mover 340 is determined by the permanent magnet 341 and the outer stator 310 of the mover 340 . In more detail, a length of the permanent magnet 341 is the same as the added length ((h)+(g)) of a length (h) of the pole 312 and an inlet length (g) of the open groove 311 , the permanent magnet 341 is moved by the mutual operation of the flux formed on the inner and outer stators 310 , 320 according to the current flowing onto the wound coil 330 , the reciprocating distance of the permanent magnet 341 is the length (h) of the pole portion 312 of the outer stator 310 , and accordingly the end of the permanent magnet 341 does not escape from the end of the pole portion 312 in the linear reciprocating motion.
[0074] And, the linear reciprocating driving force of the mover 340 is transmitted to the piston 420 combined with the mover 340 , the piston 420 performs a linear reciprocating motion in the compression space 411 .
[0075] Herein, the flange portion 422 of the piston 420 connected to the mover 340 performs a reciprocating motion between the end surface (d) of the supporting portion 232 (of the front frame 230 ) and the inner stator 320 of the reciprocating motor.
[0076] The spring unit stores, discharges the linear reciprocating force of the reciprocating motor as elastic energy and causes a resonance motion.
[0077] With the linear reciprocating motion of the piston 420 in the compression space 411 of the cylinder 410 , the valve unit is operated, the gas sucked into the suction pipe 10 is sucked into the compression space 411 through the suction channel 423 of the piston 420 , compressed discharged, herein, the gas is discharged to the outside through the discharge pipe 20 of the discharge cover 610 .
[0078] In more detail, when the piston 420 is moved to the bottom dead center, the suction valve 620 is curved due to a pressure difference between the compression space 411 and the outside, the suction valve 423 is open, and accordingly the gas of the suction pipe 10 is sucked into the compression space 411 through the suction channel 423 .
[0079] And, when the piston 420 is moved from the bottom dead center to the upper dead center, the suction valve 620 closes the suction channel 423 , the gas of the compression space 411 of the cylinder 410 is compressed and reaches a set pressure state, the discharge valve 620 of the valve unit is open, and accordingly the compressed gas is discharged.
[0080] As described above, the piston 420 compresses the gas by performing the reciprocating motion in the compression space 411 of the cylinder 410 .
[0081] While the piston 420 compresses the gas by moving between the bottom dead center and the upper dead center by the driving force of the reciprocating motor, the pressure force of the gas acts on the piston 420 .
[0082] In the present invention, because the flange portion 422 of the piston 420 , which places between the supporting portion 232 of the front frame 230 and the inner stator 320 of the reciprocating motor and performs a linear reciprocating motion by receiving the driving force form the reciprocating motor, is placed toward the supporting portion 232 of the front frame 230 , although the piston 420 is pushed by the gas pressure force, the piston 420 can move in a position-compensated state.
[0083] The piston 420 performs the linear reciprocating motion in the state pushed toward the reciprocating motor side by the pressure force, the flange portion 422 of the piston 420 in the eccentric state toward the front frame side is operated between the front frame 230 and the inner stator 320 of the reciprocating motor, and accordingly it is possible to prevent the flange portion 422 of the piston 420 from colliding against other construction parts.
[0084] In more detail, collision of the flange portion 422 against other parts is prevented, and a distance between the supporting portion 232 of the front frame 230 and the inner stator 320 of the reciprocating motor is minimized.
[0085] In addition, in the present invention, by making the distance (k) between the end surface (d) of the supporting portion 232 and the flange portion 422 smaller than the distance (m) between the end surface (c) of the cylinder 410 and the flange portion 422 of the piston 420 , when the flange portion 422 of the piston 420 excessively moves toward the front frame side in the unstable operation, the flange portion 422 does not collide against the cylinder 410 but collide against the supporting portion 232 of the front frame 230 , and accordingly impact of the collision can be minimized.
[0086] In addition, by making the distance (k) between the end surface (d) of the supporting portion 232 and the flange portion 422 of the piston 420 greater than a distance (r) between the discharge valve 620 and the end of the piston 420 (the suction valve 640 combined with the end of the piston 420 ), the piston 420 can move to the upper dead center without colliding the flange portion 422 against the supporting portion 232 of the front frame 230 .
[0087] In addition, by making the length (h) of the pole portion of the outer stator as the basis of the reciprocating motion distance of the mover 340 of the reciprocating motor smaller than an added distance ((k)+(m)) of the distance (k) between the end surface (d) of the supporting portion 232 and the flange portion 422 and the distance (m) between one side of the inner stator 320 of the reciprocating motor and the flange portion 422 , it is possible to prevent the flange portion 422 of the piston 420 performing the linear reciprocating motion with the mover 340 from colliding against the supporting portion 232 of the front frame 230 and the inner stator 320 of the reciprocating motor.
[0088] In addition, by making the distance (m) between the flange portion 422 of the piston 420 and the reciprocating motor facing the flange portion 422 smaller than a distance (p) between the end surface (n) of the mover 340 and the rear frame 210 facing the end surface (n), in the unstable operation of the mover 340 or the piston 420 , before the mover 340 collides against the rear frame 210 , the flange portion 422 of the piston 420 collides against a certain side of the inner stator 320 of the reciprocating motor, and accordingly it is possible to minimize damage of construction parts.
[0089] In addition, on the basis of the center of the open groove 311 at which the wound coil 330 is placed, the center of the permanent magnet 341 is placed toward the compression unit, when the piston 420 and the mover 340 are pushed by the pressure power in the operation, the mover 340 moves in the position-compensated state, and accordingly the permanent magnet 341 of the mover 340 does not escape from the end of the pole portion 312 of the outer stator 310 and move stably.
INDUSTRIAL APPLICABILITY
[0090] As described above, in the reciprocating compressor in accordance with the present invention, by preventing collision of parts moving with the mover of the reciprocating motor against other parts due to displacement occurred by the pressure power acting on the piston of the compression unit while pressing gas in the compression unit by receiving the linear reciprocating driving force of the reciprocating motor, damage of construction parts can be prevented, and accordingly it is possible to improve stability of the compressor. In addition, by constructing the parts compactly, it is possible to miniaturize the compressor. | A reciprocating compressor, wherein a flange unit connected to the mover constituting the reciprocating motor is installed on the piston constituting the compressing unit, the distance between the piston flange unit and the front frame of the frame unit is shorter than that of between the piston flange unit and the reciprocating motor. In the process of being transmitted the linear reciprocal movement driving force of the reciprocating motor and compressing the gas in the compressing unit, the stability of the compressor is raised by preventing the components moving together with the mover of reciprocating motor from impacting with other components by the displacement generated by compression force applying to the piston constituting the compressing unit. Also, the size of compressor can be scaled down by compactly constituting the components. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 10/780,260, filed Feb. 17, 2004, each of which are hereby expressly incorporated by reference herein in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates to a device for filling a trench with the dirt previously removed to form the trench.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a rear-perspective view of the device attached to the rear of a pulling vehicle, such as a tractor.
[0004] FIG. 2 is a perspective view of the device looking at the right, rear corner of the device.
[0005] FIG. 3 is a longitudinal cross sectional view through the device.
[0006] FIG. 3 a is the same view as FIG. 3 , but illustrating the location of the dirt being put back into the trench.
[0007] FIG. 4 is a plan view of the device.
[0008] FIG. 5 is perspective view of the front left corner of the device.
[0009] FIG. 6 is a front, perspective view of a portion of the device.
[0010] FIG. 7 is a schematic, plan view of an alternate embodiment.
DETAILED DESCRIPTION
[0011] Referring to the drawings in detail, and particularly FIG. 1 , reference character 10 generally designates the trench filling device of this invention which is adapted to be towed along a trench by a tractor or the like 12 . In general, the device 10 comprises a frame 14 supporting a pair of rearwardly converging scraper blades 16 ( FIG. 4 ) in the forward end 18 of the frame; a temporary leveling blade 20 ( FIG. 3 ) rearwardly of the blades 16 and a compaction roller 22 in the rearward end 24 of the frame 14 .
[0012] As shown in FIGS. 1 and 2 , the frame 14 comprises a pair of side plates 26 interconnected by cross braces 28 and having a skid 30 formed along the lower edge 32 of each side plate.
[0013] As shown in FIGS. 3 and 4 , a pair of brackets 34 are secured to the forward end 18 of the frame 14 near each side of the frame, and an upper bracket 38 is provided in the center of the frame for connection with the three point hitch 40 of the tractor 12 . The device 10 can thus be towed as well as raised to an inoperative position by the use of the three point hitch 40 of the tractor 12 .
[0014] The forward end 42 of each of the rearwardly converging scraper blades 16 is suitably secured to the forward end 18 of the respective side of the frame 14 by a suitable bracket 44 as shown in FIG. 5 . The rearward end 46 of each rearwardly converging scrape blade 16 is supported horizontally by a suitable adjustable bracket 48 , by means of which the spacing between the rear end portions 46 of the scraper blades 16 may be adjusted as desired. The rear end portion 46 of each scrape blade 16 is secured vertically by a suitable bracket 50 .
[0015] As indicated in FIG. 3 , each end of the horizontally extending blade 20 is secured to the respective frame side plate 26 by an adjustable bracket 52 in order that the overall height of the blade 20 may be adjusted as desired by the local conditions. Normally, the blade 20 is positioned about three inches above the level of the skids 30 .
[0016] As shown in FIG. 1 , the roller 22 is mounted on a shaft 54 . Each end of the shaft 54 is supported in a bearing 56 suitably secured to the respective side plate 26 by bolts 58 . As indicated in FIG. 2 , two sets of bolt holes 60 are provided in the frame side walls 26 to receive bolts 58 and provide for a vertical adjustment of the height of roller 22 . Normally, the roller 22 is adjusted at a height a short distance above the skids 30 , such as about one and one quarter inches.
[0017] An alternate embodiment 10 a is shown schematically in FIG. 7 . This alternate embodiment utilizes a virtually identical frame 14 , as well as the rearwardly converging scraper blades 16 at the forward end of the device, and the roller 22 at the rear end of the device. Rather than the use of a scraper blade extending horizontally across the frame 14 , the alternate embodiment 10 a utilizes a rubber tire 62 for temporarily compressing the dirt moved into the trench by the blades 16 , and a second pair of scraper blades 64 between the rubber tire 62 and the roller 22 to move dirt into the path of the central portion of the roller 22 which is disturbed by the rubber tire 62 . The rubber tire is suitably supported by a linkage 66 from one of the cross frame members 28 utilizing a compression spring 68 and an adjustable jack mechanism or hydraulic cylinder 70 , by means of which the rubber tire 62 will be urged downwardly against dirt moved by the scraper blades 16 , and the amount of the compression provided by the spring 68 may be adjusted by the jack or cylinder 70 to provide the desired force on the dirt moved over the trench by the scraper blades 16 . The secondary scraper blades 64 will be suitably mounted on cross braces 28 in such a manner that the angle of these blades may also be adjusted.
[0018] It will be understood by those skilled in the art that the blades 16 and 64 in FIG. 7 may be mounted in the frame 14 using hydraulic cylinders, rather than mechanically, for the convenience of the operator of the device.
Operation
[0019] The purpose of device 10 is to move the dirt 72 ( FIG. 3 a ) at each side of an open trench 74 into the trench and provide some compaction of the dirt moved back into the trench. As indicated in FIG. 3 a , the scraper blades 16 move the dirt 72 into and over the trench 74 as the device 10 is pulled forwardly with the skids 30 straddling the trench.
[0020] The dirt moved by the scraper blades 16 will extend above the level of the ground on each side of the trench and the horizontally extending scraper blade 20 will temporarily level that dirt, before it is contacted and somewhat compressed or compacted by the roller 22 . The level of the dirt behind the device 10 will be a short distance above the ground on each side of the trench, allowing for the dirt to settle in the trench and eventually end up with a relatively level surface where the trench had been.
[0021] The modified device 10 A shown in FIG. 7 will provide a first compaction and spreading of the dirt first moved by the scraper blades 16 by operation of the rubber tires 62 , and the dirt disturbed by the rubber tire 62 will be moved back over the center portion of the trench by the small scraper blades 64 . Then the roller 22 will further compact the dirt and leave a surface slightly above the surrounding ground in the same manner as the device shown in the preferred embodiment.
[0022] Changes may be made in the combination and arrangement of parts or elements as here to fore set forth in the specification and shown in the drawing without departing from the spirit and scope of the invention as defined in the following claims. | A device for filling an open trench with the dirt previously removed from the trench lying alongside the trench, using a skid-mounted frame having blades to initially fill the trench and leveling the dirt, followed by a compactor. | 4 |
TECHNICAL FIELD
The invention relates to an adjustable spindle for rotating round elastomeric objects. Specifically, the invention relates to changing the camber angle of a spindle used for rotating tires.
BACKGROUND ART
In the automotive industry, some manufacturers design their vehicles having a suspension which provides a camber to the wheels that are used on the vehicle. When developing tires for such vehicles, it is important to test an experimental tire under conditions very similar to those encountered on a vehicle. Accordingly, spindles used for spinning tires on test equipment have been adapted to provide camber to a tire during dynamic testing.
In prior art testing equipment, however, spindles providing a camber were not adjustable and could be set up only at one angle. Conversion to a different angle was possible but involved dismantling the equipment to change the angle. Even then, only a limited number of angles were possible.
Vehicle manufacturers often experiment with different camber angles on vehicles, and a large variety of vehicles are being manufactured with camber angle on the suspension systems, and it is important that tires be tested at the large number of camber angles which are used, or are considered experimentally.
It is an object of the present invention to provide an adjustable spindle which makes possible the quick adjustment of the camber angle of the spindle.
SUMMARY OF THE INVENTION
A spindle assembly ( 10 ) for rotating round objects comprises a spindle ( 12 ) and a spindle plate ( 14 ) attached to a back plate ( 16 ), the spindle plate ( 14 ) and back plate ( 16 ) having interposed there between at least two wedge rings ( 18 , 20 ), wedge rings( 18 , 20 ) having a wider portion ( 22 , 22 a ) and a narrower portion ( 24 , 24 a ). In the assembly, when a narrower portion ( 24 ) of wedge ring ( 18 ) is adjacent to wider portion ( 22 a ) of wedge ring ( 20 ), an axis ( 26 ) of the spindle ( 12 ) is normal to the plane ( 28 ) of the back plate ( 16 ). The assembly ( 10 ) is adapted to vary the angle of an axis ( 26 ) of the spindle ( 12 ) relative to a plane ( 28 ) of the back plate ( 16 ) by rotating said at least two wedge rings ( 18 , 20 ) relative to each other and to said back plate ( 16 ).
Washers ( 32 ) used with bolts ( 30 ), and nuts ( 34 ) on the bolts ( 30 ) have a portion of a sphere ( 54 ) to accommodate a plurality of angles.
The at least two wedge rings ( 18 , 20 ) are adapted to interlock with each other circumferentially, permitting rotation relative to one another while maintaining their circumferential relationship to the back plate ( 16 ). The at least two wedge rings ( 18 , 20 ) each have an outside surface ( 40 , 40 a ) corresponding to its outside diameter and an inside surface ( 41 , 41 a ) corresponding to its inside diameter, and a back plate side ( 44 , 44 a ) oriented toward the back plate ( 16 ) and a spindle plate side ( 46 , 46 a ) oriented toward the spindle ( 12 ), and in the spindle assembly ( 10 ) in a wedge ring ( 18 ) closest to the back plate ( 16 ) the back plate side ( 44 ) forms a ninety degree (90°) angle with the outside surface ( 40 ), and in a wedge ring ( 20 ) closest to the spindle plate ( 14 ) the spindle plate side ( 46 a ) forms a ninety degree angle with the outside surface ( 40 a ).
The at least two wedge rings ( 18 , 20 ) are marked with indicia ( 48 , 48 a ) whereby the angle of the axis ( 26 ) of the spindle ( 12 ) relative to a plane ( 28 ) of the back plate ( 16 ) can be determined by the indicia.
In one embodiment, the back plate ( 16 ) and spindle plate ( 14 ) are attached to each other by a plurality of bolts ( 30 ), and the at least two interposed wedge rings ( 18 , 20 ) are free to rotate relative to the spindle plate ( 14 ) and the back plate ( 16 ) when the bolts ( 30 ) are not tightened. In a second embodiment, bearings ( 56 ) are interposed between spindle plate ( 14 ) and a wedge ring ( 20 ), and between wedge ring ( 20 ) and wedge ring ( 18 ), and between wedge ring ( 18 ) and back plate ( 16 ) and a pinion gear ( 67 ) is associated with the wedge rings ( 18 , 20 ) for rotating the wedge rings.
Also provided is a method for varying the camber angle of a spindle ( 12 ) having a spindle plate ( 14 ), comprising the steps of interposing at least two wedge rings ( 18 , 20 ) between a spindle plate ( 14 ) and a back plate ( 16 ) in a spindle assembly ( 10 ), wherein at least two of the at least two wedge rings ( 18 , 20 ) have a wider portion ( 22 , 22 a ) and a narrower portion ( 24 , 24 a ).
The method may comprise the further steps of (a) releasing tension between a back plate ( 16 ) and a spindle plate ( 14 ) in a spindle assembly, and (b) rotating at least two of the at least two wedge rings ( 18 , 20 ) independent of each other and the back plate ( 16 ), or the further steps of (a) associating a pinion gear ( 67 ) with the wedge rings ( 18 , 20 ), and (b) using the pinion gear ( 67 ) to change the angle of spindle ( 12 ).
The method may comprise the further step of providing indicia ( 48 , 48 a ) on at least two of the at least two wedge rings ( 18 , 20 ) whereby the exact angle of an axis ( 26 ) of the spindle ( 12 ) relative to a plane ( 28 ) of the back plate ( 16 ) can be determined from the indicia.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a side elevational view of a spindle assembly of the invention.
FIG. 2 illustrates an elevational view of the assembly from the spindle end.
FIG. 3 illustrates a cross sectional view of a spindle assembly of the invention taken along the line 3 — 3 of FIG. 1 .
FIG. 4 illustrates a top plan view cross sectional view of a spindle assembly of the invention along the line 4 — 4 of FIG. 1 .
FIG. 5 illustrates a side sectional view of a spindle assembly taken along the line 5 — 5 of FIG. 4 .
FIG. 6 is a side sectional view showing the spindle in 6° positive position.
FIG. 7 is a side sectional view showing the spindle in 6° negative position.
FIG. 8 is an enlarged, detached, exploded view of the wedge rings of the spindle assembly.
FIG. 9 is an end view of the spindle plate wedge ring showing the indicia.
FIG. 10 is an exploded perspective view of the spindle assembly.
FIG. 11 illustrates a view similar to FIG. 5 showing an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The spindle invention is designed to provide angle adjustments in whatever degree increments are desired for testing, e.g. 0.05 degrees, and is capable of substantially an infinite number of angle adjustments. The spindle assembly is composed of four principle parts, the spindle section, at least two wedge rings, and an axle section. Rotating the wedge rings causes the spindle to move in a vertical or horizontal plane to whatever angle is required for testing. The inventor has illustrated embodiments of a passenger tire spindle which uses three degree wedge rings for a plus or minus 6 degrees of adjustment, and has developed a truck tire spindle embodiment, using the same principles, which uses one and one-half degree wedge rings for a plus or minus 3 degree adjustment.
The spindle assembly of the invention is designed and illustrated specifically for use with testing equipment, but those skilled in the art will recognize that the spindle assembly can be used on vehicles where quick adjustment of the camber angle is desirable, for example on race cars.
With reference now to FIGS. 1-10, a spindle assembly 10 of the invention is illustrated. The spindle 12 is integrally connected to spindle plate 14 , and spindle plate 14 is bolted to back plate 16 which is connected to the axle assembly 17 . In the illustrated embodiment, eight bolts 30 having washers 32 with a spherical portion 54 are used together with nuts 34 to tightly connect back plate 16 to spindle plate 14 . The spherical portion 54 of washers 32 facilitates the different angles encountered between the back plate 16 and spindle plate 14 when the angle of the spindle is adjusted, since substantially even pressure is exerted by washers 32 regardless of the angle of spindle 12 .
At least two wedge rings may be interposed between the back plate 16 and the spindle plate 14 to vary the angle of spindle 12 with respect to the axle assembly 17 , and especially with respect to the plane 28 of back plate 16 . At least two wedge rings are needed to vary the angle of the spindle according to the invention, but additional rings may be added to provide more control to changing the angles, provide multiple planes of adjustment, or to improve the accuracy of the angles achieved.
In the illustrated embodiment a first wedge ring 18 and a second wedge ring 20 are interposed between back plate 16 and spindle plate 14 . Each of the wedge rings, 18 , 20 , has a wider portion 22 , 22 a and a narrower portion 24 , 24 a . When a narrower portion 24 of the first wedge ring 18 is adjacent to wider portion 22 a of second wedge ring 20 , the axis 26 of spindle 12 will be perpendicular to plane 28 of back plate 16 . Conversely, when narrower portion 24 of first wedge ring 18 is adjacent to narrower portion 24 a of second wedge ring 20 , as illustrated in FIGS. 6 and 7, the maximum angle of the spindle will be seen, the position of the narrower portions 24 , 24 a determining whether the angle will be positive or negative.
With reference now to FIGS. 8 and 9, a first wedge ring 18 is provided with a boss 36 which is adapted to engage register 38 of a second wedge ring 20 . Wedge rings 18 , 20 have a wider portion 22 , 22 a and a narrower portion 24 , 24 a , and a back plate side 44 , 44 a and a spindle plate side 46 , 46 a . By “back plate side”, it is meant that when the rings are installed between back plate 16 and spindle plate 14 , the back plate side 44 , 44 a is installed toward back plate 16 . Likewise, “spindle plate side” means that spindle plate sides 46 , 46 a are oriented toward spindle plate 14 when wedge rings 18 and 20 are installed between back plate 16 and spindle plate 14 .
Wedge rings 18 and 20 have an outside surface 40 , 40 a and an inside surface 41 , 41 a . Indicia 48 is located on the back plate side 44 of wedge ring 18 , and indicia 48 a is located on the spindle plate side 46 a of wedge ring 20 . Rotating means 50 , 50 a are used to turn the wedge rings when nuts 34 are loosened on bolts 30 .
When incorporated in spindle assembly 10 , the inside surface 41 a of wedge ring 20 rests on shoulder 13 of spindle plate 14 , and the inside surface 41 of wedge ring 18 rests on shoulder 15 of back plate 16 . Shoulders 13 , 15 stabilize wedge rings 18 , 20 in the assembly, and together with boss 36 and register 38 , which provide an interlocking relationship between wedge rings 18 and 20 , insure that the angles indicated by indicia 48 , 48 a are consistent as the angles of spindle 12 are changed back and forth.
In the illustrated embodiment, rotating means 50 , 50 a are levers projecting from the outside surface 40 , 40 a of the wedge rings 18 , 20 , which can be used to provide leverage for turning a wedge ring when a change of camber angle for the spindle is desired. Other means of turning the wedge rings will be apparent to those skilled in the art.
In the illustrated embodiment, the outside surfaces 40 , 40 a form a 90-degree angle with the back plate side 44 of wedge ring 18 , and a 90-degree angle with the spindle plate side 46 a of wedge ring 20 . The center of the wedge ring is determined by measuring the center of the angled face 46 of wedge ring 18 , and the angled face 44 a of wedge ring 20 . Determining the center of wedge ring 18 , 20 on the angled face places the axis point 47 , 47 a on the angled side of the wedge ring. Thus, when wedge ring 18 and wedge ring 20 are interposed between back plate 16 and spindle plate 14 , the axis points 47 , 47 a of the two wedge rings are contiguous with each other.
The inventor has found that when the wedge rings are made such that the axis points 47 , 47 a are on opposite sides of the wedge rings, away from each other in spindle assembly 10 , the two axis points, being separated by the total width of the wedge rings, may create an oscillation in the rotation of the spindle. The invention has been found to be operable with these two separated axis points, however, when a shoe 52 is placed in the axis assembly 17 , to dampen or eliminate the oscillation.
Shoe 52 is flat on spindle plate side 53 , and square boss 61 on spindle plate 14 fits into register 62 of shoe 52 in spindle assembly 10 . Back plate side 51 of shoe 52 is curved, to permit changing angles in the vertical plane without binding the spindle assembly 10 .
The shoe 52 also allows for multiple planes of motion when an additional pair of wedge rings are used. The shoe 52 moves within the axis assembly 17 on curved back plate side 51 to allow one plane of motion, and the boss 61 on the wedge ring side of the spindle plate 14 is free to move within register 62 on the inside of the shoe 52 to allow the other plane of motion.
In the implementation of the invention, to vary the angle of the spindle, nuts 34 on bolts 30 are loosened sufficiently to permit movement or rotation of wedge rings 18 and 20 , and rotation means 50 , 50 a on the wedge rings 18 , 20 provide leverage for turning the rings. Marks are provided on the back plate 16 and the spindle plate 14 which are used for aligning indicia 48 , 48 a for the desired angle. In the illustrated embodiment, if 2.5 degrees is the desired angle of the spindle, the indicia of wedge ring 18 is placed at the mark on the back plate 16 to read 2.5 degrees and the indicia 48 a on wedge ring 20 is placed at the mark on the spindle plate 14 to read 2.5 degrees. Nuts 34 are then tightened on bolts 30 until the spindle assembly is secure. Spherical portion 54 of washers 32 accommodate the change in angle by providing consistent contact throughout the perimeter of bore holes 31 in the back plate 16 and spindle plate 14 , regardless of the angle of adjustment.
Those skilled in the art will recognize that other systems with different indicia arrangements can be used to obtain the desired angles.
With reference now to FIG. 11, in an alternative embodiment, bearings 59 , such as ball bearings or roller bearings, may be mounted in wedge rings 18 and 20 to simplify and make easier rotation of the wedge rings to the desired location. An additional stabilizing plate 33 can be used to make possible changing the spindle angles without loosening bolts 30 . The stabilizing plate 33 remains parallel to the spindle plate when the angle of spindle 12 is changed. Accordingly, when the angle of spindle plate 14 is changed, stabilizing plate 33 moves against surface 19 of axle assembly 17 . Assuming the back plate remains stationary (attached to the axle), when the widest part of the wedges are rotated to the top of assembly 10 , this would cause the spindle to turn down. When the widest part of the wedges are at the top, the top cross-section width becomes greater, and the resulting cross-section at the bottom of assembly 10 becomes narrower. When both wedge rings are rotated at the same time, the total cross section width of the wedge rings at angular displacement locations of 90° and 270° from the top of the spindle assembly 10 remain equal to each other. When the widest part of the wedges are at the top of assembly 10 , this normally requires nuts 34 to be loosened to allow for the increase in cross section width. Conversely, the nuts 34 at the bottom of assembly 10 would have to be tightened to allow for the decrease in cross section width. The stabilizing plate 33 being free to move against surface 19 and remaining parallel to spindle plate 14 keeps the distance contained by bolt 30 and nut 34 constant throughout the angle adjustment of spindle 12 . This arrangement makes it unnecessary to loosen or tighten the bolts as the wedge rings 18 , 20 are moved. It is necessary that the dimension 56 and 57 (the horizontal distance between the washer pivots 58 and the plate pivots 59 , 60 ) be the same for both plates to keep the “bolt length” equal. The radius from the plate pivot 59 , 60 to each of the washer pivots 58 would then be equal by design. Conical spring washers may still be required under the bolt head, or similar mechanical arrangements be made, to make up any slight irregularities and make allowances for wear, and to maintain the pre-load on the bearings. The two wedge rings would need to be coupled so that they move an equal distance simultaneously in opposite directions. This can be accomplished by using a pinion gear 67 on the centerline between the two wedge rings 18 , 20 , and in mesh with gear teeth 68 of both wedge rings 18 , 20 .
As illustrated above, spindle assembly 10 is designed primarily for angle adjustments in the vertical plane, i.e. ±6 degrees vertical (i.e. perpendicular to the contact testing surface of a wheel mounted on spindle 12 ). It is contemplated by the inventor that at least two additional wedge rings can be added to the assembly to vary the spindle angle in the horizontal plane, functioning in the same manner as wedge rings 18 , 20 , but having an angular displacement of 90° as compared to the orientation of wedge rings 18 , 20 . As discussed above, the dimensions of shoe 52 will permit movement of boss 61 in register 62 of shoe 52 to permit such angular displacement. | An apparatus and method for making possible an infinite variation in the adjustment angle of a spindle assembly makes possible a rapid changeover for testing the dynamic properties of elastomeric objects. In spindle assembly ( 10 ), wedge rings ( 18, 20 ) having wider portions ( 22, 22 a ) and narrower portions ( 24, 24 a ) interposed between a spindle ( 12 ) and an axle assembly ( 17 ), whereby the relative placement of the wider portions ( 22, 22 a ) and the narrower portions ( 24, 24 a ) determine the angle of the spindle ( 12 ) relative to axle assembly ( 17 ). Indicia ( 48, 48 a ) on the wedge rings ( 18, 20 ) make possible quick determination of the exact angle. Means ( 50, 50 a , 67 ) may be provided to make easier rotation of the wedge rings ( 18, 20 ). | 1 |
This invention relates to a coil that may be used, for example, as a component of a transformer or as a choke.
BACKGROUND OF THE INVENTION
The applicant of the present application filed U.S. patent application Ser. No. 10/006,478 on Dec. 6, 2001, entitled “High-Frequency Large Current Handling Transformer”, which was published on Jun. 13, 2002 under US-2002-0070836-A1. The transformer disclosed in the U.S. application includes coil sheets or planar coil members 1 , 2 , 3 , 4 , 5 and 6 of metal, e.g. copper, as shown in FIG. 1 . The metallic coil sheets 1 , 2 , 3 , 4 , 5 and 6 are formed in a rectangular shape with windows 1 a , 2 a , 3 a , 4 a , 5 a and 6 a in their center portions. One side of each coil sheet is cut to form a slit 1 b , 2 b , 3 b , 4 b , 5 b , 6 b therein. Tabs 1 c and 1 d extend outward from the portions facing across the slit 1 b . Similarly, tabs 2 c and 2 d , 3 c and 3 d , 4 c and 4 d , 5 c and 5 d , and 6 c and 6 d extend outward from the portions of the respective sheet coils 2 , 3 , 4 , 5 and 6 facing each other across the slits 2 b , 3 b , 4 b , 5 b and 6 b . The tabs 1 c , 2 c , 3 c , 4 c , 5 c and 6 c provide winding start terminals, while the tabs 1 d , 2 d , 3 d , 4 d , 5 d and 6 d provide winding end terminals. The coil sheets 1 , 2 and 3 are stacked, with the tabs 1 d and 2 c interconnected and with the tabs 2 d and 3 c interconnected, to thereby provide a primary winding of the transformer. Similarly, the coil sheets 4 , 5 and 6 are stacked, with the tabs 4 c , 5 c and 6 c interconnected and with the tabs 4 d , 5 d and 6 d interconnected, to thereby provide a secondary winding. Insulating sheets 9 , 10 , 11 and 14 are disposed in such a manner that each coil sheets 1 , 2 and 3 are sandwiched between two of the insulating sheets. An insulating sheet 17 is disposed on the stack of the coil sheets 4 , 5 and 6 so as to sandwich them between the insulating sheets 17 and 14 . The insulating sheets 9 , 10 , 11 , 14 and 17 have center windows 9 a , 10 a , 11 a , 14 a and 17 a , respectively. Two core halves of, for example, ferrite, 18 and 19 are used. The core halves 18 and 19 have center legs 18 a and 19 a , respectively, with grooves 18 b and 18 c , and 19 b and 19 c located on opposite sides of the respective legs 18 a and 19 a . Outward of the grooves 18 b and 18 c are outer legs 18 d and 18 e , respectively, and outward of the grooves 19 b and 19 c are outer legs 19 d and 19 e , respectively. The core halves 18 and 19 are combined in such a manner that the center legs 18 a and 19 a can be placed to extend through the center windows 1 a - 6 a in the coil sheets 1 - 6 and the center windows 9 a - 14 a and 17 a in the insulating sheets 9 - 14 and 17 .
In manufacturing this transformer, work for stacking the metallic coil sheets and the insulating sheets alternately is necessary, which increases the cost of the transformer. Furthermore, with this arrangement, the metallic coil sheets are exposed to air and, therefore, may be oxidized and rust after long use. In addition, in order to fulfill safety standards for transformers, it must be so arranged that a sufficient creepage distance can be kept even when the insulating sheets 9 , 10 , 11 , 14 and 17 are displaced more or less with respect to is the metallic coil sheets. For that purpose, larger insulating sheets must be used, which makes transformers larger in size.
An object of the present invention is to provide a coil that requires fewer steps in manufacturing it, is hardly oxidized and is small in size.
SUMMARY OF THE INVENTION
A coil according to one embodiment of the present invention includes a coil section having a plurality of metallic coil sheets. The coil sheets are planar and each have a window in the center portion thereof. A slit is formed in each coil sheet, which extends from a location on the periphery of the window through the sheet to the outer periphery of the sheet. Connection terminals are formed on the sheet at locations facing each other across the slit. The coil sheets are stacked, and adjacent coil sheets are electrically connected with each other by the connection terminals. A core is disposed within the windows in the coil sheets. Each of the metallic coil sheets is individually coated completely with an insulating coating before the metallic coil sheets are stacked.
With the above-described arrangement, since each of the metallic coil sheet of the coil is individually pre-coated with an insulating coating, there is no need for placing an insulating sheet between adjacent coil sheets when the metallic coils sheets are stacked, which can reduce the manufacturing steps, which, in turn, can reduce the manufacturing cost. Furthermore, by covering the entire surface of each of the metallic coil sheets with an insulating coating, the metallic coil sheets are hardly oxidized and rusted. In addition, since each of the metallic sheets is individually pre-coated with an insulating coating, there is no need to take care to keep that insulating sheets are not displaced relative to the metallic coil sheets when the metallic coil sheets are stacked. Accordingly, it is not necessary to take such displacement into account when setting a creepage distance, and, therefore, the creepage distance can be set small. Then, the size of transformers can be reduced.
A plurality of coil sections may be used. The core is disposed to extend through the windows in the metallic coil sheets of the coil sections, so that the plural coil sections are inductively coupled with each other. This arrangement provides a transformer which can be manufactured at a low cost and hardly rust, and is small in size.
The insulating coatings may be formed by applying an insulative resin directly over the metallic coil sheet. Alternatively, an insulating film may be bonded to the metallic coil sheet to cover part of or the entirety of the surface of the metallic coil sheet before stacking the metallic coil sheets. The insulating resin may be used as an adhesive to bond the pre-formed insulating film to the metallic coil sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a prior art transformer.
FIG. 2 is an exploded perspective view of a transformer according to a first embodiment of the present invention.
FIGS. 3 a , 3 b , 3 c and 3 d illustrate steps for manufacturing a metallic coil sheet useable in the transformer shown in FIG. 2 .
FIG. 4 a is a plan view of a metallic coil sheet useable in the transformer of FIG. 2,
FIG. 4 b is a cross-sectional view of the metallic coil sheet shown in FIG. 4 a along a line 4 b — 4 b , and
FIG. 4 c is a cross-sectional view of the metallic coil sheet of FIG. 4 a along a line 4 c — 4 c.
FIG. 5 a is a cross-sectional view of a metallic coil sheet useable in the transformer of FIG. 2, and
FIG. 5 b is a cross-sectional view of a metallic coil sheet used in a prior art transformer.
FIG. 6 is an exploded perspective view of a choke manufactured using a coil of the present invention.
DESCRIPTION OF EMBODIMENTS
The present invention may be embodied in a high-frequency large current handling transformer, as shown in FIG. 2 . The transformer includes a plurality, two, for example, of coil sections, or windings 30 and 32 .
The winding 30 includes a plurality, three, for example, of metallic coil sheets 34 , 36 and 38 , which are formed in a rectangular shape and have the same size. The metallic coil sheets 34 , 36 and 38 have windows 34 a , 36 a and 38 a , respectively, in their center areas. The windows 34 a , 36 a and 38 a have the same size. The metallic coil sheets 34 , 36 and 38 are formed of metal, e.g. copper. Each of the coil sheets 34 , 36 and 38 includes a slit 34 b , 36 b , 38 b in one of the four sides around the window. The sides in which the slits are formed are on the same side of the completed transformer, but the locations of the slits 34 b , 36 b and 38 b are offset with respect to each other. On the portions of the coil sheet 34 facing each other across the slit 34 b , terminals 34 c and 34 d are provided. Similarly, terminals 36 c and 36 d and terminals 38 c and 38 d are provided on the portions of the coil sheets 36 and 38 facing each other across the respective slits 36 b and 38 b . The terminals 34 c , 36 c and 38 c provide winding start terminals, and the terminals 34 d , 36 d and 38 d provide winding end terminals. The metallic coil sheets 34 , 36 and 38 are stacked up with the windows 34 a , 36 a and 38 a therein aligned with each other. The locations of the slits 34 b , 36 b and 38 are determined such that, when the coil sheets are stacked, the terminals 34 d and 36 d are vertically aligned, and the terminals 36 d and 38 c are vertically aligned.
The winding 32 includes metallic coil sheets 40 , 42 and 44 configured similarly to the metallic coil sheets 34 , 36 and 38 of the winding 30 . The metallic coil sheets 40 , 42 and 44 have respective windows 40 a , 42 a and 44 a , respective slits 40 b , 42 b and 44 b , respective pairs of terminals 40 c and 40 d , 42 c and 42 d , and 44 c and 44 d . The metallic coil sheets 40 , 42 and 44 , too, are stacked in such a manner that the windows 40 a , 42 a and 44 a therein are vertically aligned. The locations of the slits 40 b , 42 b and 44 b are determined such that the terminals 40 d and 42 c can be vertically aligned and the terminals 42 d and 44 c can be vertically aligned when the metallic coil sheets 40 , 42 and 44 are stacked.
Each of the metallic coil sheets 34 , 36 , 38 , 40 , 42 and 44 has an insulating coating ( 46 ) thereon, as represented by the metallic coil sheet 38 shown in detail in FIGS. 4 a , 4 b and 4 c . The insulating coating 46 covers the entire surface of the metallic coil sheet 38 . FIG. 4 b is a cross-sectional view of the metallic coil sheet 38 with the insulating coating shown in FIG. 4 a along a line 4 b — 4 b , and FIG. 4 c is a cross-sectional view along a line 4 c — 4 c.
The insulating coating 46 is formed of an insulating film and an epoxy resin layer, and is formed in the following manner. First, the metallic coil sheet 38 is formed by punching a copper sheet 50 along broken lines, as shown in FIG. 3 a . At this stage, holes 52 and 54 are also formed in the terminals 38 c and 38 d , respectively. Next, as shown in FIG. 3 b , two insulating films, e.g. polyimide films 56 with an insulating adhesive layer, e.g. an epoxy resin layer 58 , are prepared by applying epoxy resin over one surface of each polyimide film 56 . The polyimide films 56 are rectangular and larger in size than the metallic coil sheet 38 .
When the epoxy resin layers 58 are partly dried, the polyimide films 56 are joined to opposing two major surfaces of the metallic coil sheet 38 , by placing, as shown in FIG. 3 c , the epoxy resin layers 58 to contact with the major surfaces of the metallic coil sheet 38 . Thus, the metallic coil sheet 38 is sandwiched. As is seen from FIG. 3 c , the terminals 38 c and 38 d are not covered with the polyimide films 56 .
Then, as shown in FIG. 3 d , downward and upward pressures are applied to the polyimide films 56 joined to the metallic coil sheet 38 , by means of a press (not shown), e.g. a press with silicone rubber pressing surfaces, and the metallic coil sheet 38 and the polyimide films 56 are heated at a temperature between about 150° C. and about 180° C. for a time period of from three (3) hours to five (5) hours, to thereby cure the epoxy resin 58 . After that, unnecessary peripheral and center portions of the polyimide films 56 and epoixy resin layers 58 are punched and removed, which results in the metallic coil sheet 38 with the polyimide films 56 , shown in FIG. 4 a . The holes 52 and 54 in the terminals 38 c and 38 d are used in positioning the metallic coil sheet 38 for this punching step. The other metallic coil sheets are also provided with an insulating coating in the same manner as described above. It should be noted that the thickness of the polyimide films 56 and epoxy resin layers 58 is exaggerated in FIGS. 3 a - 3 d and 4 a - 4 c.
The metallic coil sheets 34 , 36 and 38 with the respective insulating coatings formed in the manner described above are stacked in such a manner that the terminal 36 c is placed on the terminal 34 d and the terminal 38 c is placed on the terminal 36 d , whereby the winding 30 is formed. Similarly, the metallic coil sheets 40 , 42 and 44 with the respective insulating coatings formed in the manner described above are stacked such that the terminal 42 c is placed on the terminal 40 d and the terminal 44 c is placed on the terminal 42 d , whereby the winding 32 is formed. The terminals 34 d and 36 c of the winding 30 are electrically connected together, and also, the terminals 36 d and 38 c are electrically connected. Similarly, the terminals 40 d and 42 c of the winding 32 are electrically connected together, and the terminals 42 d and 44 c are electrically connected together.
The two windings 30 and 32 are stacked in such a manner that the windows 34 a , 36 a , 38 a , 40 a , 42 a and 44 a are vertically aligned, and cores 60 and 62 of, for example, ferrite, are placed to sandwich the vertically stacked windings 30 and 32 . More specifically, the upper core 60 has a center leg 60 a , two outer legs 60 d and 60 e , and grooves 60 b and 60 c between the center leg 60 a and the outer leg 60 d and between the center leg 60 a and the outer leg 60 e , respectively. Similarly, the lower core 62 has a center leg 62 a , two outer legs 62 d and 62 e , and grooves 62 b and 62 c between the center leg 62 a and the outer leg 62 d and between the center leg 62 a and the outer leg 62 e , respectively. The center legs 60 a and 62 a are adapted to be placed into the windows 34 a , 36 a , 38 a , 40 a , 42 a and 44 a , and two opposing sides of each metallic coil sheet 34 , 36 , 38 , 40 , 42 and 44 are placed in the respective spaces defined by the grooves 60 b , 60 c , 62 b and 62 c , when the cores 60 and 62 are placed over the stacked windings 30 and 32 from above and below the stack.
FIG. 5 a is a cross-sectional view of the metallic coil sheet 38 provided with the insulating coating 46 . FIG. 5 b is a cross-sectional view of the prior art metallic coil sheet 2 (FIG. 1) which does not have an insulating coating like the coating 46 , but is insulated by means of the insulating sheets 10 and 11 , for example. The metallic coil sheets 38 and 2 have the same size. As is understood from FIG. 5 b , the prior art metallic coil sheet 2 requires larger insulating sheets so as to provide a larger creepage distance “a” in order to secure its necessary creepage distance when the position of the coil sheet 2 relative to the insulating sheets 10 and 11 is deviates from the nominal position. In contrast, according to the present invention, as shown in FIG. 5 a , since the metallic coil sheet 38 is joined with the insulating coating 46 , the creepage distance “b” can be only what is required and need not be longer than required. Shorter creepage distance can make it possible to downsize the transformer. Furthermore, since the metallic coil sheets are individually covered with the insulating coatings 56 , working to place an insulating sheet between adjacent metallic coil sheets can be eliminated, which reduces the manufacturing cost. In addition, the insulating coatings 56 entirely covering the individual metallic coil sheets 38 can prevent the sheets 38 from rusting.
FIG. 6 shows a coil according to the present invention as used for forming a high-frequency choke. The structure of the high-frequency choke show is same as that of the transformer shown in FIG. 2 from which the coil 30 is removed. Therefore, the same reference numerals as used in FIG. 2 are used for equivalent portions, and detailed description of the choke is not given.
In place of the two windings 30 and 32 used for the transformer shown in FIG. 2, more windings may be used so that a transformer with one primary winding and a plurality of secondary windings may be formed. In place of polyimide and epoxy, other materials may be used for the insulating films and insulating adhesive. | Metallic coils sheets ( 34, 36, 38 ) are planar and include center windows ( 34 a, 36 a, 38 a ). Slits ( 34 b, 36 b, 38 b ) extend outward through the respective sheets from the windows. Connection terminals ( 34 c, 34 d; 36 c, 36 d; 38 c, 38 d ) are provided on the sheets at locations facing across the respective slits. The metallic coil sheets are stacked, and adjacent ones of the stacked metallic coil sheets are electrically connected by means of the connection terminals. A core ( 60, 62 ) is disposed in the windows of the stacked metallic coil sheets. The metallic coil sheets are individually covered with an insulating coating. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to International Application No. PCT/EP2012/005244 filed on Dec. 19, 2012 and German Application No. 10 2012 005 236.7 filed on Mar. 13, 2012, the contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to an automatic transmission having an operator control which has at least one manually actuable switching rocker which is arranged on a steering wheel and which comprises a sensor for sensing the actuation and is connected via a signal path to a transmission control device of the automatic transmission.
[0003] Nowadays, in vehicles with an automatic transmission the drive position (P, R, N, D, M, S) which is selected by a driver is sensed electronically by a switching signal and is transmitted to the transmission control device via a data bus. This technology is referred to as shift-by-wire. In this context, vehicles with an automatic transmission generally have a steering wheel with at least one switching rocker in order to be able to switch gear stages manually. The switching rockers usually have a microswitch and the transmission of the signal to the transmission control device is not secured.
[0004] EP 2 101 086 A1 describes an operator control for an automatic transmission in which the selection of drive positions and gearspeeds is carried out by switching rockers on the steering wheel.
[0005] DE 102 41 014 A1 discloses an automatic transmission having an operator control, in which in the case of manual actuation of an operator control, information is transmitted to an electronic transmission controller via a bus system.
[0006] DE 100 18 661 A1 proposes an operator control for changing a drive position or gear stage of an automatic transmission, switching information being transmitted via a vehicle-specific bus system here.
[0007] Conventional automatic transmissions have the disadvantage that for safety reasons actuation of the switching rockers does not permit drive positions to be selected. For example, it would be desirable to change from the drive position or gear stage P, R, N directly to M by actuating a switching rocker, in order to switch on a manual forward movement program. Since such switching processes are categorized as safety-relevant functions, the selection of the drive position cannot be carried out by simple actuation of a switching rocker which is characterized by“+” or “−”.
SUMMARY
[0008] One possible object therefore relates to specifying an automatic transmission having an operator control in which safety-relevant switching processes can be carried out by switching rockers.
[0009] The inventors propose an automatic transmission having an operator control which has at least one manually actuable switching rocker which is arranged on a steering wheel and which comprises a sensor for sensing the actuation, the sensor being connected via a signal path to a transmission control device of the automatic transmission. The inventors propose that the switching rocker and the transmission control device are additionally connected to one another via a second signal path which is independent of the signal path.
[0010] The proposal is based on the idea that conventional sensing and transmission of switching rocker signals can be extended with a second detection and transmission process which is independent thereof, with the result that safety-relevant functions can be carried out with the switching rockers. With the proposed automatic transmission it is possible to use the operator control to implement new functions which are prohibited with conventional automatic transmissions for reasons of safety. This includes the selection of drive positions or gear stages by actuating switching rockers on the steering wheel. For example, the gear stage N could be switched on by actuating both switching rockers on the steering wheel.
[0011] One variant proposes that the switching rocker has two sensors and each sensor is assigned a signal path. In this context, the second signal path can be a discrete signal path and the first, conventional signal path can be a component of a bus system.
[0012] With the automatic transmission it is preferred that the sensor, or a sensor, is embodied as a microswitch, a digital or analogue Hall sensor, a capacitive sensor, an inductive sensor or as a photoelectric barrier. Insofar as the switching rocker has two sensors, these may also be different sensors, for example a switching rocker can have a microswitch and additionally a capacitive sensor.
[0013] However, with the automatic transmission a variant is alternatively also possible, in which the switching rocker has a single sensor whose sensor signal is evaluated by two separate evaluation units.
[0014] The scope also includes the sensor being connected to an input of an evaluation unit via a resistance network.
[0015] In addition, the inventors propose a motor vehicle. The motor vehicle is defined by the fact that it has an automatic transmission having an operator control of the type described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawing of which:
[0017] The drawing shows schematically one embodiment of a proposed automatic transmission having an operator control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawing, wherein like reference numerals refer to like elements throughout.
[0019] An automatic transmission 1 is assigned a transmission control device 2 . A multifunction steering wheel 3 comprises a control device 4 which is connected to two switching rockers 5 , 6 . Each switching rocker 5 , 6 has two microswitches 7 , 8 or 12 , 13 . Switching rockers 5 , 6 are printed with the symbols “+” and “−”, respectively, and accordingly when the section of the switching rocker 6 which is labeled with “+” is actuated, the switching contact of the microswitches 7 and 8 is closed, and when the section which is printed with “−” is actuated, the switching contact of the microswitches 12 and 13 is closed. The microswitches 7 , 12 are connected via a resistance network to an analogue input of the control device 4 (evaluation unit) of the multifunction steering wheel 3 , with the result that short circuits to positive or negative, disconnections or shunts can be detected. The control device 4 of the multifunction steering wheel 3 evaluates a switching signal and outputs via a data bus 9 a signal who plausibility is checked. The data bus 9 can have a gateway 10 and is connected to the transmission control device 2 .
[0020] The pushbutton-key signal of the switching rockers 5 , 6 is additionally detected by second microswitches 8 , 13 whose switching point corresponds to that of the microswitches 7 , 12 . The second microswitches 8 , 13 are directly and discretely connected via a resistance network and the cable harness 11 of the motor vehicle to the transmission control device 2 . Short circuits to positive and negative, disconnections and shunts from the transmission control device 2 are detected by the resistance network, with the result that the plausibility of the raw signal transmitted via the cable harness 11 can be checked. The cable harness 11 of the motor vehicle therefore corresponds to a second signal path, with the result that switching signals are transmitted both via the data bus 9 and via the cable harness 11 . Accordingly, switching signals of the microswitches 7 , 12 are transmitted via the first signal path (data bus 9 ), and switching signals of the microswitches 8 , 13 are transmitted via the second signal path (cable harness 11 ). Making two separate and independent signal paths available provides a redundancy. If the first signal path, i.e. the data bus 9 , is used, the data transmission occurs via the multifunction steering wheel 3 , and if the second signal path is used, the data transmission occurs via discrete lines, specifically the cable harness 11 .
[0021] As a result of the two evaluation paths data bus 9 and cable harness 11 , two completely independent signals are made available to the transmission control device 2 , the plausibility of which signals can be in turn checked against one another. With this redundancy which is ensured over the entire signal chain it is possible to carry out safety-relevant functions: If detection occurs via both signal paths “+” at the switching rocker 6 , the drive position M is engaged, and this is also possible from the drive positions or gear stages P, R and N. On the other hand, if simultaneous actuation of both switching rockers 5 and 6 is detected via both signal paths, the gear stage N is engaged, provided that one of the drive positions or gear stages P, R, D, S or M was previously engaged.
[0022] The signal evaluation for the change of a gear can be restricted to the second signal path (cable harness 11 ) since the signals are present significantly more quickly by virtue of the discrete connection to the transmission control device 2 , which connection has low transmission latency.
[0023] In other embodiments, instead of microswitches for sensing, it is also possible to use other sensors, for example digital or analogue Hall sensors, capacitive sensors, inductive sensors, photoelectric barriers or the like. Instead of two sensors per switching rocker it is possible to use a single sensor whose sensor signal is evaluated on two different paths of two different evaluation units. Instead of a resistance network it is also possible to use respectively a digital input provided in the multifunction steering wheel and/or transmission control device or an analogue input without resistance coding.
[0024] The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004). | An automatic transmission having an operator control which has at least one manually actuable switching rocker which is arranged on a steering wheel. A sensor senses the actuation of the switching rocker and is connected via a signal path to a transmission control device of the automatic transmission. The switching rocker and the transmission control device are additionally connected to one another via a second signal path which is independent of the signal path. | 8 |
[0001] The present invention relates to industrial fabrics, more particularly to fabrics for use as through-air dryer fabrics to mold a web of cellulosic fibers into a three dimensional paper structure in a papermaking machine.
BACKGROUND OF THE INVENTION
[0002] In the manufacture of paper, an aqueous slurry of about 99% by weight of water and 1% by weight of cellulosic fibers and other papermaking constituents is deposited from a headbox onto a moving forming fabric, or in between two moving forming fabrics on a two-fabric papermaking machine. The web is initially formed and partially drained in the forming section, and is transported downstream where it is consolidated and dried by known means, such as conventional press dewatering in the press section, and evaporative drying in the dryer section. However, if the finished sheet is intended to have liquid absorbency properties, for end uses such as for tissue or towel, improved results can be obtained through the use of a through-air drying (TAD) instead of the conventional press and drying methods.
[0003] Water removal in a TAD process occurs as air is passed through the web and through the TAD fabric being used to support and convey the web through the TAD dryer section. This air movement molds the web to the surface topography of the TAD fabric, while removing most of the remaining moisture. The molding creates a more three dimensional web, thus increasing the thickness (known as bulk) of the finished web, which improves the efficacy of the finished product for applications such as tissue or towel. One means of imparting a desired topography to a TAD fabric is to apply a polymeric resin with precision in a desired pattern to the paper contacting, or paper side (PS), surface of the fabric.
[0004] Polymeric resin coated fabrics are well known, and have been described for example in U.S. Pat. No. 4,514,345 to Johnson et al., and U.S. Pat. Nos. 4,528,239, and 4,529,480 to Trokhan. Such resin coated structures generally comprise a reinforcing structure, referred to herein as a Acarrier fabric@, onto which a functional polymeric resin is deposited and subsequently pattern cured, for example by using a light source of activating wavelength through a mask. The resulting TAD fabric will generally have a macroscopically monoplanar patterned resinous network, either semicontinuous or discontinuous, on one surface.
[0005] The physical properties of the carrier fabric onto which the polymeric resin is to be deposited, and the balancing interaction between these properties, are critical to the effectiveness of the resultant TAD fabric. Some of the factors which affect the selection of these physical properties include the following:
[0006] Firstly, a high amount of projected open area, being the amount of open space per unit area projected through a fabric when viewed perpendicularly to the plane of the fabric, is required. Thus a woven carrier fabric must have a relatively open structure, in order to provide sufficient void volume for the polymeric resin in the finished TAD fabric, and to allow for the passage of sufficient air from the TAD dryer drum through the fabric and the web. If the carrier fabric is a closely woven structure, it will tend to become filled when the polymeric resin is applied, thus closing or unduly restricting the air passages.
[0007] Secondly, the carrier fabric must be dimensionally stable, and capable of resisting in-plane distortion such as is encountered when the fabric passes over bowed or spreader rolls in the papermaking machine. If the fabric does not have this stability, it may become narrowed or lengthened along its centre line, or suffer from creasing, or undulations across its width, any of which may impair its runnability and effectiveness. Such variations in the otherwise smooth planar nature of the fabric may cause localized variations in the paper product being conveyed by the fabric, which can lead to sheet breaks and a disruption in the operation of the papermaking machine.
[0008] Thirdly, the carrier fabric must be capable of being seamed effectively, preferably by a relatively narrow woven seam, which must be of sufficient strength to resist the longitudinal i.e. machine direction (MD) tensile forces to which the fabric is exposed. Typically, when a fabric such as this is prepared for a woven seam, the warp and weft yarns at the opposing fabric ends are unravelled and then rewoven into each other to form a seam region, usually having a width of between 5 and 12 inches. This woven seam must possess sufficient tensile strength so that the warp yarns resist sliding apart when the fabric and the seam are exposed to the expected MD tensile forces during use, which are typically up to 50 or 60 pounds per linear inch. One means of ensuring sufficient tensile strength at the woven seam is to impart sufficient crimp to the warp yarns during the fabric weaving, so that the yarns will have a greater resistance to sliding apart when the fabric is in use, and the seam will tend to have greater resistance to opening under longitudinal stress. If the crimp is insufficient for a given seam width, the warp yarns will tend to slide apart from the weft yarns, and the seam is more likely to fail. One means of ensuring that the warp yarns are crimped sufficiently to resist seam failure is to weave the fabric according to a plain weave pattern, which maximizes the number of crimps per unit length of the warp yarn.
[0009] Designers of carrier fabrics such as those of the prior art have been faced with the difficulty of meeting and reconciling these and other criteria. In particular, for an effective TAD fabric, it is necessary to provide a weave structure which has a high open area, while at the same time is woven to a pattern which provides sufficient yarn crimp to provide stability in each dimension, and to provide a durable seam.
[0010] Single layer TAD fabrics are well known and have been described in U.S. Pat. Nos. 5,839,479 and 5,853,547 to Wright et al. These patents teach that sheet bulk is enhanced by the use of cross direction (CD) yarns of alternating large and small diameters, the weave pattern in each case resulting in paper bulking depressions on the PS surface.
[0011] Double or multilayer fabrics have also been developed for use as TAD fabrics. For example, U.S. Pat. Nos. 5,496,624 and 5,840,411 to Stelljes each describe a double layer fabric which can be subjected to resin coating by means of a resinous pattern layer cast over the PS surface.
[0012] It has further been found that sheet bulk can be enhanced by the use of multilayer fabrics including vertically stacked yarns. For example in PCT Publication No. WO 03/006732 to Johnson et al., two sets of weft yarns are substantially vertically aligned, to urge the warp yarns into greater prominence on the PS surface; and alternatively, two sets of warp yarns can also be vertically stacked.
[0013] It is known to use pairs of either or both warp and weft yarns to bind together the layers of double or multilayer forming fabrics. For example, U.S. Pat. No. 5,826,627 to Seabrook et al. discloses a forming fabric including pairs of intrinsic weft binder yarns, which are weft yarns that contribute to the structure of both the PS and MS fabric surfaces, and also serve to bind these fabric layers together. However, other “regular” weft yarns are interspaced with the intrinsic weft binder yarns of this fabric.
[0014] Further, Application No. PCT/EP01/09398 to Odenthal shows a composite forming fabric comprising a PS layer having a plain weave pattern, formed of intrinsic weft pairs, one member of each pair also serving to bind together the PS and MS layers. However, in each pair the other member does not serve to bind the two layers together, and the long MS warp floats would contra-indicate use of this fabric as a TAD carrier fabric.
[0015] It has been found that an effective TAD carrier fabric can be successfully manufactured using a weave pattern in which all the weft yarns are arranged as pairs of intrinsic binder yarns, and are woven so as to bind together the warp yarns of each of the PS and MS layer, which are arranged in vertically stacked pairs. By the selection of an appropriate weave pattern, a high open area can be provided, enabling effective resin coating, and at the same time providing a dimensionally stable fabric having sufficient crimp in the warp yarns to allow for durable seaming.
SUMMARY OF THE INVENTION
[0016] The present invention therefore seeks to provide a triple layer woven industrial fabric having a paper side (PS) layer and a machine side (MS) layer comprising polymeric warp and weft yarns woven to a repeat pattern wherein:
[0017] (i) all of the warp yarns are arranged as vertically stacked pairs;
[0018] (ii) all of the weft yarns comprise pairs of intrinsic weft binder yarns each having a first and second member each of which contributes to the structure of both the PS and the MS layers of the fabric and binds together the PS and MS layers; and
[0019] (iii) each pair of intrinsic weft binder yarns forms an unbroken weft path in both the PS layer and the MS layer, whereby when either the first or second member passes from the PS layer to the MS layer, the other member of the pair passes from the MS layer to the PS layer at an exchange point located between at least one common pair of warp yarns.
[0020] The present invention further seeks to provide a woven triple layer industrial fabric which is suitable for resin coating for use as a through-air dryer fabric for a papermaking machine.
[0021] The fabrics of the present invention are unique in that the warp yarns are vertically stacked and paired, and are interwoven with pairs of intrinsic weft binder yarns so as to provide a triple layer fabric structure. The combination of stacked warp yarns and pairs of intrinsic weft binder yarns allows the fabrics of this invention to be woven so as to provide a high projected open area while, at the same time, providing adequate dimensional stability, stretch resistance and seam strength.
[0022] In particular, in a preferred embodiment, each of the MS and PS layers are woven according to the same weave pattern, which is preferably a plain weave. The fabric is woven so as to have a projected open area of at least 35%, and an air permeability of at least 850 cubic feet per minute (cfm). The high open area facilitates the retention and adhesion of a polymeric coating of the fabric which may be arranged according to a desired pattern, while ensuring that, after coating, sufficient air movement is allowed through the fabric. The use of intrinsic weft binder yarn pairs in combination with the stacked warp yarn arrangement provides the fabric with enhanced dimensional stability, to resist distortion. The use of a plain weave pattern for both the MS and the PS layers imparts sufficient crimp to the warp yarns such that the seams are able to withstand greater amounts of longitudinal tension than comparable seams formed in fabrics using other weave patterns.
[0023] Further, the weave pattern is selected to maximize the number of yarn knuckles on the PS surface of the PS layer, which is the surface to receive the resin coating. This serves to improve the attachment of resin coating to the fabric by providing a large number of surface features which can be encapsulated by the resin.
DETAILED DESCRIPTION
[0024] In the context of this invention, the following terms have the following meanings:
[0025] “Intrinsic weft binder yarns” are weft yarns which are interwoven with the other fabric yarns so as to contribute to the structure of the PS surface of the PS layer, and to the structure of the MS surface of the MS layer, and also serve to bind the PS and the MS layers together; and
[0026] “Projected open area” is the amount of open space per unit area projected through a fabric when viewed perpendicularly to the plane of the fabric.
[0027] In the fabrics of this invention, all the weft yarns are woven as intrinsic weft binder yarns.
[0028] The invention will now be described by way of reference to the Figures, in which
[0029] FIG. 1 is a photographic isometric view of a first embodiment of the invention;
[0030] FIGS. 2A to 2 D show the paths in the CD of four successive weft yarn pairs of the embodiment of FIG. 1 ;
[0031] FIG. 3 shows the path in the MD of one stacked pair of warp yarns of the embodiment of FIG. 1 ;
[0032] FIG. 4 is a weave diagram showing one repeat of the weave pattern of the embodiment of FIG. 1 ; and
[0033] FIGS. 5A to 5 C show respectively the paths of one weft yarn pair of a second, third and fourth embodiment of the invention.
[0034] Referring to FIG. 1 , it can be seen that the fabric of this embodiment is woven to a plain weave design in each of the PS layer 70 and the MS layer 80 , to which each member of each pair of weft yarns, identified by the generic reference numeral 100 , contributes. In each embodiment, the paths of each member of each pair of weft yarns 100 in each repeat comprise two portions, so that each member alternates between the PS layer 70 and the MS layer 80 , and so that between the first and second portions of the repeat, the first and second members of the pair of weft yarns 100 exchange positions at an exchange point 90 . In the first portion, the first member is exposed over a preselected number N 1 of PS warp yarns identified by the generic reference numeral 110 , while the second member is exposed over a preselected number N 2 of MS warp yarns identified by the generic reference numeral 120 . In the second portion, after the exchange of the two members of the pair of weft yarns 100 , the first member is exposed over a preselected number M 1 of MS warp yarns 120 while the second member is exposed over a preselected number M 2 of PS warp yarns 110 .
[0035] Referring to FIGS. 2A to 2 D, the paths in the CD of four successive pairs of weft yarns 100 are shown. For each pair, a first member is shown by a solid line and ascribed an even number 30 , 32 , 34 , and 36 , and the second member is shown by a broken line and ascribed an odd number 31 , 33 , 35 and 37 . These numbers correspond with the weft yarn numbering indicated at the left side of the weave diagram of FIG. 4 .
[0036] In the PS layer, a first set of warp yarns 110 , shown as the odd numbered yarns forming the upper layer in FIGS. 1A to 1 D, is vertically aligned with a second set of warp yarns 120 , shown as the even numbered yarns forming the lower layer in FIGS. 1A to 1 D, to form vertically stacked pairs. These numbers correspond with the warp yarn numbering indicated across the top of the weave diagram of FIG. 4 .
[0037] In the first embodiment, as can be seen for example in relation to first and second members 30 and 31 in FIG. 2A , the two members of each pair of weft yarns 100 follow an identical path, the path of the second member 31 being displaced by one-half of a pattern repeat from the first member 30 . In this embodiment, the first member 30 in a first portion of the repeat pattern is exposed over two PS warp yarns 1 and 5 , and then switches to the MS layer, passing under PS warp yarn 7 and over MS warp yarn 8 , whence it follows a second portion of the repeat pattern, being exposed over two MS warp yarns 10 and 14 . At the same time, the second member 31 in a first portion of the repeat pattern is exposed over two MS warp yarns 2 and 6 , and then switches to the PS layer, also passing under PS warp yarn 7 and over MS warp yarn 8 , whence it follows a second portion of the repeat pattern, being exposed over two PS warp yarns 9 and 13 . A second exchange point 90 occurs between PS warp yarn 15 and MS warp yarn 16 . Thus it can be seen that the two members 30 and 31 exchange positions at an exchange point 90 between the vertically stacked pair of warp yarns 7 and 8 . Similarly, with reference to FIGS. 1B, 1C and 1 D, each pair of weft yarns follows the same path, displaced by an appropriate number of PS and MS warp yarns, 110 and 120 . It can be seen that for this embodiment, N1=N2=M1=M2=2.
[0038] Referring to FIG. 3 , the warp path in the MD of the first stacked pair of warp yarns 110 and 120 is shown, the PS warp yarn being shown as yarn 1 and the MS yarn being shown as yarn 2 . These yarns, and the weft yarns 100 , are identified to correspond with the numbering in the weave diagram of FIG. 4 .
[0039] Referring to FIG. 4 , some examples of the exchange points 90 are indicated. These occur, for example, for weft yarns 30 and 31 , between warp yarns 7 and 8 , and 15 and 16 . Similarly, exchange points for weft yarns 32 and 33 occur between warp yarns 5 and 6 , and 13 and 14 ; and for weft yarns 34 and 35 between warp yarns 3 and 4 , and 11 and 12 .
[0040] Referring to FIGS. 5A, 5B and 5 C, three further embodiments of a fabric according to the invention are shown. In FIG. 5A , each member of the weft pair, identified as 50 A and 51 A, follows an identical path, displaced by one-half of the repeat, and the two members exchange positions in the PS layer 70 and the MS layer 80 at exchange points 90 . However, in the PS surface of the PS layer 70 , the weave pattern is a 3/1 broken twill, whereas the weave pattern for the MS surface of the MS layer 80 remains a plain weave. In this embodiment, N1=M2=3, and N2=M1=2.
[0041] Similarly, in FIG. 5B , each member of the weft pair, identified as 50 B and 51 B, follows an identical path, displaced by one-half of the repeat, and the two members exchange positions in the PS layer 70 and the MS layer 80 at exchange points 90 . However, in both the PS surface of the PS layer 70 and the MS surface of the MS layer 80 , the weave pattern is a 2/1 twill. In this embodiment, N1=N2M1=M2=2.
[0042] FIG. 5C shows an embodiment similar to that shown in FIG. 5B . However, the weave pattern in both the PS surface of the PS layer 70 and the MS surface of the MS layer 80 is a 2/2 basket weave, and the exchange points occur between two adjacent pairs of stacked warp PS yarns 110 and MS yarns 120 . Thus, the first exchange point 90 for weft yarns 50 C and 51 C in FIG. 5C occurs below both PS warp yarns 5 and 7 and above both MS warp yarns 6 and 8 .
[0043] As noted above, the fabrics of this invention have a high projected open area, which after heatsetting is at least 35%, and is preferably between 35% and 50%. These values are necessary to allow sufficient passage of air from the TAD drum through the sheet, particularly where a patterned resin coating is applied to the fabrics. Further, the fabrics of this invention have an air permeability, after heatsetting, within the range of 800 to 1200 cubic feet per minute per square foot. More preferably, the fabrics of the invention have an air permeability in the range of 900 to 110 cubic feet per minute per square foot.
[0044] It has been found that the preferable mesh ranges for the fabrics of this invention are between 35×2 (warp) by 25×2 (weft) and 50×2 (warp) by 40×2 (weft) per inch, so that the mesh ranges, without regard to the stacking of the warp yarns 110 and 120 and the paired weft yarns 100 , are between 70 to 100 for the warp and 50 to 80 for the weft. Taking into account the stacking of the warp yarns and the pairing of the weft yarns as intrinsic weft binder yarns, the effective mesh ranges of the fabric are from 35-50 warp/in. and 25-40 weft/in. The effective mesh is that which is seen when determining projected open area.
[0045] When used as carrier fabrics for a TAD process, the yarns used for both the warps and the wefts in the fabrics of the invention must be resistant to both heat and hydrolytic degradation. Suitable materials both for the warp yarns 110 and 120 and for the weft yarns 100 include polyetheretherketone, polyphenylene sulphide, polyethylene terephthalate, and polycyclohexamethalyne terephthalate, acid modified. The materials used for the MS warps can be different from the materials used for the PS warps or for the wefts. Other polymeric materials such as are commonly used for industrial fabrics, may be appropriate in applications other than for a TAD process.
[0046] It has been found that suitable yarn sizes for the fabrics of the invention are a minimum of 0.18 mm for the weft yarns 100 , and a minimum of 0.20 mm for the warp yarns 110 and 120 . However, other yarn sizes may be selected depending on the intended use for the fabric. | A triple layer woven industrial fabric, particularly suitable for through-air drying applications, has a paper side (PS) layer and a machine side (MS) layer of polymeric warp and weft yarns woven to a repeat pattern wherein all the warp yarns are arranged as vertically stacked pairs, all the weft yarns comprise pairs of intrinsic weft binder yarns, and each pair of weft yarns forms an unbroken weft path in both the PS layer and the MS layer whereby when either the first or second member of the pair passes from the PS layer to the MS layer, the other member of the pair passes from the MS layer to the PS layer at an exchange point located between at least one common pair of warp yarns. | 8 |
BACKGROUND OF THE INVENTION
This application is a continuation-in-part of U.S. application Ser. No. 07/818,262 filed Jan. 8, 1992, U.S. Pat. No. 5,249,644, issued Oct. 5, 1993, and is also a continuation-in-part of U.S. application Ser. No. 07/818,120 filed Jan. 8, 1992.
FIELD OF THE INVENTION
The present invention relates to pole grasping-type climbers utilizing paired grasping structures, and more particularly, to paired tree climbing members which are worn on the feet to be alternately raised by the user to attain a desired elevation on a vertical member such as a pole, a tree trunk or the like.
DESCRIPTION OF THE PRIOR ART
According to the prior art, a variety of tree stands or climbers have become available commercially to serve as, for instance, elevated hunting platforms or work platforms for gaining access to elevated structures. One variety of tree climber comprises upper and lower climbing frames. Tree climbers of this variety described in U.S. Pat. No. 4,331,216 to the present inventor typically are comprised of paired grasping structures, each structure being moved independently of the other in a step-wise fashion to attain the desired elevation on the vertical member.
Typical of such conventional tree stands is the widespread use of bolted connections which must be properly completed and/or adjusted prior to use. Such connections and adjustments often prove time consuming and cumbersome, especially in the dark, and require the user to carry wrenches or similar tools into the field. According to some designs, a two-person assembly team is virtually a necessity in completing such installation.
Another problem with tree climbers of the prior art is the restrictive closed frame structure which encircles the tree or pole. Unless the tree is of a relatively uniform cross-section (not likely), protruding limbs of excessive length or other oversized outcroppings will prevent further vertical progress, or at least make it difficult to navigate around the obstruction. One solution to this problem is addressed in U.S. Pat. No. 4,225,013, the apparatus of which includes a pair of C-shaped arcuate clamping members which partially encircle the tree. In use, branches and other protrusions are passed through the open portion of the arcuate clamping members as the climber ascends and descends the tree. These C-shaped openings, however, will accommodate only those trees sized within a limited range of diameters. Another problem with this apparatus is the absence of the rigidity offered by various closed-frame designs.
Yet another problem with prior art devices is their relatively cumbersome bulk and weight, even in their collapsed condition, which hinders transportability especially over heavily wooded terrain.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a tree or pole climbing device which is readily assembled, even in darkness, and which is easily adjusted, both during and after installation about the pole, tree trunk, or other similar vertical member, and during removal therefrom, such assembly, adjustment, and removal is readily accomplished by a single person.
It is another object of the present invention to provide a tree or pole climbing device which can readily accommodate and operate on vertical members having a relatively wide range of diameters.
It is a further object of the present invention to provide a tree or pole climbing device which can easily traverse those protruding limbs of excessive length and other oversized outcroppings extending from the vertical member which otherwise hinder vertical access by the user.
It is yet another object of the present invention to provide a tree or pole climbing device which offers a relatively rigid structure while affixed to the vertical member and which safely secures the climber to the vertical member.
It is yet a further object of the present invention to provide a tree or pole climbing device which offers improved platform stability in the installed, load-bearing condition when installed on a tree or pole, and when ascending and descending the tree or pole.
Another object of the present invention is to provide a climbing device having relatively compact dimensions when in the collapsed condition, and which is easily transportable by a single person.
An additional object of the present invention is to provide a safety strap which is engaged with the climbing device and with the tree or pole to add further security to the user.
These and other objects are achieved in the present invention which includes two climbing members which are attached to the climber's feet and alternately raised in a stepwise fashion while ascending or descending the tree to attain the desired elevation. Each foot climbing member includes a platform portion and a clamping portion. The platform portion is affixed to the climber's feet by a set of quick release straps. A support arm extends forward from each platform portion and terminates at a clamping portion rigidly attached thereto. The clamping portion has a hook or bow-like shape with its concave side directed back toward the platform portion. Teeth-like protrusions are integrally formed within the concave side and engage with the back side of the tree pole. The forwardmost edge of the platform may also include said teeth-like protrusions for engaging with the front side of the tree pole. The teeth-like protrusions are symmetrically arranged about a line extending thru the longitudinal extent of the climbing member, the line being offset from but parallel to the longitudinal centerline of the climbing member. This offset line is coincidental with the apex of the concave side of the clamping portion. This off set geometry promotes enhanced stability of the climbing members. The climbing members are constructed to be mirror images of each other to be respectively worn on the right and left feet of the climber.
One end of the clamping portion is releasably affixed to the support arm. In a like manner, the support arm is releasably affixed to the platform portion. According to the invention and its various embodiments, the clamping portion is adjustable relative to the platform portion so as to accommodate vertical members having a wide range of diameters. According to one embodiment of the invention, a flanged end of the clamping portion is releasably engaged with the channel of the support arm and secured thereto at any of a selection of engagement points arrayed along the support arm by a spring-tensioned locking pin projecting through and securing together both elements. According to a second embodiment, the end of the clamping portion is affixed to a collar through which a tubular support arm slidably extends. A spring-tensioned or other quick-release locking pin is projected through overlapping engagement holes in both members to secure them together.
A third embodiment of the present invention replaces the spring-tensioned locking pin of the first embodiment with a knurl-ended bolt which secures the flange of the clamping portion to the support arm. According to any one of the first three embodiments, the support arm extends out of the plane of the platform portion at a predetermined angle, the support arm selectively collapsing against the platform portion into a compact configuration for enhanced ease of transport. According to a fourth embodiment, the platform end of the support arm telescopes through a collar which is rigidly affixed to an upturned edge of the platform portion. The support arm of this fourth embodiment is longitudinally fixed within the collar at any one of an array of spaced-apart engagement holes disposed in the support arm through which a spring-tensioned locking pin, knurl-ended bolt or the like is projected to secure together the two elements. During longitudinal adjustment of the clamping portion relative to the support arm of any of the embodiments, a resilient biasing member, such as an elastic cord or spring maintains the clamping portion in tension with the platform portion. Thus, when each climbing member is raised in alternating fashion, slack spacing between pin engagement points is taken up by the biasing member.
After the climbing members have been moved by the climber in stepwise fashion to the desired elevation, one or both of the climbing members is then secured to the tree by a strap lock referred to as an "Am-Lock" * strap. Each Am-Lock strap includes two hooks securely fixed to the opposite ends of a sturdy strap and a tensioning device affixed at an intermediate position between the hooks. The tensioning device may have a cinch-type over-center buckle or a ratchet-type take-up reel which is easier for children and women to use. The strap is wrapped about the diameter of the vertical member and the hooks are affixed to opposite ends of the climbing member. Optionally, notches may be formed into the hook portion or the climbing member to accommodate the hooks. The tensioning device is then operated to bring the strap into a tightened embracing relationship with the vertical member and the clamping portion.
Adjustable backpack-style carrying straps are attached to the platform portion to enable transportability. When not in use, the straps are folded and stored within recesses formed in insulative seat cushion material layered on the platform portion.
With the foregoing and other objects, advantages and features of the invention that will become hereinafter apparent, the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several views illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a pictorial view of the tree climbing members of the present invention shown mounted in a tree and supporting a hunter;
FIG. 2 is a top plan view of one of the paired climbing members of the first embodiment of the invention, said climbing member intended to be worn on the right foot of the user;
FIG. 3 is a bottom plan view of the climbing member of the first embodiment shown in FIG. 2;
FIG. 4 is a perspective view of one of the paired climbing members of the first embodiment of the invention, showing the longitudinal centerline of the climbing member, and a parallel line offset thereto about which the teeth-like protrusions of the platform member are symmetrically arranged;
FIG. 5 is a top plan view of the climbing member of FIG. 4, showing the climbing member mounted about a vertical member such as a tree trunk;
FIG. 6 is a perspective view of the Am-Lock strap shown in FIG. 2 in a detached condition from the clamping portion of the climbing member, illustrating additional details of the strap and a cinch-type over-center tensioning device installed thereon;
FIG. 7 is a perspective view of an alternative embodiment of Am-Lock strap shown in FIG. 2, showing a ratchet-type tensioning device for use with the strap;
FIG. 8 an enlarged side view of FIG. 3, partially in cross-section, showing the spring-tensioned locking member in an engaged position and securing together the clamping member and support arm of one embodiment of the invention;
FIG. 9 is a fragmentary view of FIG. 8, showing the spring-tensioned locking pin in a withdrawn, disengaged position;
FIG. 10 is an enlarged, fragmentary, cross-sectional view of the platform portion of the climbing member shown in FIG. 2, showing the, platform and seat cushion material;
FIG. 11 is a perspective view of the engaged clamping portion and support arm of a second embodiment of the invention;
FIG. 12 is a perspective, partially exploded, view of the engaged clamping portion and support arm of a third embodiment of the invention;
FIG. 13 is a perspective, partially exploded, fragmentary view of the angularly adjustable support arm of any of the first three embodiments engaged with an upturned edge of the platform portion;
FIG. 14 is a perspective view of the paired climbing members of a fourth embodiment of the invention;
FIG. 15 is a top plan view of a right-foot climbing member of the embodiment of the invention, shown in its mounted position about a vertical member such as a tree trunk;
FIG. 16 is a side view of FIG. 15, partly in cross-section, showing the preferred mounted position;
FIG. 17 is an enlarged side view of FIG. 16, showing a resilient biasing member mounted to the climbing member;
FIG. 18 is a top plan view of a right-foot climbing member of the first embodiment of the invention, showing carrying straps affixed to the climbing member, positioned for transport; and
FIG. 19 is a side view, partly in cross-section, of the carrying straps and climbing member shown in FIG. 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to the drawings wherein like parts are designated by like reference numerals throughout, there is illustrated in FIG. 1 a pictorial view of the climbing stand of the present invention mounted in a tree 150 and supporting a hunter, the tree climbing stand designated generally by reference numeral 10. The climbing stand 10 comprises a pair of left and right members, each of which is designated generally by reference numeral 20.
Now referring to FIG. 2, each climbing member 20 made in accordance with this invention includes an elongated platform portion 22 constructed preferably of a sturdy metal such as sheet steel or aluminum. The platform portion 22 includes a forward end 24, a back end 26, and is framed along its length by a pair of substantially parallel edges 28, 30. An upturned edge 32 integrally formed with the platform portion 22 is disposed along the outer parallel edge 30 of a right climber member 20 worn on the user's right foot. In like manner, an upturned edge 32 is integrally formed with the platform portion 22 of a left climber member, said upturned edge 32 disposed along a corresponding outer parallel edge 28 of the platform portion 22. The platform portion 22 is affixed to the user's foot by two paired sets of quick release strap means 34. The strap means 34 comprise a tongue end 36 disposed on one of each pair of strap means 34, said tongue end 36 being adjustably engagable with a cinch-type fastening means or buckle 38 disposed on each of the corresponding strap means 34 of each pair.
Referring to FIG. 3, which is a bottom view of the climbing apparatus shown in FIG. 2, the strap means 34 are shown securely fastened to the platform portion 22 with a bolted connection 35 passing therethrough.
A flange 41 of a support arm 40 is disposed parallel to the upturned edge 32 of the platform portion 22. A back end 42 of the arm 40 is affixed to the upturned edge 32 by a bolted connection 44 which enables the arm 40 to swivel out of the plane of the platform portion 22 as will be further described. The forward end 46 of the support arm 40 extends beyond the forward end 24 of the platform portion 22. A plurality of spaced attachment holes 47 are disposed along the length of the support arm 40 to accommodate the varying diameter of poles encountered during use.
A clamping portion or hook 48 is adjustably affixed to the extended support arm 40. The clamping portion 48, which is constructed of a relatively stiff and strong metal such as steel, has a symmetrical bow-like shape with its concave side directed back to the platform portion 22 when one end 50 of the clamping portion 48 is affixed to the support arm 40. The apex 48a of the clamping portion 48 is coincidental with a line of symmetry A passing therethrough, shown in FIGS. 4 and 5. An array of teeth-like protrusions 51 are integrally formed along the forward edge 24 of the platform portion 22 to securely engage with the tree 150. Although four such protrusions 51 are shown, it will be apparent to the skilled artisan that variations in number, spacing, and profile thereof will provide different gripping characteristics of the climbing member 20. The protrusions 51 are symmetrically arrayed about the line of symmetry A which is projected along the longitudinal extent of the climbing member 20, the line A being offset from, but parallel to, the longitudinal centerline B of the platform portion 22. Optionally, another array of like protrusions (not shown) are integrally formed along the concave side of the clamping portion 48 in symmetrical opposition to the first array of projections 51. In those instances where it is desirable to protect the tree 150 from injury caused by the impacting protrusions 51, a conventional protective sheath (not shown) made of a non-skid material such as an elastomer formed with a U-shaped cross-section may be removably positioned over the protrusions 51.
In operation, and again with reference to FIGS. 4 and 5, the climbing member 20 is assembled about the tree member 150 in the manner shown. Application of the climber's weight to the platform portion 22 causes that weight to act through a distance C perpendicular to lines A and B. The resulting moment causes the protrusions 51 to become firmly embedded in the tree member 150, thereby enhancing the stability of climbing member 20 at the selected elevation. More particularly, it can be seen that the symmetrically arrayed protrusions 51, being in symmetrical opposition to the opposing contact surfaces of the concave side of the clamping portion 48, further secure and stabilize the climbing member 20 at that elevation as it is manipulated into a cocked position shown by the dashed and dotted lines.
A clamping portion end 50 includes a flange 52 with an L-shaped cross-section which is slidably engaged with a corresponding channel 54 formed in the support arm 40. The clamping portion end 50 is slidably adjustable along the length of the support arm 40. After the climbing member 10 has been adjusted about the tree member (not shown) such that the forward end 24 of the platform portion 22 and the clamping portion 48 are in simultaneous contact with the tree member, the clamping portion 48 is then selectively engaged with the support arm 40 at the appropriate one of the attachment holes 47 with a quick-release spring-tensioned locking device 56 shown in detail in FIGS. 8 and 9. Locking device 56, which is also described in my concurrently filed patent application entitled "Automatically Adjustable Tree Climbing Stand" and is incorporated herein by reference, includes an engagement pin 58 which is biased into engagement by a spring 60, causing projection of the pin 58 into the overlapped engagement recesses 47 of the support arm channel 54 and clamping portion flange 52. To disengage the engagement pin 56 from the openings 47 for purposes of adjustment, disassembly, or maintenance, a pull ring 62 affixed to the opposite end of the pin 56 is grasped and pulled to slidably withdraw the pin 56 from said recesses 47, as shown in FIG. 9.
Referring generally to FIGS. 1-5, after the user has reached the desired elevation, each of the climbing members 20 are secured thereto by an "Am-Lock" safety strap. As shown in greater detail in FIGS. 6 and 7 which illustrate the strap in a detached condition from the clamping portion 48 of the climbing member 20, the two embodiments of the Am-Lock strap include hooks 70 disposed at opposite ends of a bifurcated strap 72. A tensioning device 74 joins the bifurcated ends 76 of the strap 72 at an intermediate location thereof. Each hook 70 is made of a metal rod 70a which is doubled-over forming an opening 70b and terminating at C-shaped or L-shaped ends 70c. The opening 70b of each hook 70 receives and is secured within a looped strap end 72a passing therethrough.
The tensioning device 74 is comprised of a cinch-type, over-center buckle 74a having a plurality of crossbars 74b. A lever 74c is rotatably affixed to an inboard crossbar 74b. Laterally extending protrusions 74d disposed on the lever 74c engage with corresponding detents 74e disposed in the buckle 74a when the lever 74c is rotated in the direction of arrow D into a locked position. The strap 72 is threaded in a serpentine manner into one end of the unlocked buckle 74a, between the crossbars 74b, about the lever 74c, and exits at the opposite end of the buckle 74a after passing around another crossbar 74b. When the lever 74c is rotated into the locked position, the strap 72 becomes firmly cinched within the buckle 74a. Tensioning adjustment is made by altering the length of strap 72 within the buckle 74a. Alternatively, a bifurcated strap (not shown) may be used, having one bifurcated end affixed to an outboard crossbar 74b, the other bifurcated end threaded into the tensioning device in the above-described manner from the opposite end of the buckle 74a. Tensioning adjustment is accomplished by extending or withdrawing the strap through the buckle 74a prior to locking.
A second embodiment of the Am-Lock strap is shown in FIG. 7 and comprises a ratchet-type tensioning device 75. The ratchet device 75 per se is conventional and is easier to operate than the over-the-center buckle of FIG. 6. The ratchet 75 includes a plurality of aging teeth 75a having directionally-oriented surfaces for engaging with a stop 75b mounted on frame 75c. When the strap 72 is proximately engaged with the tree or pole (not shown), slack strap length is taken up by rotating a lever 75d about pinned connection 75e projecting through from 75c in the direction of arrow E. The strap 72 is restrained in that condition by the engaging teeth 75a and stop 75b. The ratchet device 75 is held in a tensioned condition by a biasing element such as a spring (not shown) disposed within the pinned connection 75e.
In operation, the Am-Lock strap is loosely wrapped about the diameter of the tree 150 and each hook means 70 is engaged with opposite ends of the clamping member 48. Preferrably, spaced openings or notches 78 are provided on the clamping member 48 to receive the hook 70. Once the hooks engage the clamping member 48, the tensioning device 74 or 75 is then operated to bring the strap 72 into a tightened embracing relationship with the tree 150 and the clamping portion 48 to further secure the clamping portion to the climbing member 20.
It should be understood that the Am-Lock safety strap of the present invention may be used in conjunction with any of the variety of commercially available tree stands or pole climbers having tree- or pole-embracing clamping members, including but not limited to those pole climbing devices having crossbar, square-shaped, or arcuate-shaped clamping members. By such use, the frequency of accidents can be significantly reduced.
Now referring to FIG. 10, an enlarged, fragmentary, cross-sectional view of the platform portion 22 of the climbing member 20 shown in FIG. 2 shows a foam cushion layer 80 placed on the platform 22. The cushion 80 is resilient, and protects the climber's feet while climbing and serves as a cushioned and insulating seating surface.
A second embodiment of the present invention is shown in FIG. 11. According to this embodiment, the flanged clamping or gripping end 50 of the first embodiment shown in FIGS. 2 and 3 is replaced with a rigid metal square collar 90 having a square shaped opening 92 through which a tubular support arm 94 having a corresponding cross-section extends. An engagement recess or hole 98 is disposed in the square collar 90. A plurality of engagement recesses or holes 100 is arrayed along the length of the support arm 94. A retention pin 96 is projected through the collar recess 98 and one of the overlapping support arm recesses 100, and secured thereto, to rigidly affix the support arm 94 at a desired extension relative to the collar 90, after adjustment of the support arm 94 along the direction of the arrow 102. An array of teeth-like protrusions 104 is arrayed along the concave side of the clamping member 48 for gripping the tree 150 at a chosen elevation.
A third embodiment of the present invention is shown in FIG. 12. According to this embodiment, the square collar 90 of the second embodiment shown in FIG. 11 is replaced with a planar flange element 106. At least two engagement recesses 108 are disposed through the element 106. The clamping member 48 of this embodiment is positioned longitudinally relative to the platform member (not shown) in the direction shown by arrow 110 such that the two engagement recesses 108 overlap two similarly spaced-apart engagement recesses 112 disposed through the support arm 94. A bolted connection utilizing a knurl-knob bolt 114 is projected through each of the overlapped recesses 108, 112, the bolt end captured by a securing nut (not shown) affixed to an inner surface of the support arm 94. Alternatively, the support arm recesses 112 may be tapped such that the bolts 114 may be securely engaged therein. A protective U-shaped sheath 116 is shown installed along the concave side of the clamping portion 48 in the manner previously described to protect the tree from the teeth 51 shown in FIG. 11.
According to any of the three embodiments described above and shown in FIGS. 2-5, 11, 12, the support arm 40, 94 is pivotable about the bolted connection 44 through the upturned edge 32 of the platform portion 22. The support arm 40, 94 is pivoted to a desired angle, such as 30 degrees from the plane of the platform portion 22, to establish the necessary structural and geometrical relationship of the support arm 40 and its attached clamping member 48 with the pole 150, and also to orient the platform member 22 in a generally preferred horizontal position relative to the ground.
Now referring to FIG. 13, the support arm 40, 94 is shown in an operative position after being reoriented along the direction of the arrow 47 from its collapsed position within the plane of the platform portion 22. Two angularly spaced apart engagement recesses or holes 43, relative to the pivoting connection 44, are disposed in the upturned edge 32 and selectively correspond with an overlapping recess 49 disposed in the support arm 40. A bolt 45 and wingnut 45' secures the support arm 40, 94 either within or without the plane of the platform portion 22 in a collapsed or operative position, respectively, after the bolt 45 has been simultaneously projected through the corresponding engagement recesses 43, 49.
A perspective view of a fourth embodiment of the present invention is shown in FIG. 14. The pivotable connection 44 of the first three embodiments previously described is replaced with a rigid metal square collar 120 having a corresponding shaped opening through which any of the support arms 40, 94 may slidably extend. The collar 120 is rigidly affixed by a weld bead 122 to the upturned edge 32 of the platform portion 22, and extends angularly outwardly from the plane of the platform portion 22 at about a 30 degree angle. A lengthwise array of engagement recesses or holes 124 are disposed along the platform portion end of the support arm 40, 94. An engagement recess 126 is disposed through the collar 120. After the support arm 40, 94 has been extended a desired length through the collar 120, a locking pin 128 is projected through the collar engagement recess 126 and then through the support arm recess 124 corresponding to the desired extension.
Now referring to the clamping portion end of the support arm 40, 94, it will become clear to one skilled in the art to which this invention pertains that any of the configurations of the first three embodiments previously described may be affixed thereto to provide an extensive degree of flexibility including the ability of the apparatus to accommodate poles 150 of extreme girth. In like manner, the support arm 40, 94 may be extended to enable easy traversal about protruding limbs of excessive length or other oversized protrusions. According to FIG. 14 and for exemplary purposes only, the flanged end portion 50 of the third embodiment is shown affixed to the support arm 40, 94 by locking pins 130. Other connecting devices such as bolts may be used. Quick release strap means 132 of the type previously described affix the climber 10 to the user's feet prior to ascending or descending the tree or pole in a stepwise manner. The strap means may also be configured with an ankle encasing arrangement 134 to provide additional stability to the user. As shown in this view, an array of pole-engaging protrusions 136 are integrally formed into the concave side of the clamping portion 48, as well as along each of the forward platform edges 138.
FIG. 15 is a top plan view of a right-foot climbing member 20 of the fourth embodiment of the invention shown in its mounted position about the tree or pole 150. Protrusions 136 disposed on both platform and clamping portions 22, 48 are shown engaging with an exemplary tree trunk 152 shown in this view. A side view of the embodiment of FIG. 15, partly in cross-section, is shown in FIG. 16, further illustrating the preferred mounting angle of the platform portion 22 relative to the support arm 40, 94 and the tree trunk 152 on which the climber 10 is mounted. The angle between the plane of the platform portion 22 and the support arm 40, 94 is about 30 degrees, and the platform portion 22 is about perpendicular to the longitudinal axis of the tree trunk 152.
As shown in FIG. 17, an automatic adjustment feature is added to the climber of the present invention in a manner similar to that described in my copending application Ser. No. 07/818,262 which is incorporated herein by reference. Here, the clamping portion 48 relative to the platform portion 22 is maintained under tension by a resilient biasing member 160 such as an elastic cord or spring. The resilient biasing member 160 is fitted through a hole 162 at the platform portion end of the support arm 40, 94 and secured by a knot 164. The other end of the biasing member 160 is drawn through a hole (not shown) in a flange 166 securely affixed to or adjacent the clamping portion 48, the biasing member 160 attached to the flange 166 by another knot 168. Other suitable means of attaching the biasing member 160 to the climbing member 20 are contemplated. By such construction, the clamping portion 48 may be automatically moved toward or away from the platform portion 22 when ascending or descending a tree or any columnar member having a cross-sectional dimensional which varies with elevation, merely by releasing the locking member 56 thereby enabling the support arm 40, 94 to move and carry the clamping member 48 into a secured relationship with the tree.
Although the biasing member 160 shown in FIG. 17 is installed at the external periphery of the longitudinal extent of the climbing member 20, it is contemplated that such biasing member may be captured entirely within the walls of the support arm 40, 94 so as to limit or prevent exposure to snagging, weather, abrasion, or other wear or performance compromising factors.
Locking device 56 is shown positioned at the upper lateral side of support arm 40, 94 to provide access to the climber when the biasing member 160 is employed. Thus, the hunter can reach down to pull the ring 62 to release pin 58 (FIG. 8) from engagement. It is contemplated that the location of locking device 56 may be further varied to accommodate alternative ergonomic requirements as would be apparent to one skilled in the art to which this application pertains.
Now referring to FIG. 18, a top plan view of a right-foot climbing member 20 of the first embodiment of the invention shows a pair of adjustable carrying straps 138 for transporting the climber 10 in a backpack-like manner. Each of straps 138 is affixed to the platform portion 22 with a pair of bolted or riveted connections 140, and is adjustable through a buckle means 142. When the climber 10 is not being transported, the straps 138 are folded and stored within recesses 144 formed into the seat cushion material layered on the top side of the platform portion 22. Padded sleeves 146 may be installed about the straps 138 to provide an additional degree of carrying comfort to the user during transport. FIG. 19 is a side view, partly in cross-section, of the embodiment of FIG. 18, further showing the carrying straps 138 affixed to the collapsed climber 10, which is shown in its fully transportable configuration.
Only one of the climbing devices 20 is provided with carrying straps 138 since the other climbing device may be compactly nested therein with the Am-Lock strap device, previously described, and can be used to maintain the two climbing devices in a compact nested condition during transportation or storage.
Although certain presently preferred embodiments of the invention have been described herein, it will be apparent to those skilled in the art to which the invention pertains that variations and modifications of the described embodiments may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law. | A tree climber comprising a pair of climbing members, adapted to be affixed to the user's feet by quick release straps. Each climbing member includes a support arm extending forward from a platform portion and terminating at one end of a movable hook shaped clamping portion which engages the back side of the pole. Several embodiments show a clamping portion which is adjustably affixed to the terminus of the support arm with either a slidable collar and tube configuration or a clamped configuration. Another embodiment includes a slidable collar affixed to the platform portion, the support arm extending therethrough to a desired length corresponding to the diameter of the pole. The adjustable clamping portion of any of the embodiments may be used in combination with the extendable support arm to accommodate a wide range of tree trunk or pole diameters and to easily traverse protruding limbs which would otherwise arrest further vertical progress. A safety strap assembly secures the tree climber to the tree at the desired elevation. In its collapsed configuration the climbing members are nested and easily transported or stored. | 4 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/482,722, filed 2 Jan. 2004, which is a national phase application under 35 U.S.C. § 371 of PCT Application No. PCT/EP02/07239 filed 1 Jul. 2002, which claims priority to U.S. application Ser. No. 09/899,367 filed 2 Jul. 2001. The contents of these application are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an improved inflatable membrane apparatus and a process or method for transferring a coating onto at least one surface of a lens blank which can be implemented in a short period of time without any risk of deformation of the lens blank.
[0003] It is a common practice in the art to coat at least one face of an ophthalmic lens with several coatings for imparting to the finished lens additional or improved optical or mechanical properties.
[0004] Thus, it is usual practice to coat at least one face of an ophthalmic lens, typically made of an organic glass material, with successively, starting from the face of the lens, an impact resistant coating (impact resistant primer), a scratch resistant coating (hard coat), an anti-reflecting coating and, optionally, a hydrophobic top coat. Other coatings such as polarized coating, photochromic or dyeing coating may also be applied onto one or both faces of the ophthalmic lens.
[0005] Numerous processes and methods have been proposed for coating a face of an ophthalmic lens.
[0006] U.S. Pat. No. 4,061,518 discloses a process for fabricating an article having a replicated coating with a durable dielectric overcoat thereon which comprises forming onto an optically polished surface of a master a release layer, a protective coat and a reflective coat, applying a pre-measured amount of an epoxy resin adhesive on a face of a support member of casting, and thereafter transferring the coating from the master to the support member of casting by applying the coating face of the master to the epoxy resin adhesive, curing the epoxy resin adhesive under heat and withdrawing the master. The support member of casting is preferably an aluminium casting. The described method is particularly suited for making mirrors.
[0007] WO 99/24243 discloses a method of making a thermoplastic lens by placing a laminated layer/coating having the desired lens characteristics required for the prescription between a preheated lens blank and preheated mold halves and pressing the mold halves toward each other to compress the lens blank and uniformly apply the layer/coating thereon without any creases or cracks therein.
[0008] In this method, the lens molds are pressed toward each other and against the lens blank to immediately size down the lens blank and any laminations included therewith to its finished lens size with the desired layer coatings in a few minutes. In fact, the lens blank and juxtaposed laminations are compressed at a predetermined programmed rate of speed, whereby the lens blank is compressed and spread out into the mold cavity with a layer/coating uniformally applied thereon.
[0009] In order to obtain the required geometry for the final lens, spreading of the blank must be carefully controlled and therefore heating and compression have also to be carefully controlled.
[0010] U.S. Pat. No. 5,512,371 discloses a composite plastic optical quality lens, comprising a plastic lens preform of optical quality material, and a cured plastic attached portion that is bonded to said plastic lens preform portion; said cured plastic attached portion having higher scratch resistance, and lower chromatic aberration than said plastic lens preform.
[0011] Such a lens is obtained by pouring a lens composition in a molding cavity delimited by a mold part and a lens preform and then curing said lens composition.
[0012] According to one preferred embodiment of U.S. Pat. No. 5,512,371, coatings may be provided on the resultant lens by transferring coatings from the mold to the resultant lens.
[0013] The purpose of U.S. Pat. No. 5,512,371 is to substantially modify and improve the mechanical properties of the plastic lens preform, generally made of bisphenol-A polycarbonate. In particular, properties such as edging and chromatic aberration of the whole resultant lens are supposed to be significantly modified by the cured attached portion. Such results are achievable only for cured attached portions having a thickness globally in the same range or even higher than the thickness of the preform, taking into account that the usual center thickness of the final resultant lens is generally, as known in the art, of more than 1 mm.
[0014] If it was not the case, the modifications brought by the cured portion would have no significant effects on the properties of the composite lens such as chromatic aberration and edging.
[0015] WO 93/21010 also relating to the manufacture of composite lenses gives a minimum thickness for the preform: 100 microns, with typical thickness of 0.5 to 1.5 mm.
[0016] In general, it is difficult to manufacture and handle preforms that are less than 500 microns thickness.
[0017] Based on the above elements, it is clear that thicknesses for the cured attached portion of U.S. Pat. No. 5,512,371, even if not specifically mentioned, are typically around 0.5 mm or above.
[0018] According to the method of manufacture described in U.S. Pat. No. 5,512,371, a resin is poured in a mold and a lens polycarbonate preform is placed on the top of the resin filled mold, slight pressure is applied to squeeze out excess resin until a carrier of sufficient thickness is obtained.
[0019] The assembly lens/preform/mold part is held together with the capillary action of the resin material and the weight of the lens preform.
[0020] WO 97/35216 discloses a process for transferring a multilayer coating onto the surfaces of a lens which comprises:
providing a thin polymeric film substrate which is flexible and extensible and having one face coated with the transferable multilayer coating; placing the coated film substrate in an apparatus including a film deforming member; disposing a drop of an adhesive between the film substrate and a lens surface; urging the film into conforming engagement with a surface of the lens; and curing to adhere the multilayer coating on the lens surface.
[0026] In this process, the film substrate is stretched to conform to the surface of the lens, thereby stretching the multilayer coating. Stretching shall in fact be avoided because it entails a high risk of tearing and/or cracking the layers of the multilayer coating, in particular mineral layers such as conventional antireflective layers.
SUMMARY OF THE INVENTION
[0027] It is an object of the present invention to provide an inflatable membrane apparatus for use in a process or a method for transferring a coating from a support onto at least one surface of a lens blank which does not entail any deformation of the lens blank and the use of specific mold parts, for each prescribed final lens geometry.
[0028] It is an additional object of this invention to provide a process or a method for transferring a coating from a support onto at least one surface of a lens blank using the above membrane inflatable apparatus.
[0029] In accordance with the above objects and those that will be mentioned and will become apparent below, there is provided according to the invention an inflatable membrane apparatus comprising:
a fluid accumulator having an upper and a lower face and a fluid entrance, said lower face being partly formed by an inflatable membrane, and a trunconical part projecting outwardly from the lower face of the accumulator whose greater base is closest by at least part of the inflatable membrane and smaller base forms a circular opening, whereby, when pressurized fluid is introduced into the accumulator deformation of the inflatable membrane is guided by the trunconical part.
[0032] The invention also concerns a process or method for transferring a coating from at least one support onto at least a geometrically defined surface of a lens blank using the inflatable membrane apparatus of the invention which comprises:
providing a lens blank having at least one geometrically defined surface; providing a flexible support having an internal surface bearing a coating and an external surface; depositing on said geometrically defined surface of said lens blank or on said coating a pre-measured amount of curable glue; moving relatively to each other the lens blank and the support to either bring the coating into contact with curable glue or bring the curable glue into contact with the geometrically defined surface of the lens blank, thus forming an assembly comprising the lens blank, the curable glue and the coated support; placing the assembly in front of the inflatable membrane apparatus with the support facing the inflatable membrane; inflating the inflatable membrane for urging the flexible support against the lens blank, thereby applying a pressure onto the external surface of the support so that the thickness of a final glue layer after curing is less than 100 micrometers; curing the glue; and withdrawing the support to recover the lens blank with the coating adhered onto the geometrically defined surface of said lens blank.
[0041] By pre-measured amount, one means a sufficient amount of glue to obtain transfer and adhesion of the coating to the lens blank.
[0042] In one embodiment of the process of the invention, the pre-measured amount of the curable glue may consist in the external layer of the coating itself, in particular an impact-resistant primer layer of the coating to be transferred. This could be the case when the impact-resistant primer layer comprises UV polymerizable (meth)acrylate monomers. It can also be the anti-abrasion layer, in particular when no primer layer is to be transferred to the blank.
[0043] It also can be the external layer of an anti-reflection coating, in particular when only such an anti-reflection coating is being transferred. In that case, of course, the anti-reflection coating is deposited in a liquid form.
[0044] In another embodiment of the inventive process an adhesive primer layer may be deposited on the blank, prior to the deposition of the pre-measured amount of the curable glue.
[0045] Of course, the pre-measured amount of curable glue can be deposited in any appropriate form such as in the form of a drop or of a layer.
[0046] By geometrically defined surface of the lens blank or of a mold part, there is meant either an optical surface, that is a surface of required geometry and smoothness or a surface having a required geometry but that may still exhibit some roughness, such as a lens blank that has been grinded and fined, but not polished to the required geometry. The surface roughness typically ranges from Sq 10 −3 μm to 2 μm, preferably from 10 −3 μm to 1 μm, more preferably from 10 −3 to 0.5 μm and most preferably from 10 −3 to 0.1 μm.
[0047] By optical surface, there is meant a surface of the lens blank or of a mold part that has been ground, fined and polished or molded to required geometry and smoothness.
[0048] An important feature of the process of the present invention is that the transfer of the coating onto the geometrically defined surface of the lens blank is performed without any substantial compression of the blank and thus without any risk of deformation of the blank geometry and in particular of the geometrically defined surfaces thereof.
[0049] Nevertheless, the pressure exerted on the external surface of the support is preferably substantially maintained at least up to the gelling of the glue. Maintaining the pressure is effected through the use of an inflatable membrane placed on the external surface of the support.
[0050] Preferably, the applied pressure ranges from 5 to 50 Psi (0.35 to 3.5 kgf/cm 2 ), and more specifically 0.3 to 3 kgf/cm 2 .
[0051] A more preferred range is 5 to 30 Psi, and a most preferred range is 5 to 20 Psi (0.35 to 1.40 kgf/cm 2 ).
[0052] Using the above described process, coatings may be transferred successively or simultaneously to both front and rear geometrically defined surfaces of the lens blank. The transfer of the coatings may also be performed only to one side of the lens blank, preferably to the back side (or rear side).
[0053] The flexible coating support or carrier may simply be a thin supporting film made of an appropriate material such as a plastic material, for example a polycarbonate film. The coating support is preferably a mold part made of any appropriate material, preferably made of a plastic material especially a thermoplastic material and in particular of polycarbonate.
[0054] The working surface of the mold part may have a relief organized according to a pattern, in other words, may be microstructured and may confer to the final lens an optical surface having the properties imparted by the microstructure (for example anti-reflection properties).
[0055] Different techniques for obtaining a microstructured mold part are disclosed in WO99/29494.
[0056] The mold part or carrier may be obtained by using known processes such as surfacing, thermoforming, vacuum thermoforming, thermoforming/compression, injection molding, injection/compression molding.
[0057] When using a flexible mold part it is only necessary to provide the mold part with a surface the geometry of which conforms to the general shape of the optical surface of the lens blanks onto which the coating is to be transferred, either a concave or convex shape, but it is not necessary that this surface strictly corresponds to the geometry of the lens blank surface to be coated. Thus, the same mold part can be used for transferring coatings onto lens blanks having surfaces of different specific geometries. Generally, the flexible mold part has two parallel main surfaces and consequently has an even thickness.
[0058] The coating bearing surface of the flexible mold is preferably spherical.
[0059] Flexible mold parts would typically have a thickness of 0.2 to 5 mm, preferably of 0.3 to 5 mm, more preferably of 0.3 to 1 mm. More preferably, the flexible mold part is made of polycarbonate, and in this case the thickness is from 0.5 to 1 mm.
[0060] The inventors have found that the best embodiments of the invention are achieved if specific requirements regarding the base curvatures of the mold part and lens blank are fulfilled.
[0061] In this patent application, when one refers to the base curvature of the mold part, one means the base curvature of the working surface of the mold part, that is to say the surface which bears the coatings to be transferred to the lens or lens blank.
[0062] In the same way, base curvature of the lens or lens blank means the base curvature of the surface to which the coatings are going to be transferred from the above cited mold part.
[0063] In this application, the base curvature has the following definition:
For a spherical surface, having a radius of curvature R, Base curvature (or base)=530/R (R in mm); such kind of definition is quite classical in the art. For a toric surface, there are two radii of curvature and one calculates, according to the above formula, two base curvatures BR, Br with BR<Br.
[0066] For a coating transfer to a spherical back side of a lens or lens blank, in order to avoid distortions, in particular when using a flexible mold part, the base curvature (BC) of the flexible mold part (front side) must be slightly higher than the base curvature (BL) of the geometrically defined surface of the lens or the lens blank on which the coating is to be transferred. However, BC shall not be too high in order to avoid cracking of the coating during the transfer process or an optical power outside tolerance of Z801 after the transfer.
[0067] Typically, for a spherical lens or lens blank, base curvature BL of the lens or lens blank and base curvature BC of the flexible mold part shall satisfy the relationship:
[0000] 0< BC−BL< 1.5
[0000] Preferably
[0000] 0.2< BC−BL< 1
[0068] For a coating transfer to a toric back side of a lens or a lens blank (cylindrical lens or lens blank), having two principal meridians, of radii R and r with R>r, it is possible to calculate two base curvatures BLR and BLr corresponding respectively to radii R and r defining the toric surface.
[0069] Base curvatures of the lens BLR and BLr and the base curvature of the flexible mold part shall satisfy the following relationships:
[0000] BLR<BLr and: a) if BLr−BLR≦3.5, then 0<BC−BLR<3 and |BC−BLr|<1, preferably 0.2<BC−BLR<2.5 and |BC−BLr|<0.5. b) if BLr−BLR>3.5, then BLR<BC<BLr.
[0072] Preferably, when moving relatively to each other the mold part and the blank, the contact between coating(s) and curable glue or between curable glue and lens blank geometrically defined surface occurs respectively in the center area of the coated mold part or in the center area of the lens blank geometrically defined surface.
[0073] In particular in the case of a flexible mold part, the convex front face of the mold part may have a shorter radius of curvature than the concave surface of the blank to be coated. Thus, pressure is applied at the center and the mold part is then deformed to conform to the blank surface. The glue layer is formed starting from the center of the blank, which avoids entrapping air bubbles within the final cured glue layer. The same will be true using the concave surface of a mold part of longer radius of curvature than a convex blank surface to be coated.
[0074] As previously mentioned, transfer from a flexible mold part is effected using an inflatable membrane.
[0075] The inflatable membrane can be made of any elastomeric material which can be sufficiently deformed by pressurization with appropriate fluid for urging the flexible mold part against the lens or lens blank in conformity with the surface geometry of the lens or the lens blank.
[0076] The inflatable membrane can be made of any appropriate elastomeric material. Typically, the inflatable membrane has a thickness ranging from 0.50 mm to 5.0 mm and an elongation of 100 to 800%, and a durometer 10 to 100 Shore A.
[0077] If the glue is thermally cured, then the material of the inflatable membrane shall be selected to bear the curing temperature.
[0078] If the glue is UV cured, then a transparent material shall be selected, for example a transparent silicone rubber or other transparent rubbers or latexes: the UV light is preferably irradiated from the mold side.
[0079] The pressure applied to the mold part by the inflatable membrane will preferably range from 30 kPa to 150 kPa and will depend on the lens or lens blank and flexible mold part sizes and curvatures. Of course, the pressure needs to be maintained onto the flexible mold part and the lens or lens blank until the glue or adhesive is sufficiently cured so that enough adhesion of the coating to the lens or lens blank is obtained.
[0080] The lens blank can be a lens having one or both of its faces surfaced or casted to the required geometry. (A lens having only one of its faces surfaced or casted to the required geometry is called a semi-finished lens).
[0081] Preferably, the lens blank has a first face conferring progressive power and a second face conferring non-progressive power, but of spherical or torical shape onto which coating transfer according to the invention process is preferably performed. Preferably, the progressive face is the front face of the blank.
[0082] The lens blank can also be a semi-finished lens wherein one face of the lens, preferably the front face of the lens has previously been treated with an appropriate coating (anti-reflection, hard coat, etc. . . . ) and the remaining face, preferably the rear face, of the lens is coated using the transfer process of the invention. The lens blank can be a polarized lens.
[0083] The lens blank can be pre-treated before applying the method of the invention.
[0084] The pre-treatment can be physical such as a plasma treatment or chemical such as a solvent treatment or a NaOH treatment.
[0085] The transferred coating may comprise any coating layer or stack of coating layers classically used in the optical field, such as an anti-reflection coating layer, an anti-abrasion coating layer, an impact resistant coating layer, a polarized coating layer, a photochromic coating layer, an optical-electronical coating, an electric-photochromic coating, a dyeing coating layer, a printed layer such as a logo or a stack of two or more of these coating layers.
[0086] According to a preferred embodiment of the invention, it is transferred to the geometrically defined surface of the lens blank a stack comprising:
optionally, a hydrophobic top coat; an antireflection stack, generally comprising inorganic material such as metal oxide or silica; a hard coat, preferably comprising a hydrolyzate of one or more epoxysilane(s) and one or more inorganic filler(s) such as colloidal silica; optionally, an impact strength primer, preferably a polyurethane latex or an acrylic latex; each of the layers of the stack being deposited onto the support in the above recited order.
[0092] The method of the invention is particularly interesting for transferring the whole stack comprising “top coat, antireflection coat, hard coat and primer coat”.
[0093] Generally the thickness of the antireflection coat or stack ranges from 80 nm to 800 nm and preferably 100 nm to 500 nm.
[0094] The thickness of the hard coat preferably ranges from 1 to 10 micrometers, preferably from 2 to 6 micrometers.
[0095] The thickness of the primer coat preferably ranges from 0.5 to 3 micrometers.
[0096] Typically, the total thickness of the coating to be transferred is 1 to 500 μm, but is preferably 50 μm or less, more preferably less than 20 micrometers, or even better 10 μm or less.
[0097] The glue or adhesive may be any curable glue or adhesive, preferentially a thermally curable or photocurable, in particular room temperature or UV curable, glue or adhesive that will promote adhesion of the coating to the optical surface of the blank without impairing the optical properties of the finished lens.
[0098] Some additives such as photochromic dyes and/or pigments may be included in the glue.
[0099] Although the liquid glue or adhesive is preferably dispersed at the center, it can be dispersed in a random pattern, spread out firstly via spin coating, or sprayed using a precision dispensing valve. By even layer distribution, it is meant that the variation of thickness of the glue or adhesive layer, once cured, has no consequence on the optical power of the final lens.
[0100] The curable glue or adhesive can be polyurethane compounds, epoxy compounds, (meth)acrylate compounds such as polyethyleneglycol di(meth)acrylate, ethoxylated bisphenol A di(meth)acrylates.
[0101] The preferred compounds for the curable glue or adhesive are acrylate compounds such as polyethyleneglycoldiacrylates, ethoxylated bisphenol A diacrylates, various trifunctional acrylates such as (ethoxylated) trimethylolpropane triacrylate and tris(2-hydroxyethyl)isocyanurate.
[0102] Monofunctional acrylates such as isobornylacrylate, benzylacrylate, phenylthioethylacrylate are also suitable.
[0103] The above compounds can be used alone or in combination.
[0104] Preferably, when cured, the glue layer has an even thickness. Suitable glues are commercially available from the Loctite Company.
[0105] As previously mentioned, the thickness of the final glue layer after curing is less than 100 μm, preferably less than 80 μm, most preferably less than 50 μm and usually 1 to 30 μm.
[0106] The lens blank may be made of any material suitable for making optical lenses but is preferably made of a plastic material and in particular of diethyleneglycol bis-allylcarbonate copolymer (CR-39® from PPG INDUSTRIES), polycarbonate (PC), polyurethane, polythiourethane, episulfide ultra-high index materials, optionally containing photochromic compounds.
[0107] The final lenses obtained by the method of the invention have very good optical quality and they have no or very low level of interference fringes.
BRIEF DESCRIPTION OF THE DRAWING
[0108] The foregoing and other objects, features and advantages of the present invention will become readily apparent to those skilled in the art from a reading of the detailed description hereafter when considered in conjunction with the accompanying drawings wherein:
[0109] FIGS. 1A to 1C are schematic views of the main steps of a first embodiment of a process for transferring a coating onto an optical surface of a lens blank.
[0110] FIGS. 2A to 2C are schematic views of the main steps of a second embodiment of a process for transferring a coating onto an optical surface of a lens blank wherein coatings are simultaneously transferred to both optical surfaces of a lens blank.
[0111] FIGS. 3A and 3B are schematic views of the main steps of a third embodiment of a process for transferring a coating onto an optical surface of a lens blank using a new inflatable membrane apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0112] Referring now to the drawings and in particular to FIGS. 1A to 1C , a lens blank 1 having a concave surface 2 is placed on a supporting element 3 with its concave surface 2 facing upwardly. A pre-measured drop of a UV curable glue 4 is then deposited onto the surface 2 of the lens blank 1 . A flexible mold part 5 having a convex optical surface, which has been previously coated with a prescribed coating 6 , is placed onto a supporting element 7 with its surface bearing the optical coating facing downwardly.
[0113] Deposition of coating 6 on the surface of the flexible mold part 5 can be done through any usual deposition process employed in the optical field, such as vacuum deposition, spin coating, brush coating, dip coating etc. . . . Of course, the deposition process will depend on the nature of the coating layer or layers deposited on the surface of the flexible mold part 5 .
[0114] Thereafter the supporting elements 3 , 7 are moved relatively to each other to bring into contact coating 6 and UV curable glue drop 4 and a pressure is exerted to the external surface of the mold part opposite to the coating in such a manner that the UV curable glue drop will spread on the surface 2 of the lens blank 1 and on the coating 6 . However, the exerted pressure shall only be sufficient for spreading the drop of glue in order to obtain the required thickness for the final cured glue film but insufficient to impart any deformation to the lens blank 1 .
[0115] As shown in FIG. 1B , the assembly formed by the lens blank 1 , the glue film 4 , the coating 6 and the mold part 5 is then placed into a device for UV curing the glue film 4 . After curing of the UV film 4 , the mold part 5 is withdrawn and a blank 1 having a coating 6 adhered onto its concave surface 2 is recovered as shown in FIG. 1C .
[0116] Referring now to FIGS. 2A to 2C , there is shown a similar process as described in connection with FIGS. 1A to 1B but in which both surfaces of lens blank 1 are coated with a coating by the transfer method of the invention.
[0117] As shown in FIG. 2A , a flexible mold part 8 , for example a mold part made of polycarbonate having a thickness of 1 mm, whose concave surface has been previously coated with an optical coating 9 is placed onto a supporting element 3 . A pre-measured drop 10 of a UV curable glue is then deposited onto coating 9 . A lens blank 1 is then placed on mold part 8 with its convex surface 2 ′ in contact with glue drop 10 . A pre-measured UV curable glue drop is then deposited on concave surface 2 of lens blank 1 . A flexible mold part 5 , for example a polycarbonate mold part of 1 mm thickness, whose convex surface has been previously coated with an optical coating 6 is placed on a supporting element 7 . Supporting elements 3 , 7 are then moved relatively to each other to bring coating 6 into contact with glue drop 4 and a pressure is exerted on at least the external surface of one of the mold part to spread the glue drops 4 and 10 to form glue films. As indicated previously, the pressure exerted must only be sufficient to spread the glue drops and form glue films of required thicknesses after curing but insufficient to create any deformation in the lens blank 1 .
[0118] Thereafter, the assembly formed by the mold parts, optical coatings, glue films and lens blank is placed into a UV curing device where the glue films 4 , 10 are UV cured.
[0119] After completion of curing of the glue films, mold parts 5 and 8 are withdrawn and a finished lens having optical coatings 5 , 6 adhered to both surfaces of the lens blank 1 is recovered, as shown in FIG. 2C .
[0120] FIGS. 3A and 3B are schematic views of a third embodiment of the process of the invention in which the transfer of the coating is performed using a flexible mold part or carrier which is urged against the lens blank surface using an inflatable membrane apparatus according to the invention.
[0121] FIG. 3A shows the lens blank, flexible carrier and inflatable membrane before pressurization and inflation of the membrane, whereas FIG. 3B shows the same after pressurization and inflatation of the membrane.
[0122] Although, the following description will be made in connection with UV curing of the adhesive, similar apparatus and process can be used using a thermally curable adhesive.
[0123] Referring to FIG. 3A , a lens blank 1 , for example a toric lens blank is placed in a lens blank support with its geometrically defined surface 1 a facing outwardly.
[0124] A drop of liquid transparent adhesive 3 is deposited at the center of the geometrically defined surface 1 a of the lens blank 1 .
[0125] A thin flexible carrier 4 , for example a spherical carrier, having a tansferable coating 5 deposited on one of its faces, is placed on the adhesive drop 3 so that the transferable coating 5 is in contact with the adhesive drop 3 . The base curvature of the flexible carrier 4 is slightly higher than the base curvature of the geometrically defined surface 1 a of lens blank 1 .
[0126] The whole assembly is placed in front of an inflatable membrane apparatus 10 .
[0127] The inflatable membrane apparatus 10 comprises a fluid accumulator 11 , for example an air accumulator provided with fluid port 12 , for example an air port connected to a pressurized fluid source (not represented) for introducing pressurized fluid within the accumulator and also evacuating pressurized fluid from the accumulator. The upper face of the accumulator 10 comprises a light transparent portion 13 , for example a UV transparent quartz glass portion, whereas the lower face of the accumulator 10 comprises a transparent inflatable membrane 14 in register with the transparent quartz glass 13 .
[0128] As shown in FIG. 3A , the apparatus 10 further comprises a guiding means 15 for laterally guiding the inflatable membrane 14 during inflatation thereof. More specifically, this guiding means comprises a trunconical part or funnel 15 projecting outwardly from the lower face of the accumulator 10 and whose greater base is obturated by the inflatable membrane and whose smaller base is a circular opening having a diameter at least equal to the base diameter of the flexible carrier 4 but preferably slightly larger (up to 5 mm larger . . . ).
[0129] Typically, the funnel height will range from 10 to 50 mm, preferably 10 to 25 mm, and will have a taper of 10 to 90°, preferably 30 to 50°.
[0130] Finally, a light source, for example a UV light source 16 is placed behind the accumulator 10 in front of the transparent quartz plate 13 .
[0131] Generally, the assembly comprising the lens blank holder 2 , the lens blank 1 , the adhesive drop 3 and the flexible carrier 4 is placed so that the rim of the flexible carrier 4 be within the plan of the rim of the smaller base opening of funnel 15 or separated therefrom by a distance up to 50 mm, preferably up to 20 mm.
[0132] As shown in FIG. 3B , a pressurized fluid, such as pressurized air, is introduced into the accumulator 11 from an external source (not represented) through entrance 12 . The pressure increase within the accumulator, inflates the inflatable membrane 14 and, thanks to the membrane guiding means 15 , the membrane 14 uniformly urges the flexible carrier against the lens blank 1 , while uniformly spreading the adhesive 3 .
[0133] The adhesive is then UV-cured.
[0134] After completion of the curing step, the lens blank 1 is disassembled from the holder 2 and the flexible carrier 4 is removed to recover a lens blank 1 whose geometrically defined surface 1 a bears the transferred coating 5 .
[0135] Of course, in case of a thermal curing process, light source and transparent portion of the upper face of the accumulator are not needed.
[0136] In this case also, the inflatable membrane needs not to be transparent. Otherwise, the apparatus remains the same.
[0137] Using the funnel type of apparatus just described, a good coating transfer is obtained, with good optical quality meeting the America Optical Laboratory Standard (ANSI Z80.1-1987) as far as the power, cylinder, prism and distortion are concerned.
[0138] The membrane guiding means (funnel) is very important to let the membrane expand in good shape and direction for applying an even pressure on the flexible carrier through the lens blank without any extra pressure on the carrier and lens blank edges.
[0139] The following examples illustrate the process of the present invention.
Adhesion Test
[0140] Dry adhesion test was measured by cutting through the coating a series of 10 lines, spaced 1 mm apart, with a razor, followed by a second series of 10 lines, spaced 1 mm apart, at right angles to the first series, forming a crosshatch pattern. After blowing off the crosshatch pattern with an air stream to remove any dust formed during scribing, clear cellophane tape was then applied over the crosshatch pattern, pressed down firmly, and then rapidly pulled away from coating in direction perpendicular to the coating surface. Application and removal of fresh tape was then repeated two additional times. The lens was then submitted to tinting to determine the percentage adhesion, with tinted areas signifying adhesion failures.
EXAMPLES
Examples 1 to 6
[0141] HMC coatings comprising a hydrophobic top coating layer, an anti-reflection layer, an anti-abrasive coating and an impact and/or adhesion enhancing layer as specified above are deposited on the convex surface of different flexible carriers and were transferred to geometrically defined backside surfaces of lenses using the process and apparatus as defined in connection with FIGS. 3A and 3B .
[0142] The materials used, apparatus and process conditions are defined hereinunder:
[0000] 1) Flexible mold part (carrier):
[0143] Polycarbonate (thickness 0.5 mm)
base curvature (BC) 6, 8 or 11, diameter of the flexible mold part (periphery) 68 mm.
2) Lenses:
[0146] CR39®, peripheral diameter 70 mm, lenses, backsides with base curvatures as indicated in table III below,
[0147] power as indicated in table III below.
[0000] 3) Liquid adhesive:
UV curable liquid adhesive: OP-21 from DYMAX Corporation.
4) Inflatable membrane apparatus:
[0148] Membrane: transparent silicone rubber membrane 1.6 mm thick, durometer hardness 40 A, tensile strength 5516 kPa and elongation 250%,
[0149] Air pressure: pressure applied to the mold part 10 psi.
5) UV-cure
[0150] light intensity 145 mW/Cu 2 ;
[0151] cure time: 40 seconds.
[0000] Results are given in Table I:
[0000]
TABLE I
Optical properties comparison before and after HMC film transfer onto different curved lenses from thin HMC-PC carriers (0.50 mm)
Overall ISO
Lens
BL or BLR-
Lens Power
Lens Power
Cylinder
Cylinder
Prism
Prism
Performance
Ex.
power
Cylinder
BLr
BC
before BST
After BST
before BST
after BST
before BST
after BST
Z80.1
1
(+) 4.00
0
5.40
6
4.01
3.93
−0.04
−0.09
0.63
0.64
Good
5.40
2
(+) 3.00
−2
5.70
8
3.02
3.03
−1.98
−2.02
0.21
0.46
Good
7.70
3
(+) 1.00
−2
6.20
8
0.97
1.02
−1.93
−1.94
0.14
0.05
Good
8.20
4
(−) 1.00
−2
6.60
8
−1.01
−1.02
−2.05
−2.05
0.12
0.02
Good
8.50
5
(−) 3.00
0
7.70
8
−2.99
−2.94
−0.03
−0.05
0.37
0.31
Good
7.70
6
(−) 4.00
−2
8.50
11
−4.06
−4.04
−1.93
−1.99
0.86
0.30
Good
10.50
BST: Backside transfer.
Example 7
[0152] Examples 1 to 6 are reproduced except polycarbonate lenses were used instead of CR-39 lenses with powers varying from −2.00 to +2.00. The optical and HMC film qualities of the obtained lenses after the coating transfer were the same as in examples 1 to 6.
Example 8
[0153] Examples 1 to 6 are reproduced except photochromic lenses were used instead of CR-39 lenses. The optical and HMC film qualities of the obtained lenses after the coating transfer were the same as in examples 1 to 6.
Examples 9 to 18 AND COMPARATIVE EXAMPLES 1 TO 2
[0154] The procedure of examples 1 to 6 was repeated with the following conditions: thin PC carriers of:
a) HMC thin carrier preparation: firstly, different size and base curvature carriers having a thickness of 0.5 mm were prepared by surfacing PC blanks as shown in the following table IV. The PC carrier is made by non-UV absorber PC materials. The peripheral diameter of the carrier is 68 mm. These carriers were then coated by protective coating, AR coating, hard coating and latex primer coating to make a HMC front-coated carrier for backside coating transferring process. b) Lens blank preparation: HMC front coated PC SF (semi-finished) lenses with peripheral diameter of 70 mm were back-surfaced to the different powers with different backside base curvatures or base as shown in the same table. c) BST: the lenses were washed by soap and water and dried and then a small amount of UV acrylic adhesive were dropped on the backside of the lens and the HMC carrier was placed upon the glue. After that, the UV funnel type accumulator apparatus was placed on top of the carrier. The membrane was inflated at a constant pressure of 69 kPa to deform the HMC carrier and spread out the glue liquid to match the backside curvature of the lens, and then a UV light was irradiated from the top (carrier side) for 40 seconds. After UV curing, the lens with HMC carrier stack was edged to remove excess glue on the edge and then the carrier was blown off by air to leave HMC stacked on the backside of the lens. The optical quality and distortion of the obtained lenses with HMC on the backside by BST process was checked by HUMPHERY 350 Power.
[0158] The results are given in Table II:
[0000]
TABLE II
Optical
PC lens
Cylinder of
BL
BC/HMC
Power
Power
Cylinder
Cylinder
distortion
Ex.
power
PC lens
BLR ≈ BLr
Carrier base
before BST
after BST
before BST
after BST
after BST
9
+2.00
0
3.6
4.1
+2.04
+2.02
0.04
0.06
Good
10
+2.00
2.00
3.6 ≈ 5.5
5.5
+2.04
+2.11
1.99
2.05
Good
11
+1.00
0
4.5
5.5
+0.99
+0.94
0.03
0.01
Good
12
+1.00
2.00
4.5 ≈ 6.3
6.1
+1.02
+1.06
1.98
1.94
Good
13
−1.00
0
5.2
5.7
−0.98
−1.00
0.02
0.07
Good
14
−1.00
2.00
5.2 ≈ 7.0
7.5
−1.02
−0.92
1.96
2.03
Good
15
−2.00
0
5.1
6.1
−2.05
−1.95
0.02
0.05
Good
16
−2.00
2.00
5.1 ≈ 6.9
6.5
−2.00
−1.93
1.99
2.01
Good
17
−3.00
0
6.0
6.5
−2.92
−2.95
0.02
0.04
Good
18
−3.00
2.00
6.0 ≈ 7.8
7.5
−2.90
−3.03
2.02
1.96
Good
Comp. 1
+1.00
2.00
4.5 ≈ 6.3
4.5
+1.05
2.03
2.03
3.07
NG
Comp. 2
0.00
0
5.5
4.5
0.00
1.00
0.00
0.45
NG
Comp. 1-2: The carrier base curvature was smaller than the lens back base curvature;
NG: Not good.
[0159] HMC pre-coating of the mold parts of the above examples was as follows, except in example 5 wherein no hard coat and no primer coat is used.
[0160] HMC front coated PC SF in examples 19 to 28 are obtained following step 2 and 3 of HMC deposition but with the deposition of each layer being performed in the reverse order (primer/hardcoat/AR layers) i.e. normal order.
Step 1: Protecting and Releasing Coating
[0161] The composition of the protecting and releasing coating was as follows in Table III:
[0000]
TABLE III
Component
Parts by weight
PETA LQ (acrylic ester of pentaerythritol)
5.00
Dowanol PnP
5.00
Dowanol PM
5.00
n-propanol
5.00
1360 (Silicone Hexa-acrylate, Radcure)
0.10
Coat-O-Sil 3503 (reactive flow additive)
0.06
Photoinitiator
0.20
[0162] The PC mold parts are cleaned using soap water and dried with compressed air. The mold part convex surfaces are then coated with the above protecting coating composition via spin coating with application speed of 600 rpm for 3 seconds and dry speed of 1200 rpm for 6 seconds. The coating was cured using Fusion System H+ bulb at a rate of 1.524 m/minute (5 feet per minute).
Step 2: Anti-Reflection (AR) Coating
[0163] The PC mold parts after deposition of the protecting coating was vacuum coated as follows:
[0000] A/ Standard Vacuum AR Treatment: The Vacuum AR treatment is accomplished in a standard box coater using well known vacuum evaporation practices. The following is one procedure for obtaining the VAR on the mold:
1. The molds having the protective coating already applied on the surface, are loaded into a standard box coater and the chamber is pumped to a high vacuum level.
2. Hydrophobic coating (Chemical=Shin Etsu KP801M) is deposited onto the surface of the molds using a thermal evaporation technique, to a thickness in the range of 2-15 nm.
3. The dielectric multilayer AR coating, consisting of a stack of sublayers of high and low index materials is then deposited, in reverse of the normal order. Details of this deposition are as such:
[0164] The optical thicknesses of the alternating low and high index layers are presented in Table IV:
[0000] TABLE IV Low index 103-162 nm High index 124-190 nm Low index 19-37 nm High index 37-74 nm
B/At the completion of the deposition of the four-layer anti-reflection stack, a thin layer of SiO 2 , comprising of a physical thickness of 1-50 nm, is deposited. This layer is to promote adhesion between the oxide anti-reflection stack and a laquer hard-coating which will be deposited on the coated mold at a later time.
Step 3: Hard Coat (HC) & Latex Primer Coating
[0165] The composition of the hardcoating was as follows in Table V:
[0000]
TABLE V
Component
Parts by weight
Glymo
21.42
0.1 N HCl
4.89
Colloidal silica
30.50
Methanol
29.90
Diacetone alcohol
3.24
Aluminium acetylacetonate
0.45
Coupling agent
9.00
Surfactant FC-430 (3M company)
0.60
[0166] The composition of the primer was as follows in Table VI:
[0000]
TABLE VI
Component
Parts by weight
Polyurethane latex W-234
35.0
Deionized water
50.0
2-Butoxy ethanol
15.0
Coupling agent
5.00
[0167] The PC mold parts after deposition of protecting coating and AR coating in Steps 1 and 2 are then spin coated by HC solution at 600 rpm/1200 rpm, and precured 10 minutes at 80° C., and again spin coated by latex primer solution at the same speed and postcuring for 1 hour at 80° C.
[0168] The coupling agent is a precondensed solution of as follows in Table VII:
[0000]
TABLE VII
Component
Parts by weight
GLYMO
10
(Glycidoxypropyltrimethoxysilane)
Acryloxypropyltrimethoxysilane
10
0.1 N HCl
0.5
Aluminium acetylacetonate
0.5
Diacetone alcohol
1.0 | An inflatable membrane apparatus ( 10 ) comprising (a) a fluid accumulator ( 11 ) having an upper and a lower face and a fluid entrance ( 12 ), said lower face being partly formed by an inflatable membrane ( 14 ), and (b) a trunconical part ( 15 ) projecting outwardly from the lower face of the accumulator whose greater base is closed by at least part of the inflatable membrane ( 14 ) and smaller base forms a circular opening, whereby, when pressurized fluid is introduced into the accumulator ( 11 ), deformation of the inflatable membrane ( 14 ) is guided by the trunconical part. | 1 |
This application is a continuation of application Ser. No. 08/537,448 filed Oct. 2, 1995, now abandoned.
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to a sheet post-processing apparatus, more particularly to a sheet post-processing apparatus for post-processing sheets such as copy sheets, after sorted or accommodated on sheet trays, the sheets being discharged from an image forming apparatus such as a copying machine, printer, laser beam printer or the like.
Heretofore, in a sheet post-processing apparatus having a binding means (stapler) retractable relative to a bin tray, the stapler 501, as shown in FIG. 64, is advanced to a predetermined position (e.g. a front corner, or two end edges) of the bin tray B, and staples sets or bundles of sheets on the bin tray B.
Before the stapling operation by the stapler 501, the sets of sheets sorted and accommodated on the bin trays B, are aligned by abutting edges of the sheets to a reference guide 503 by a movable aligning guide 502.
However, in the conventional example, if the sizes of the sheets sorted and accommodated on the bin trays are different, the stapling positions are different. For example, as shown in FIG. 64, when the edges of the A4 size sheets 504A and B5 size sheets 504B are stapled at two positions, the staple positions are symmetrical (a1=a2) in the case of A4 size sheets but not for the B5 size sheets (b1>b2).
SUMMARY OF THE INVENTION
Accordingly, it is a principal object of the present invention to provide an apparatus with which the staple positions are symmetrical for a plurality of sizes of sheets (A4 or B5, or the like).
According to an aspect of the present invention, there is provided a sheet post processing apparatus, comprising at least one sheet receiving tray for accommodating sheets; sheet discharging means for discharging sheets to said sheet receiving tray; sheet processing means for processing sheets accommodated on said sheet receiving tray; a reference member for guiding edges of the sheets on said sheet receiving tray and for functioning as a reference for alignment of the sheets to a reference position; an aligning member movable to a predetermined alignment position to urge the sheets on the receiving tray to the reference member; means for changing a reference position of said reference member to make constant a distance from an edge of the sheet to a position where the sheets are processed by said sheet processing means.
With this structure, the reference position for the alignment is made different depending on the sizes of sheets, so that the distances from the staple positions to the ends are equal.
Additionally, in the case of corner stapling at the alignment side, the distance from the staple position and the edge is constant irrespective of the sizes of the sheets.
When the stapling is effected at a corner of the alignment side, the staple position at the corner of the alignment side and an edge staple position at the alignment side are made the same, by changing the reference position in accordance with the size of the sheet. By doing so, it becomes unnecessary to enlarge the cut-away portion of the sheet receiving tray for the corner stapling at the alignment side, thus avoiding the reduction of the rigidity and stacking property of the sheet receiving tray.
The sheet post-processing apparatus is provided with an operation panel for inputting signals for the sheet alignment or stapling. When there is no input before the operation, the post processing operation is carried out after operation of the apparatus, in accordance with the signals therefrom, and therefore, the operatively to permit various types of operations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical side cross sectional view showing a sheet processing apparatus and an image processing apparatus comprising the sheet processing apparatus according to the present invention;
FIG. 2 is a partially-broken perspective view showing the sheet processing apparatus;
FIG. 3 is a vertical side cross sectional view showing the sheet processing apparatus;
FIG. 4 is an explanatory view of a lower discharge roller pair of the sheet processing apparatus;
FIGS. 5(a), 5(b), and 5(c) are schematic views showing the structure of an upward moving mechanism for swinging the leading passage of the sheet processing apparatus;
FIG. 6 is a perspective view showing a bin unit of the sheet processing apparatus;
FIG. 7 is a top view of the bin unit of the sheet processing apparatus;
FIGS. 8(a) and 8(b) are schematic side views showing the movement position for a reference guide;
FIGS. 9(a) and 9(b) are top views showing the operations of the reference guide, an aligning rod and a multiguide;
FIG. 10 is a diagram showing the operation relationship among the reference guide, the aligning rod and the multiguide;
FIGS. 11(a), 11(b), 11(c), and 11(d) are top views showing a state where the sheet is aligned and moved upwards on a bin tray;
FIGS. 12(a), 12(b), 12(c), and 12(d) are schematic cross sectional views showing the bin tray;
FIG. 13 is a side view showing an operation of opening the bin tray by a lead cam of the sheet processing apparatus;
FIG. 14 is a horizontal plan view showing a bin roller attached to the bin tray, a trunnion and lead cam for rotating the bin roller;
FIGS. 15(a), 15(b), and 15(c) are schematic side views showing the relationship between bin rollers attached to the bin tray;
FIG. 16 is a diagram showing the structure of a sheet retaining mechanism;
FIG. 17 is a diagram showing the structure of the sheet retaining mechanism;
FIG. 18 is a plan view showing a bin tray portion of the sheet processing apparatus;
FIG. 19 is a vertical side view of a stapler portion of the sheet processing apparatus;
FIG. 20 is a plan view showing the stapler portion and the bin tray portion;
FIG. 21 is a side view showing the structure of the stapler portion;
FIG. 22 is a plan view showing the structure of the stapler portion;
FIG. 23 is a graph of waveform showing electric current that flows in a staple motor during one stapling process of the stapler;
FIG. 24 is a plan view showing a staple-less display portion showing a staple-less state and a staple-jam display portion showing a staple-jam state of the stapler;
FIG. 25 is a vertical cross sectional view showing a guide member of the stapler;
FIG. 26 is an explanatory view showing an operation of the stapler to introduce into the bin tray;
FIGS. 27(a) and 27(b) are diagrams showing the structure for the stapling operation performed by the forming portion of the stapler;
FIG. 28 is a diagram showing a staple cartridge and staples;
FIG. 29 is a diagram showing a mechanism for rotating a support member having the stapler mounted thereon;
FIG. 30 is a plan view showing the stapler portion and the bin tray portion in a state when the stapling operation is performed in the sheet processing apparatus;
FIG. 31 is a plan view showing the stapler portion and the bin tray portion in a state when the stapling operation is performed in the sheet processing apparatus;
FIG. 32 is a plan view showing the stapler portion and the bin tray portion in a state when the stapling operation is performed in the sheet processing apparatus;
FIG. 33 is a plan view showing the stapler portion and the bin tray portion in a state when the stapling operation is performed in the sheet processing apparatus;
FIG. 34, including FIGS. 34A and 34B, is a flow chart showing the stapling operation in the sheet processing apparatus;
FIG. 35, including FIGS. 35A and 35B is a flow chart showing the stapling operation to be performed in the sheet processing apparatus;
FIG. 36 is a flow chart showing the stapling operation to be performed in the sheet processing apparatus following the operation shown in FIG. 34;
FIG. 37 is a flow chart showing the stapling operation to be performed in the sheet processing apparatus;
FIG. 38 is a flow chart showing the stapling operation to be performed in the sheet processing apparatus following the operation shown in FIG. 36;
FIG. 39 is a top view showing the bin unit of the sheet processing apparatus;
FIGS. 40(a) and 40(b) are diagrams showing a hooked portion of a stopper of the bin tray;
FIGS. 41(a), 41(b), and 41(c) are schematic views showing a portion near the stopper of the bin tray;
FIGS. 42(a) and 42(b) are schematic views showing a state where the projections and recesses of the bin rollers approach and move apart from each other;
FIGS. 43(a) and 43(b) are diagrams showing the other shapes of the projections and recesses of the bin rollers;
FIGS. 44(a) and 44(b) are schematic views showing a front locking mechanism;
FIGS. 45(a) and 45(b) are diagrams showing the operation relationship among the reference guide, the aligning rod and the multiguide;
FIG. 46 is a top view showing a state where the sheet pushed on to the bin tray is maintained;
FIG. 47 is a top view of a discharge guide;
FIGS. 48(a), 48(b), and 48(c) are cross sectional views and a front view showing the discharge guide;
FIGS. 49(a), 49(b), and 49(c) are diagrams showing the structure of the aligning rod and the quantity of pressing by the aligning rod;
FIG. 50 is a top view showing the gear changing operation to be performed at the time of performing the aligning operation;
FIGS. 51(a) and 51(b) are cross sectional views taken along arrows J--J of FIG. 50;
FIG. 52 is a top view showing the gear changing operation to be performed when the bundle is pushed;
FIG. 53 is an enlarged top view showing a state where the rear end of a sheet and a reference guide (a knurled portion and a guide portion) are in contact when the bundle is pushed;
FIG. 54 is a schematic top view showing a state where the side end of a sheet and a reference guide (a knurled portion and a guide portion) are in contact when the bundle is pushed;
FIG. 55 is an enlarged cross sectional view of the knurled portion;
FIG. 56 is a top view showing a state (the locus) of the corner of a sheet when the sheet is pushed upwards;
FIG. 57 is a top view showing a state (the locus) of the corner of a sheet when the sheet is pushed upwards;
FIG. 58 is a top view showing a state (the locus) of the corner of a sheet when the sheet is pushed upwards;
FIG. 59 is a flow chart showing a control operation for inhibiting the pushing of a bundle when one sheet sorting is performed;
FIG. 60 is a flow chart showing a control operation for inhibiting the operation of pushing the bundle when sheets by a number larger than a predetermined number are sorted;
FIG. 61 is a flow chart showing a control operation for inhibiting the operation of pushing the bundle in a nonbinding sorting mode;
FIG. 62 is a flow chart showing a control operation for inhibiting the operation of pushing the bundle when one sheet is sorted after a plurality of sheets have been sorted;
FIG. 63 is a schematic side view showing a state of a corner of a sheet that is restricted between the bin trays when the sheet is pushed upwards by the reference guide;
FIG. 64 shows a prior art arrangement.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a sheet processing apparatus according to the present invention will now be described with reference to the drawings.
The sheet processing apparatus according to the present invention will now be described with reference to the drawings. FIG. 1 is a schematic view showing the structure of a sheet processing apparatus according to the present invention. In this embodiment, a sheet processing apparatus provided for an image processing apparatus, such as a copying machine, will now be described.
As shown in FIG. 1, the image processing apparatus 1 has the top surface, on which an automatic original-document feeding apparatus 2 for automatically moving the original document is disposed. In the downstream (in the left portion of FIG. 1) of the image processing apparatus 1, a sheet processing apparatus (hereinafter called a "sorter") 11 having a bin trays B (B1, B2, . . . , Bn) is attached.
The image processing apparatus 1 is adapted to a known electrophotographic method, the detailed description of which is omitted here and in which the image of an original document located on a platen glass 3 is, by an optical system (not shown), formed on a photosensitive drum 4; and the image is transferred onto the sheet by a developing unit 5, a transferring electrode 6 and the like; and a fixing unit 7 permanently fixes the image on to the sheet.
(Overall Structure of Sheet Processing Apparatus)
The sorter 11, as shown in FIGS. 2 and 3, has a sorter body 15 comprising a pair of side plates 12, a base 13 and a cover 14, and further comprising a bin unit 17 accommodating a multiplicity of bins B and enabled to be moved vertically along guide rails 16 respectively attached to the sorter body 15.
The sorter body 15 has an introduction port 18 through which sheets S are introduced. A first sheet conveyance passage 19 is formed from the introduction port 18 toward the upper bin unit 17, while a second sheet conveyance passage 20 is branched from the first sheet conveyance passage 19. An upper discharge roller pair 21 for discharging non-sort sheets (sheets not to be classified) is disposed downstream from the first sheet conveyance passage 19. A lower discharge roller pair 22 for discharging sort sheets (sheets to be classified) is disposed downstream from the second sheet conveyance passage 20.
(Shape of Discharge Roller)
The upper discharge roller pair 21, as shown in FIG. 4, has a driving discharge roller 21a and a follower discharge roller 21b that presses the discharge roller 21a. The discharge roller 21a has four cylindrical rollers disposed in the axial direction thereof. Ribs 21c, 21d, 21e and 21f are stood erect on the two end surfaces of each discharge roller 21a.
The discharge roller 21a is so disposed that the sheet always comes in contact with the ribs 21c and 21d or 21e and 21f when the discharge roller 21a and the discharge roller 21b hold the sheet. The reason for this is that, when the sheet S is made to be rigid, a state where the sheet S comes in contact with only the internal rib 21c or 21f of the discharge roller 21a in the axial direction will cause the end of the sheet S to be gradually moved inwards, and thus the end of the sheet S is separated form the discharge roller 21b.
The discharge roller 21b presses each discharge roller 21a in such a manner that the discharge rollers 21a disposed in the central portion in the axial direction are pressed at their central portions; and the discharge rollers 21a disposed in the end portions in the axial direction are pressed at their positions dislocated outwards by about 3 mm from their central portions. The reason for this is that a gap must be maintained between the end of a sheet, which does not simultaneously come in contact with the two end rib portions of the discharge roller, and the nip between the discharge roller 21a and the discharge roller 21b. If a certain gap is not maintained between the end of the sheet and the nip, the end of the sheet and the discharge roller 21b interfere with each other in a case where the sheet S moves in a diagonal direction or the same is moved while being dislocated in the axial direction of the roller, thus causing the sheet S to be damaged or the movement of the sheet S to be made instable.
The right and left ribs 21c and 21d of the discharge rollers 21a disposed in the central portions have the same height, while the ribs 21e and 21f of the discharge rollers 21a disposed in the two end portions in the axial direction are formed such that the outer rib 21e has a lower height and the internal rib 21f has a higher height. Specifically, the ribs 21c and 21d have a height or about 2 mm, the rib 21f has a height of about 2.5 mm, and the rib 21e has a height of about 1.5 mm. The reason why the inner rub 21f is made to be higher than the outer rib 21e, and the rib 21f is made to be somewhat higher than the ribs 21c and 21d is that the degree of the rigidity of the sheet S must be uniform in the axial direction similar to the central portion even if the position, at which the discharge roller 21b presses the discharge roller 21a, is dislocated. If the rigidity of the sheet S is too strong, a trace is sometimes formed on the sheet S. If the rigidity is too weak, the sheet S cannot stably be discharged. Therefore, it is preferable that the state of the rigidity be uniform.
The material of the discharge roller 21a is ABS resin, hard rubber or the like, while the material of the discharge roller 21b is polyacetal resin or the like. Although four discharge rollers 21a and discharge rollers 21b are disposed in the axial direction, the number is not limited to this, and the number may be increased or decreased.
As a result of the foregoing structure, when the sheet S is discharged while being held by the upper discharge roller pair 21, the ribs 21c, 21d, 21e and 21f, which are stood erect on the discharge roller 21a, make rigid the sheet S in the discharge direction. To maintain a gap from the end of the sheet S, the heights of the ribs 21f and 21e formed on the discharge rollers 21a at the two ends in the axial direction are arranged such that the inner rib is made to be high and the outer rib is made to be low so that the rigidity of the sheet S attained at the end of the sheet S can be made uniform even if the discharge roller 21b presses the discharge roller 21a at the outer position from the central position. Therefore, the sheets S can be stacked accurately.
Since the discharge roller 21b presses only the sheet S that is brought into contact with the two end ribs of the discharge rollers 21a at the two ends in the axial direction, undesirable movement of the two ends of the sheet S toward the central portion causing dislocation of the sheet S from the nip between the discharge roller 21a and the discharge roller 21b can be prevented. Thus, problems experienced with the conventional structure such that the end of the sheet cannot be held between the discharge roller 21a and the discharge roller 21b, or the end of the sheet comes in contact with the side surface of the discharge roller 21b and thus the movement is made instable depending upon the size of the sheet, thus causing the diagonal discharge to take place can be prevented. As a result, the discharge operation can be made stable.
At the branched portion between the sheet conveyance passages 19 and 20, there are disposed an introduction roller pair 23 and a deflector 24. When a non-sort mode (a mode in which sheets are not classified) is selected, the deflector 24 is displaced to introduce the sheet S into the first sheet conveyance passage (hereinafter called a "non-sort passage) 19. When a sort mode (a mode in which sheets are classified) is selected, the deflector 24 is displaced to introduce the sheet S into the second sheet conveyance passage (hereinafter called a "sort passage") 20.
The sort passage 20 has a relay roller pair 25 between the introduction roller pair 23 and the discharge roller pair 22, the relay roller pair 25 being disposed at a position that enables the minimum size sheet (the minimum size in the sheet feeding direction), that can be discharged from the main body of the apparatus, can be conveyed.
The sort passage 20 has the leading portion (downstream from the relay roller pair 25) formed into a leading passage 26. The leading passage 26 can be rotated around a drive roller 25a of the relay roller pair 25.
(Leading Passage)
The leading passage 26 is located at an operating position 26a (the position indicated by a continuous line shown in FIG. 3) when the sheet S is conveyed in a usual manner. The lower portion of the leading passage 26 abuts against a pushing mechanism, to be described later, so as to be located. The position of the leading passage 26 can be detected by a detection means 27, such as a microswitch.
The leading passage 26 is pushed to a relief position 26b (a position indicated by an alternate long and two short dashes line shown in FIG. 3) by the pushing mechanism when the stapler, to be described later, is operated. At a position to which the leading passage 26 is raised by a predetermined quantity, there is disposed a detection means 28, such as a microswitch, to detect the leading passage 26 at the foregoing position.
The pushing mechanism, as shown in FIG. 5, comprising an eccentric cam 29a that is rotated by a rotational force transmitted from a drive motor of a sheet conveyance system (not shown) through a one-way clutch; and a rotary damper 29c that is engaged to a sector gear 29b integrally formed with the eccentric cam 29a to supply rotational load. The eccentric cam 29a is not rotated because the drive force is not transmitted through the one-way clutch when the motor is rotated forwards (when the sheet S is conveyed). On the other hand, it is rotated due to the action of the one-way clutch when the motor is rotated reversely (when the conveyance of the sheet S is stopped).
Therefore, the rotation of the eccentric cam 29a when the motor is rotated reversely upwards pushes a rotative roller 26c disposed in the lower portion of the leading passage 26 to a relief position 26b (the position indicated by the alternate long and two short dashes line shown in FIG. 3) (a state 5(a)). when upward pushing by means of the eccentric cam 29a is suspended, the leading passage 26 tends to be moved downwards due to the gravitation. Since the sector gear 29b integrally formed with the eccentric cam 29a is engaged to the rotary damper 29c and thus the rotational load is applied to the eccentric cam 29a which is in contact with the rotative roller 26c (a state shown in FIG. 5(b)), the leading passage 26 is slowly moved downwards due to the rotational load of the rotary damper 29c so as to be rotated to the operating position 26a (the position indicated by the continuous line shown in FIG. 3) so that the leading passage 26 is located (a state shown in FIG. 5(c)).
(Discharge Guide)
Referring to FIG. 47, a plurality of drive discharge rollers 22a and the follower discharge rollers 22b forming the lower discharge roller pair 22 are disposed in the axial direction. Furthermore, discharge guides 170 (an upper discharge guide 170a and a lower discharge guide 170b) forming the sheet conveyance passage connected to the lower discharge roller pair 22 are disposed vertically. In the sort mode, the sheet S conveyed through the discharge guide 170 is, by the lower discharge roller pair 22, discharged and stacked on each bin tray B.
Among the discharge guides 170, in the portions of the lower discharge guide 170b corresponding to the end of the sheet (the two end positions of, for example, A4R-size sheet), there are formed guide portions 171 projecting upwards over the guide surface. The guide portions 171, as shown in FIG. 48(a), project upwards to face the sheet discharge port so as to discharge the sheet S in such a manner that the end of the sheet S, which is discharged as indicated by an alternate long and two short dashes line, is raised. The quantity of raising of the end of the sheet S is determined to be somewhat larger than the usual quantity of warp of the ends of sheets S previously stacked on the bin tray B.
As a result, even if the end of the sheet S discharged to the bin tray B and aligned to the reference position is warped upwards, the end of the sheet S, to be discharged by the lower discharge roller pair 22, is upwards raised by the guide portion 171 when discharged. Therefore, the sheet S can be discharged without interference of the two sheets S. Thus, undesirable movement of the upper most sheet S among the sheets S stacked in the bin in the sheet discharge direction occurring due to the friction between the sheet S, which is being discharged, and the sheets S, which have been stacked in the bin, can be prevented. Therefore, the sheets S can be stacked accurately, and the afterward processing operation can be performed desirably. Since the sheet discharge direction is partially changed (into a direction g), and the overall sheet discharge direction (a direction h) is changed, the quantity of skipping of the sheet S is not changed. Thus, the sheet S can be stacked stably.
The discharge guide 170 is made of a metal plate, such as a steep plate, while the guide portion 171 may be formed, as shown in FIGS. 48(b) and 48(c) by drawing or in such a manner that a cut portion is formed in a portion of the lower discharge guide 170b, followed by being bent upwards. Although two guide portions 171 are formed in the lower discharge guide 170b, the number of the guide portions 171 may be increased to be adaptable to the size and the state of curl of the sheet S. In FIG. 48(b), to enable the guide portion 171 to be brought into contact with only the left end curl portion (a portion i) of the stacked sheet bundle when the sheet S is discharged, the guide portion 171 may be formed only in one left portion 171a of the lower discharge guide 170b.
(Bin Unit)
The bin unit 17 has a pair of bin frames 30 which are disposed in the front portion and the inner portion and each of which consists of an erect portion 30a and a bottom portion 30b. A bin slider 31 is attached to the leading portion of the bottom portion 30b of the bin frame 30; and the erect portion 30a and the bin slider 31 of the bin frame 30 are respectively secured to the leading portion by a bin cover 32.
(Penetration Sensor)
The bin unit 17 includes a penetration sensor 151 for detecting whether or not a sheet S exists on the bin tray in such a manner that the penetration sensor 151 vertically penetrates cut portions 152 of all bin trays formed in the same positions when viewed from a position above each bin tray, and it detects the closing/opening of the cut portion 152 by the sheet S so as to detect whether or not the sheet S exists (see FIG. 2). The penetration sensor 151 is disposed in the region corresponding to the minimum size of the sheet S that is discharged on to the bin tray and as well as in an overlapped portion when the sheets S have been aligned and the same have been pushed forward for the purpose of taking the sheets S. Thus, the penetration sensor 151 is able to detect the sheet S regardless of the position of the sheet S on the bin tray.
(Aligning Rod)
In the inner portion of the base portion of the bin frame 30, there is rotatively supported a rotation central shaft 36 having the two vertical ends secured to the upper arm 34 and a lower arm 35, the rotation central shaft 36 being made rotative by a rotational shaft (not shown) provided for the bin frame 30 and a rotational shaft 32a provided for the bin cover 32. The bin frame 30 has a sector gear 37 that is made rotative around a rotational shaft provided for the bin frame 30. The lower arm 35 is secured to the sector gear 37. A pulse motor 38 is disposed on an alignment unit frame 173 at a position above the bin frame 30, as shown in FIG. 51. The pulse motor 38 rotates the sector gear 37 through a gear train, to be described later. An aligning rod 41 penetrating all cut portions 40 formed in the bin trays B is disposed at the leading portion of the lower arm 35 and the leading portion of the upper arm 34. The aligning rod 41 is so structured that it swings in the cut portion 40 when the sector gear 37 is rotated. Furthermore, the lower arm 35 has a light shield plate 42 so that rotation of the light shield plate 42 integrally with the lower arm 35 turns on or off a home position sensor 43 disposed in the inner portion of the bin frame 30.
(Change in Speed of Aligning Rod between Alignment Mode and Bundle Pushing Mode)
Referring to FIG. 51 (FIG. 51 is a cross section taken along line J--J shown in FIG. 50), the alignment unit frame 173 to which the pulse motor 38 is secured and which has a U-shape cross sectional shape facing side is rotatively supported around a support shaft 175 vertically supported by a support plate 174 and the bin frame 30. As shown in FIG. 50, the alignment unit frame 173 and the support plate 174 are connected to each other by a tension spring 176 so that the alignment unit frame 173 is urged in a direction indicated by an arrow K. On the alignment unit frame 173, there are rotatively supported an aligning gear 177 having a large diameter and a bundle-pushing gear 178 having a small diameter. The aligning gear 177 and the bundle-pushing gear 178 respectively have pulleys 179 and 180 formed integrally in the axial direction.
Referring to FIG. 50, the pulse motor 38 has an output shaft to which a pulley 39 is secured; and a timing belt 181 is arranged to the pulleys 39, 179 and 180 so that the rotation of the pulse motor 38 is transmitted to the aligning gear 177 and the bundle-pushing gear 178. The bin frame 30 has an idler gear 182 that is rotatively supported so that, when the alignment unit frame 173 is rotated, the aligning gear 177 or the bundle-pushing gear 178 is engaged to the idler gear 182. The idler gear 182 is engaged to the sector gear 37 so that the aligning rod 41 is moved in a direction indicated by an arrow L.
An end of a link 184 is connected to a rotation shaft 183 of the bundle-pushing gear 178 provided for the alignment unit frame 173, while another end of the same is connected to a solenoid 185. When the solenoid 185 is turned off, the alignment unit frame 173 is, as shown in FIG. 50, pulled in a direction indicated by an arrow K by a tension spring 176 so that the aligning gear 177 is engaged to the idler gear 182. In the foregoing state, the rotational speed of the pulse motor 38 is reduced to about 1/4.
When the solenoid 185 is turned on, the alignment unit frame 173 is, as shown in FIG. 52, pulled in a direction indicated by an arrow M by the solenoid 185 against the tension spring 176 so that the bundle-pushing gear 178 is engaged to the idler gear 182. In the foregoing state, the rotational speed of the pulse motor 38 is decreased to about 1/30.
When the aligning gear 177, the bundle-pushing gear 178 and the idler gear 182 are changed, and when the solenoid 185 is turned on or off, the rotation of pulse motor 38 is controlled such that it is rotated forwards or rearwards by a somewhat angular degree to prevent defective engagement due to the contact between the gear addendums in the engaged portion. Thus, the engaged gears are slightly rotated forwards or reversely to that the engagement is made reliable.
As shown in FIG. 51, the rotational shafts of the aligning gear 177, the bundle-pushing gear 178 and the idler gear 182 respectively have abutment rollers 186, 187 (not shown) and 188 attached thereto in order to maintain the gear backlash of the aligning gear 177, the bundle-pushing gear 178 and the idler gear 182.
After the sheets S have been discharged to each bin tray, no large pushing force is required to move the aligning rod 41 to align the sheets S to the reference position. Furthermore, the aligning rod 41 must be moved at high speed to complete alignment and relieving of the sheets S in a short time during the discharge of the sheets S. Accordingly, the pulse motor 38 is rotated forwards and reversely in a state where the solenoid 185 is turned off and the aligning gear 177 having a large diameter is engaged to the idler gear 182. Thus, the rotational force is transmitted so that the sector gear 37 is operated to cause the aligning rod 41 to quickly perform the operation for aligning the sheets S with a small pushing force.
When the aligning rod 41 pushes the bundle to take the sheet bundle on each bin toward an operator after the sheet bundle discharged and aligned on each bin tray has been stapled, a large pushing force is required to move the aligning rod 41. To stably move the sheet bundle, it is preferable that the sheet bundle be pushed at relatively low speed. Accordingly, the solenoid 185 is, as shown in FIG. 52, turned on to rotate the pulse motor 38 in a direction indicated by an arrow P in a state where the bundle-pushing gear 178 having a small diameter is engaged to the idler gear 182 to operate the sector gear 37. Thus, the aligning rod 41, at low speed, pushes the bundle of the sheets S with a large pushing force.
As a result of the foregoing structure, the speed of movement of the aligning rod 41 is changed between the operation for aligning the sheets S and the operation of pushing the bundle so that the pulse motor 38 is prevented from being added an excessive load. Therefore, the alignment and bundle pushing operations can be performed reliably. By slightly rotating forwards and rearwards the pulse motor 38 when the aligning gear 177 and the bundle-pushing gear 178 are switched to be engaged to the idler gear 182, gear change can be performed smoothly. Although the movement speed of the aligning rod is, in this embodiment, changed by the gears, the speed may, of course, be changed by a pulse motor or a DC motor.
(Reference Guide)
At a position facing the aligning rod 41, there is disposed a reference guide 55 through a cut portion 153 formed in each bin tray B. The reference guide 55, as shown in FIG. 9, comprises a swing guide 55a, that swings in the direction along the sheet discharge direction; and a swing guide 55b that swings with reference to the swing guide 55a. Thus, the reference guide 55 is arranged to move and swing to be adaptable to various conditions (the side of the sheet S and the like) for aligning the sheets S.
In the reference guide 55, the swing guide 55a is secured to a belt 154b arranged in parallel to a guide rail 154a extending in the sheet discharge direction and supported below the bin cover 32. An end of the belt 154b is set to a motor pulley 154d of a pulse motor 154c secured below the bin cover 32 and another end of the same is set to an idler pulley 154e. Thus, the forward and the rearward rotation of the motor 154c, as shown in FIG. 7, moves the reference guide 55 to a relief position P1, at which the reference guide 55 is relieved to the outside of the bin tray region, a reference position P2, which is used at the time of aligning the sheets S, and an upward pushing position P3 which is used when the sheets S are pushed upward. Referring to FIG. 6, the lower portion of the reference guide 55 is, by a rail member (not shown), enabled to be swung to prevent shakiness in a direction indicated by an arrow 900.
(Shape of Knurled Molding Member)
On the surface of the reference guide 55 that comes in contact with the sheet S, a knurled molding member 55c is attached as shown in FIG. 8(a). Thus, when the reference guide 55 is moved from the relief position P1 to the upward pushing position P3, undesirable hanging of the rear end of the sheet S as shown in FIG. 8(b) is prevented (FIG. 8(b) shows the movement of the sheet S in a case where no knurled molding member is provided).
In the operation for pushing the sheet bundle to be described later, when the sheet S pushed upwards by the reference guide 55 is pushed so as to be taken from a position near the operator, a state, in which the knurled portion of the molding member 55c attached to the reference guide 55 and the side portion of the sheet S are in contact with each other, will be cause the side surface of the sheet S pushed by the aligning rod 41 is caught by the knurled portion and thus the side surface of the sheet S can be damaged. Accordingly, the molding member 55c according to this embodiment, as shown in FIG. 53, comprises a knurled portion 55c1 for guiding the side end of the sheet S when the sheet S is pushed upwards; and a guide portion 55c2 for guiding the side end of the sheet S when the sheet S is pushed outside. Thus, the side end of the sheet S is caused to come in contact with the guide portion 55c2 so as to be separated from the knurled portion 55c1 until the reference guide 55 reaches the upward pushing position P3.
As a result, the guide portion 55c2 is in contact with the side end of the sheet S that is pushed outside in the direction indicated by the arrow by the aligning rod 41 to guide the sheet S and the sheet S is apart from the knurled portion 55c1 by distance LR. Therefore, the knurled portion 55c1 is not caught by the side end of the sheet S so that the side end of the sheet S is prevented from being damaged.
To cause the side end of the sheet S to be apart from the knurled portion 55c1 by the distance LR until the reference guide 55 reaches the upward pushing position P3, the side end of the sheet S is pushed upwards by the guide portion 55c2 in a region that is required to be as follows (see FIG. 53). That is, in a portion of the surface of the bin tray B near a U-shape cut portion 57, if the knurled portion 55c1 guides to cover a portion, in which a corner SK of the sheet S is place on the left stacking surface Ba to the left of the U-shape cut portion 57 as shown in FIG. 53, a portion above the foregoing portion as brought to a state where the sheet bundle is restricted by the stacking surfaces Ba and Bb of the bin tray (see FIG. 63). Thus, it can be pushed upwards by the guide portion 55c2 so that hanging of the side end of the sheet S that is pushed upwards by the guide portion 55c2 as shown in FIG. 8(b) can be prevented. That is, the dimensions of the knurled portion 55c1 and the guide portion 55c2 (M and N shown in FIG. 53) must be determined so as to cause the knurled portion 55c1 to be in contact with the side end of the sheet S to the foregoing position.
The knurled portion 55c1 and the guide portion 55c2 are formed into a molding member 55c formed integrally and enabled to be, by snap fitting, attached to the surface of the reference guide 55 that comes in contact with the sheet S. As a result, the assembling operation and changing operation can be completed easily.
The knurled portion 55c1 has a cross sectional surface that comprises, as shown in FIG. 55, a multiplicity of sharp teeth 55e formed in a direction (the direction indicated by an arrow shown in FIG. 55) in which the sheet S is pushed upwards to catch the end of the sheet S. It is preferable that the knurled portion 55c1 be formed in such a manner that the height h1 of the tooth is about 0.1 mm to about 5.0 mm, the width h2 of the tooth is about 0.1 mm to about 5.0 mm, and the angle of the top surface of the tooth is about 0 deg. ±40 deg. with respect to the horizontal surface. As a result, when the sheet S is pushed upwards, the side end of the sheet S can be caught desirably so that upward pushing of the sheet S is performed reliably.
Although the knurled portion 55c1 and the guide portion 55c2 are formed into the molding member 55c formed integrally, the present invention is not limited to this. A similar effect can be obtained if the knurled portion and the guide portion are individually formed in the reference guide 55. Although the molding member 55c is attached to the surface of the reference guide 55 that comes in contact with the sheet S by snap fitting, the present invention is not limited to this. For example, it may be attached by an adhesive, such as an adhesive tape. Although the knurled portion 55c1 comprises a multiplicity of teeth to catch the side end of the sheet S, the present invention is not limited to this. For example, a frictional member having a friction resistance capable of catching the end of the sheet, specifically, a felt member or a rubber member may be employed to obtain a similar effect.
As shown in FIG. 9, in the reference guide 55, the swing guide 55b is, while being allowed to swing, supported by the swing guide 55a so as to be swung to an alignment reference positions ((1) to (4)) adaptable to the size of the sheet S by a drive mechanism (not shown). The drive mechanism comprises a rotary solenoid or the like that is operated in response to a pulse and that is controlled by a control means to be rotated for a predetermined angular degree in response to a sheet-size signal and a binding-type signal.
(Multiguide)
A multiguide 156 penetrating the cut portion 155 formed in each bin tray B is disposed downstream of the discharge direction for the sheet S from the reference guide 55. The multiguide 156 is, while being allowed to swing, supported in the bin unit 17 so as to be swung to the alignment reference positions ((1) to (5)) corresponding to the size of the sheet S in synchronization with swinging of the swing guide 55b in the reference guide 55. The drive mechanism comprises a rotary solenoid or the like that is operated in response to a pulse and that is controlled by a control means to be rotated for a predetermined angular degree in response to a sheet-size signal and a binding-type signal.
The multiguide 156 is brought to positions (2), (as), (4) and (5) (see FIGS. 9 and 10) to restrict dislocation of the leading portion of large size paper (LDR, A4, A4R, LGL or the like). A case will now be described where it is brought to position (1). The multiguide 156 is brought to position (1) when one or two front portions of small-size paper (A4R, LTR or B5) are bound. In this case, sheets S are aligned by displacing the swing guide 55b to the respective position and the aligning rod 41 is used to align the sheets S. After the sheets S have been aligned, the sheets S are bound as desired (a case where binding has not been performed is permitted) and the front portion of the sheet bundle S is pushed as described later in such a manner that guiding is performed to prevent the corner 995 of the sheet bundle S being caught by the bin slider 31 or the like (see FIG. 39). When the sheets S are again stacked on the bin B in the state shown in FIG. 39, rotation of the sheets S on the bin in a direction indicated by an arrow 996 due to vibration occurring when the bin is shifted causing undesirable movement toward the bin is prevented.
(Alignment of Sheets)
The reference guide 55 and the multiguide 156 change their alignment reference positions to be adaptable to the size of the sheets S when the stapler 56, to be described later, is used to bind two portions or one inner portion in order to maintain uniform or a predetermined length from each binding position to the side end of the sheet S as shown in FIGS. 9 and 10.
That is, two portions are bound, the sheet aligning operation is performed in such a manner that the reference guide 55 is moved to the reference position P2; the swing guide 55b of the reference guide 55 is swung to the alignment reference position ((1), (2) and (as)) corresponding to the size of the sheets S; and the multiguide 156 is moved to the alignment reference position ((1), (2), (3) and (5)) corresponding to the size of the sheets S in synchronization with the movement of the swing guide 55b. When the sheet S has been discharged on to each bin tray, the aligning rod 41 located to face the reference guide 55 is moved in a direction indicated by an arrow 990 so as to be swung to each alignment position that presses the inner end of the sheet S so that the sheets S are aligned. As a result, the distance from each binding position to the two side ends of the sheets S (T1, T2 and T3 shown in FIG. 9) can be maintained to be uniform for each size of the sheets S.
The sheet alignment operation in a case where one inner portion is bound is performed in such a manner that the sheets S are aligned to be made coincide with the inner binding positions in the case of where the two portions are bound. The reference guide 55 is moved to the reference position P2; the swing guide 55b of the reference guide 55 is swung to the alignment reference positions ((2) and (4)) corresponding to the size of the sheets S; and the multiguide 156 is swung to the alignment reference positions ((3) and (4)) corresponding to the size of the sheets S in synchronization with this. After the sheet S has been discharged onto each bin tray, the aligning rod 41 placed to face the reference guide 55 is swung to the alignment position so that the sheets S are aligned. As a result, the distance (T4 and T5 shown in FIG. 9) from the binding position to the side ends of the sheets S can be made to be uniform. Furthermore, one inner portion is bound at the inner position in the case where the two portions are bound so that the necessity of enlarging the cut portion (or individually forming the foregoing cut portion) in the bin tray for binding one inner portion is eliminated. Therefore, the sheets S can be stacked desirably in such a manner that the rigidity of the bin tray is maintained.
The binding position for aligning the sheets S is usually instructed with a signal supplied from an operation panel (not shown) of an image processing apparatus before the image if formed. In a case where stapling is performed after the image has been formed and the sheets S have been sorted on to the bin tray, that is, after all operations have been completed, the binding position for the sheet alignment may be instructed afterwards. The afterward instruction is performed with a signal supplied from the operation panel of the image processing apparatus or a signal supplied from an operation panel 157 disposed near the operator above the sorter 11 (see FIG. 2). As a result, the operationality of the apparatus can be improved and thus a variety of needs of the operator can be satisfied.
(Quantity of Pushing of Aligning Rod)
The aligning rod 41 is swung to the alignment position after the sheets S have been discharged to each bin tray B to cause the sheet ends to abut against the reference guide 55. Furthermore, the aligning rod 41 is swung to the alignment position before the stapling operation using the stapler 56. At this time, the sheet ends have been pushed toward the reference position by the aligning rod 41 with a uniform force, the end of the sheet pushed by the aligning rod 41 is deflected if a small number of sheets are stacked, thus causing the stacking characteristic to deteriorate. The inner binding position can be dislocated when the one inner portion is bound or two portions are bound. Accordingly, this embodiment has a structure such that the quantity of pushing of the sheet ends by the aligning rod 41 is changed to correspond to the binding mode using the stapler 56.
That is, referring to FIG. 49(a), a leaf spring 172 is provided for the support portion for the upper and lower arms 34 and 35 for vertically supporting the aligning rod 41 to urge the aligning rod 41 toward the sheet ends. The sheet bundle discharged on to the bin tray B and caused to abut against the swing guide 55b of the reference guide 55 is aligned by again swinging the aligning rod 41 before stapling is performed. If the binding mode among one front binding (binding position: H1) and two-portion binding is the front binding (binding position: H2), the aligning rod 41 is pushed toward the reference position by about 1 mm (+1 mm from the sheet ends), as shown in FIG. 49(b). Even if the end of the sheet pushed by the aligning rod 41 is deflected at this time, the dislocation of the binding position by the stapler 56 is not affected. Therefore, an excellent binding operation is performed.
If the binding mode is the inner-portion binding or one inner portion binding (binding position: H3) among the two-portion binding modes, the aligning rod 41 is, as shown in FIG. 49(c) stopped at a position of about 1 mm outside the sheet end position and the pushing operation is not performed (-1 mm from the sheet end, the quantity of pushing is minus). The foregoing value may be 0 mm to -1 mm. At this time, the aligning rod 41 does not come in contact with the sheet end and the same is not pushed from the sheet end to the reference position. The quantity of pushing of the aligning rod 41 is changed by controlling the quantity of rotation (the number of pulses) of the pulse motor 38. If the aligning rod 41 is not pushed from the sheet end in the front-portion binding mode among two-portion binding modes, no problem arises.
As a result, the binding position H3 by means of the stapler 56 is not dislocated due to the alignment operation, stapling can be performed at an appropriate position to correspond to the binding mode, the reliability of the apparatus can be improved and the afterward processing function can be performed effectively.
If the number of sheets to be stacked on each bin tray B is small, the stacking characteristic easily deteriorates due to deflection of the ends of the sheets S pushed by the alignment operation by the aligning rod 41. Therefore, the quantity of pushing of the aligning rod 41 may be changed to correspond to the number of sheets S to be stacked. That is, if the number of sheets S to be stacked on one bin is larger than 10, the aligning rod 41 is pushed toward the reference position by about 1 mm over the sheet end position. If the number is 10 or less, the aligning rod 41 is stopped at a positioned of about 0 mm to about 1 mm outside the sheet end position and no pushing is performed.
Although the alignment operation at the time of stacking sheets S has been described, the quantity of pushing of the aligning rod 41 before the stapling operation may be changed depending upon the number of sheets S to be stacked. The quantity of pushing of the aligning rod 41 may be changed between the operation where the discharged sheets S are aligned and the operation where the sheets S are aligned at the time of performing stapling.
The afterward instruction will now be described. If the instruction has been performed before an image is formed, the swing guide 55b and multiguide 156 are moved to predetermined positions; the aligning rod 41 is used to align the sheets S; and the stapling operation is performed.
If the non-binding sorting is instructed from the image processing apparatus having the foregoing structure, for example, an A4R-sheet is processed in such a manner that the positions of the swing guide 55b and the multiguide 156 are different between the one-front-portion binding and the one-inner-portion binding (the aligning positions are different). No problem arises in the case where the non-binding operation is performed regardless of the binding mode. However, if alignment is performed by, for example, one-inner-portion binding (the swing guide 55b is at position (2) and the multiguide 156 is at position (3)) and then one-front-portion binding is instructed afterwards, the front binding operation cannot be performed between the sheets S have been aligned in the inner portion.
Accordingly, the sheet processing apparatus according to this embodiment of the present invention is arranged to align all sheets S at the position for the one-inner-portion binding mode or the two-portion binding mode as shown in FIG. 10 (FIG. 45(a) shows the example of an A4R-sheet). If the foregoing binding mode (the one-inner-portion binding mode or the two-portion binding mode) has been instructed afterwards, the foregoing binding operation is performed at the foregoing positions. If the one-front-portion binding mode has been instructed afterwards, the swing guide 55b and the multiguide 156 at the foregoing alignment positions are changed to the positions corresponding to the one-front-portion binding mode. Then, the aligning rod 41 is used to push all sheet bundles in all bins so as to be swung until the sheet ends abut against the swing guide 55b and the multiguide 156 (FIG. 45(b) shows the case of A4R-sheet). Then, the stapler 56 is used to perform the one-front-portion binding operation after the movement. As a result of the foregoing structure, stapling can be performed at an arbitrary position even if the afterward instruction is performed.
Although the foregoing structure has the arrangement such that the aligning rod 41 is used to move the sheets S to the position for the one-front-portion binding mode if the afterward instruction is performed after the sheets S have been aligned. If the sheets S have been aligned at the one-front-portion binding position and as well as an afterward instruction of one-front-portion binding or two-portion binding is performed, an arrangement may be employed in which the aligning rod 41 is moved to a predetermined aligning position; the sheet bundles in all bins are moved to the predetermined positions toward the aligning rod 41 by the multiguide 156 and the swing guide 55b; and the predetermined binding operation is performed. Since the foregoing structure is arranged in such a manner that the sheets are aligned at the stapling position, the cut portion in the bin for introducing the stapler can be minimized. Therefore, the sheet stacking characteristic can be improved.
(Pushing of Sheet Bundle)
Small size sheets (B5 or A4 sheets) are enabled to be taken from the front portion of the apparatus after the sheets have been aligned by the structure in which the side ends of the sheets are pushed from the surface of the bind tray B. The sheet bundle is pushed by the aligning rod 41 and the reference guide 55.
The sheet bundle, which has been aligned (or stapled by the stapler to be described later), is pushed in such a manner that; initially the reference guide 55, which is in contact with the side end of the sheet at the reference position P2, as shown in FIG. 11(a), moved to the relief position P1 by the pulse motor 154c. At this time, the reference guide 55 is moved in a direction in which the reference guide 55 is moved away from the side end of the sheet bundle (step K). Therefore, the sheet bundle is not dislocated due to the movement.
Then, the aligning rod 41 is moved from the alignment position by a predetermined quantity La (La>K) by the pulse motor 38. The movement of the aligning rod 41 results in the sheets being pressed at the side end thereof. Thus, the sheet bundle is pushed in a direction indicated by an arrow toward the front portion of the apparatus along a stopper 158 by La (position S1 to position S2).
Then, the reference guide 55 relieved to the relief position P1 is, as shown in FIG. 11(b), moved to the upward movement position P3 while pushing upwards the rear end of the sheets. At this time, the rear end of the sheet is supported by the reference guide 55 and the stopper 158 and the side end is supported by the aligning rod 41 so that the positions of the sheets are changed to be inclined on each bin tray B (positions S2 to position S3). The molding member 55c is attached to the surface of the reference guide 55 that comes in contact with the sheet so that the rear end of the sheet is caught by the knurled portion 55c1 so that the sheet is reliably pushed upwards, followed by being separated from the knurled portion 55c1 and comes in contact with the guide portion 55c2 until the guide 55 reaches the upward movement position P3.
In the foregoing state, the aligning rod 41 is, as shown in FIG. 11(c), moved in a direction indicated by an arrow by a predetermined quantity Lb. The cover 14 in front of the sorter 11 has a space X that is sufficiently large to allow the sheet to pass through, and the cover 14 has a guide member 14a for guiding and holding the pushed sheet bundle. Therefore, the side end of the sheet is completely pushed outside the apparatus by the movement of the aligning rod 41 by the quantity Lb (position S3 to position (S4). Since the guide portion 55c2 of the molding matter 55c attached to the reference guide 55 is in contact with the rear end of the sheet and therefore guides the sheet at this time, the sheet can be discharge smoothly without the damage of the end surface of the sheet.
The reference guide 55 at the upward movement position P3 is, as shown in FIG. 11(d), moved to the reference position P2, and the end of the sheet bundle comes in contact with the guide member 14a provided for the cover 14 in front of the sorter 11 so as to be held (position S4 to position S5). As a result, the reference guide 55 and the rear end of the sheet are separated from each other. Therefore, if sheet bundles to be sorted are left after the sheet bundle have been pushed, the vertical movement of the bin tray does not cause contact between the sheet held at position S5 and the molding member 55c provided for the surface of the reference guide 55 that comes in contact with the sheet.
If a predetermined number of bundles have been sorted, the operation of the apparatus is completed here. If bundles to be sorted exist, the residual bundles are sorted on to the sheet bundles (position S5) placed on each bin tray, and the alignment and pushing are performed so that the operation of the apparatus is completed.
Although this embodiment has the structure such that the sheet bundle is brought into contact with the guide member 14a provided for the front cover 14 so as to be held (see FIG. 11(d)), a support portion 164 having the same effect as that of the guide member 14a may be provided for the erect portion 30a in front of the bin unit; and the end of the sheet bundle may be brought into contact with the support portion 164 to attain a similar effect (see FIG. 46).
After the foregoing operations have been completed, if a detection signal supplied from the penetration sensor 151 represents that a sheet exists, the aligning rod 41 maintains the position for holding the sheet bundle shown in FIG. 11(d). As a result, when an operator takes out the sheet bundle from the bin tray, undesirable introduction of the sheet bundle between the bin trays can be prevented. After taking of the sheet bundle has been completed by the operator, the detection signal supplied from the penetration sensor 151 represents that no sheet exits. Thus, the aligning rod 41 is moved from the position for holding the sheet bundle to the home position (the relief position).
(Condition for Relief Position for Aligning Rod)
To prevent introduction of the corner of the sheet in the front portion of the apparatus into the cut portion of the bin tray when the position of the sheet is changed to the inclined state by the reference guide 55 during the sheet-bundle pushing operation, the present invention has a structure such that the corner of the sheet is pushed upwards while being restricted between the bin trays. The structure will now be described with reference to the drawings. FIG. 56 shows a state where a small-size sheet bundle is pushed, and FIG. 57 shows a state where a large-size sheet bundle is pushed.
As shown in FIGS. 56 and 57, the aligning rod 41 pushes inwards the sheet S to the front portion of the apparatus before it moves upward the sheet S. The sheet is pushed inwards to a position (the position out of the cut portion 57 in the bin tray B) to which the sheet is pushed upwards in such a manner that the corner of the sheet is restricted between the bin trays when the sheet is pushed upwards. After the inward pushing operation has been completed, the aligning rod 41 is relieved to a predetermined relief position. The relief position for the aligning rod 41 is determined to a position at which the sheet is pushed upwards in such a manner that the corner SK1 is restricted between the bin trays. Note that the quantity of pushing of the aligning rod 41 and the relief position for the same are determined appropriately to correspond to the size of the sheet intended to be discharged from the space X in the front portion of the apparatus.
Since the aligning rod 41 is moved as described above, the corner SK1 of the sheet S pushed inwards to the front portion of the apparatus is, by the reference guide 55, pushed upwards through a first locus U1, the first support point for rotation of which is position A of the stopper 158 on the bin tray B. Then, it is pushed upwards to the upward movement position P3 through a second locus U2, the second support point for rotation of which the aligning rod 41 relieved to the foregoing position. As a result, as can be understood from the figure, the corner SK1 of the sheet S does not pass through the cut portion 57 in the bin tray B but the same is moved on the surface Ba of the bin for stacking sheets S. Thus, the corner SK1 of the sheet S is pushed upwards while being restricted between the bin trays. As a result, undesirable introduction into the cut portion 57 formed in the bin tray B for moving the reference guide 55 causing bending or breakage of the sheet can be prevented.
Large-size sheets (for example, A4-sheets) among sheets (that can be taken from the front portion) that are pushed upwards by the reference guide 55 are, as shown in FIG. 57, pushed upwards in such a manner that the position A of the inner stopper 158 that comes in contact with the inner corner SK2 of the sheet S is the first support point for the rotation); and the aligning rod 41 moved to the predetermined relief position is the second support point for the rotation so that the corner SK1 of the sheet S is restricted between the bin trays when the sheets S are pushed upwards. Small-size sheets (for example, B5-sheets) are, as shown in FIG. 56, pushed upwards in such a manner that the position A of the central stopper 158 that comes in contact with a portion of the rear end of the sheet serves as a first support point for the rotation and the aligning rod 41 moved to the predetermined relief position serves as a second support point for the rotation. Thus, the sheets are pushed upwards similarly in such a manner that the corner SK1 of the sheet S is restricted between the bin trays. Since the inner corner SK2 of the sheets (regardless of the size) is positioned at the inner cut portion 59 for stapling or above the same when viewed in FIG. 56, the corner SK2 of the sheet is pushed inwards to an inner position i by a distance h (>0) over a line m of the central stopper 158 when the sheets are discharged to the discharge position in the front portion of the apparatus by the aligning rod 41. As a result, even if the aligning rod 41 is relieved to the home position for the following process, undesirable introduction of the corner SK2 of the sheet into the cut portion 59 can be prevented.
A method will now be described with reference to FIG. 58 in which the aligning rod 41 is not used as the second support point for the rotation to prevent the introduction of the corner SK1 of the sheet S into the cut portion 57. After the sheets S have been aligned, the reference guide 55 is relieved to inwards push the sheets S by the aligning rod 41. Since the quantity of pushing is small at this time, and the locus UT of the corner SK3 of the sheet S passes through position SQ, that is, the cut portion 57, a similar problem arises.
Accordingly, sufficient inward pushing of the side end of the sheet to position SW will cause the locus UW of the corner SK1 of the sheet S to pass on the stacking surface Ba of the bin tray. Thus, the foregoing problem can be overcome and the sheet bundle can be taken.
(Inhibition Control of the Sheet-bundle Pushing Operation)
As described above, the operation for pushing the sheet bundle is performed after the sorting and sheet aligning operations (the stapling operation if stapling is performed) have been performed. If a sheet bundle having a thick paper cover (a cover mode) is sorted, the cover is initially sorted. If the cover is counted as one bundle when the foregoing operation for pushing the sheet bundle is performed, alignment with the sheet (copied sheet) to be discharged onto the cover cannot be established. If stapling is performed, a defect takes place during the stapling operation.
If the number of sheets of the sheet bundle discharged onto each bin tray exceeds a predetermined number of sheets after the sheets have been aligned and before the operation for pushing the sheet bundle is performed, the load acting on the aligning rod is enlarged excessively when the foregoing pushing operation is performed even if each bin tray has a sufficient stacking capacity. Thus, there arises a risk that the operation for pushing the sheet bundle cannot be performed smoothly and thus malfunction takes place.
Accordingly, the operation of pushing the sheet bundle by the aligning rod 41 to the front portion of the apparatus (the position at which the sheet bundle is taken) is inhibited by a control means (not shown) under a predetermined condition. Specifically when one sheet is sorted (in a cover mode) or sheets larger than a predetermined number are sorted, the foregoing operation for pushing the sheet bundle is inhibited. Then, the control for inhibiting the operation for pushing the sheet bundle in the one-sheet sorting mode and the mode in which sheets larger than a predetermined number are sorted will now be described with reference to flow charts shown in FIGS. 59 and 60.
<One-Sheet-Sorting Mode (Cover Mode)>
As shown in FIG. 59, in step S11 initially the operator sets an original document to the apparatus for automatically feeding the original document shown in FIG. 1, and the operator inputs the number of sheets of the original document, the desired number of copies, and the modes through the operation portion (not shown) of the image processing apparatus, followed by depressing the copy-start key. Note that the number of the sheets of the original document may be caused to be recognized by a control circuit of the body of the image processing apparatus by idly circulating the original document by the apparatus for automatically feeding the original document.
In steps S12 and S13 sheets discharged from the body of the image processing apparatus are sorted. If the number of the set number of bundles is larger than the number of the bin trays, the bundles are initially sorted by the number which is the same as the number of the bin trays. If the number is smaller the number of the bin trays, the bundles are sorted. Whenever the first sheet is sorted on each bin tray, the foregoing alignment of the sheet is performed.
In step S14 whether or the set mode is the staple mode is discriminated. If the stapling mode is set, the operation proceeds to steps S15 and S16 in which the stapling operation, to be described later, is performed. If the mode, in which stapling is not performed, has been set, the operation proceeds to step S17.
In step S17 whether or not one sheet sorting has been performed is discriminated. If the one sheet sorting operation has not been performed, the operation proceeds to steps S18 and S19 in which the reference guide 55 and the aligning rod 41 are operated so that the operation for pushing the sheet bundle is performed. Thus, the sheet bundle is pushed to the front portion of the apparatus at which the sheet bundle is taken. If one-sheet sorting is performed, the foregoing operation for pushing the sheet bundle is inhibited (step S20) and the operation proceeds to step S21. As a result, even if the cover is sorted in the cover mode, the operation for pushing the sheet bundle is not performed. Even if a sheet, on which an image has been copied, is sorted, alignment with the cover can be performed.
In step S21 whether or not a predetermined number of bundles have been sorted is discriminated. If a predetermined number of bundles has been sorted, the operation of the apparatus is completed (step S22). If bundles to be sorted exist, the operation returns to step S12 in which the foregoing operation is repeated until the bundles are sorted.
<Sorting of Sheets Larger than Predetermined Number>
As shown in FIG. 60, in step S31 initially the operator sets an original document to the apparatus for automatically feeding the original document shown in FIG. 1, and the operator inputs the number of sheets of the original document, the desired number of copies, and the modes through the operation portion (not shown) of the image processing apparatus, followed by depressing the copy-start key. Note that the number of the sheets of the original document may be caused to be recognized by the control circuit of the body of the image processing apparatus by idly circulating the original document by the apparatus for automatically feeding the original document.
In steps S32 and S33 sheets discharged from the body of the image processing apparatus are sorted. If the number of the set number of bundles is larger than the number of the bin trays, the bundles are initially sorted by the number which is the same as the number of the bin trays. If the number is smaller the number of the bin trays, the bundles are sorted. Whenever the first sheet is sorted on each bin tray, the foregoing alignment of the sheet is performed.
In Step S34 whether or the set mode is the staple mode is discriminated. If the stapling mode is set, the operation proceeds to steps S35 and S36 in which the stapling operation, to be described later, is performed. If the mode, in which stapling is not performed, has been set, the operation proceeds to step S37.
In Step S37 whether or not a predetermined number of bundles have been sorted is discriminated (the number of sheets that can be pushed by the aligning rod). If the number of the sheets is smaller than the set number, the operation proceeds to steps S38 and S39 in which the reference guide 55 and the aligning rod 41 are operated so that the operation for pushing the sheet bundle is performed so that the sheet bundle is pushed to the front portion of the apparatus at which the sheet bundle is taken. If the number of the sheets is larger than the set number, the foregoing operation for pushing the sheet bundle is inhibited (step S40), and operation proceeds to step S41. As a result, if the number of the sheets discharged onto each bin tray is larger than a predetermined number, the foregoing operation for pushing the sheet bundle is inhibited even if each bin tray has a stacking capacity. Thus, malfunction can be prevented.
The number of the sheets is the number of sheets instructed from the operation portion (not shown); the number of sheets calculated by multiplying the number of sheets of the original document instructed from the operation portion and the number of copies (the maximum number is the number of the bin trays); or the number (counted number) of sheets detected by a sheet detection sensor provided for the sheet passage. In step S37 whether or not the number of the sheets is larger than a set number is discriminated.
In step S41 whether or not a predetermined number of bundles has been sorted is discriminated. If the predetermined number of bundles has been sorted, the operation of the apparatus is completed (step S42). If bundles to be sorted exist, the operation returns to step S32 in which the foregoing operation is repeated until no residual bundle exists.
Although the foregoing control operation is arranged in such a manner that the operation for pushing the sheet bundle is automatically inhibited under a certain condition, the present invention is not limited to this. For example, another structure may be employed in which an operation portion (not shown) for inputting a signal for inhibiting the operation for pushing the sheet bundle is provided; and a user inputs the signal from the operation portion to inhibit the operation for pushing the sheet bundle. Thus, the user is able to arbitrarily inhibit the operation for pushing the sheet bundle.
<Non-Binding Sorting Mode>
If non-binding sorting is performed except the foregoing operation, there is sometimes a case where binding is desired by an operator after sorting has been completed. If afterwards binding is performed, it can be instructed by a setting means (not shown). If the operation for pushing the sheet bundle is automatically performed after the non-binding sorting operation has been completed in a case where afterward binding is required, there arises a problem in that the operator cannot select binding.
Accordingly, it is effective to inhibit operation for pushing the sheet bundle under the foregoing condition. The foregoing case will now be described with reference to a flow chart shown in FIG. 61. As shown in FIG. 61, in step S51 initially the operator sets an original document to the apparatus for automatically feeding the original document shown in FIG. 1, and the operator inputs the number of sheets of the original document, the desired number of copies, and the modes through the operation portion (not shown) of the image processing apparatus, followed by depressing the copy-start key. Note that the number of the sheets of the original document may be caused to be recognized by a control circuit of the body of the image processing apparatus by idly circulating the original document by the apparatus for automatically feeding the original document.
In steps S52 and S53 sheets discharged from the body of the image processing apparatus are sorted. If the number of the set number of bundles is larger than the number of the bin trays, the bundles are initially sorted by the number which is the same as the number of the bin trays. If the number is smaller the number of the bin trays, the bundles are sorted. Whenever the first sheet is sorted on each bin tray, the foregoing alignment of the sheet is performed.
In step S54 whether or the set mode is the staple mode is discriminated. If the stapling mode is set, the operation proceeds to steps S55 and S56 in which the stapling operation, to be described later, is performed. Then, the operation proceeds to steps S57 and S58 in which the reference guide 55 and the aligning rod 41 are operated so that the foregoing operation for pushing the sheet bundle is performed so that the sheet bundle is pushed to the front portion of the apparatus, at which the sheet bundle is taken. If the mode, in which stapling is not performed, has been set, the operation for pushing the sheet bundle is inhibited (step S59) and the operation proceeds to step S60. As a result, the problem can be prevented that takes place in a case where stapling is intended to be performed by the afterward instruction after the non-bound sheet bundle has been sorted.
In step S60 whether or not the afterward instruction of the staple mode has been performed is discriminated. If the afterward instruction has been performed, the operation returns to step S55 in which the foregoing operation is repeated. If the afterward instruction has not been performed, the operation proceeds to step S61.
In step S61, whether or not a predetermined number of sheet bundle has been sorted is discriminated. If the predetermined number of sheet bundle has been completed, the operation of the apparatus is completed (step S62). If bundles to be sorted exist, the operation returns to step S51 in which the foregoing operation is repeated until the bundles are sorted.
<Sorting of Plural Sheets (Front Cover and Rear Cover Mode)>
The foregoing control operation is arranged in such a manner that the operation for pushing the sheet bundle is inhibited when one sheet is sorted. However, in a case where one rear cover is intended to be provided, if the operation for pushing the sheet bundle is performed before the one rear cover is sorted after a plurality of copied sheets have been sorted on the one sorted front cover though the operation for pushing the sheet bundle is inhibited, defective alignment of the sheets and malfunction take place.
Accordingly, it is effective to inhibit the operation for pushing the sheet bundle under the foregoing condition. The foregoing operation will now be described with reference to a flow chart shown in FIG. 62. As shown in FIG. 62, in step S71 initially the operator sets an original document to the apparatus for automatically feeding the original document shown in FIG. 1, and the operator inputs the number of sheets of the original document, the desired number of copies, and the modes through the operation portion (not shown) of the image processing apparatus, followed by depressing the copy-start key. Note that the number of the sheets of the original document may be caused to be recognized by the control circuit of the body of the image processing apparatus by idly circulating the original document by the apparatus for automatically feeding the original document.
In steps S72 and S73 sheets discharged from the body of the image processing apparatus are sorted. If the number of the set number of bundles is larger than the number of the bin trays, the bundles are initially sorted by the number which is the same as the number of the bin trays. If the number is smaller the number of the bin trays, the bundles are sorted. Whenever the first sheet is sorted on each bin tray, the foregoing alignment of the sheet is performed.
In step S74 whether or the set mode is the staple mode is discriminated. If the stapling mode is set, the operation proceeds to steps S75 and S76 in which the stapling operation, to be described later, is performed. If the mode, in which stapling is not performed, has been set, the operation proceeds to step S77.
In step S77 whether or not one sheet is sorted on to the sorted sheet bundle (the front cover and rear cover mode) is discriminated. If the one-sheet sorting is not performed, the operation proceeds to steps S78 and S79 in which the reference guide 55 and the aligning rod 41 are operated so that the operation for pushing the sheet bundle is performed. Thus, the sheet bundle is pushed to the front portion of the apparatus, at which the sheet bundle is taken. If the one-sheet sorting is performed, the operation for pushing the sheet bundle is inhibited (step S80) and the operation proceeds to step S81. As a result, even if one front cover is sorted in the front cover and rear cover mode and then a plurality of sheets are sorted, the operation for pushing the sheet bundle is not performed. Therefore, even if the rear cover is sorted after the sorting operation has been performed, alignment with the sheet bundle can be performed.
In step S81 whether or not a predetermined number of bundles has been sorted is discriminated. If the predetermined number of bundles has been sorted, the operation of the apparatus is completed (step S82). If bundles to be sorted exist, the operation returns to step S71 in which the foregoing operation is repeated until no residual bundle exists.
In a case where one sheet is sorted after a plurality of sheets have been sorted and then a plurality of sheets are sorted in order to provide a guard sheet, it is effective to inhibit the operation for pushing the sheet bundle. As a result, the defective alignment of the sheets and malfunction can be prevented which have been experienced with the conventional technique.
<Bin Tray>
<Forming of Bin Tray into Warped Shape>
The rigidity of the bin tray B to be accommodated in the bin unit 17 deteriorates due to the cut portion and the like, and therefore it is deflected due to the weight of the stacked sheets and the like. Thus, there arises a risk that the surface for stacking the sheets cannot be maintained to be horizontal. If the bin is warped downwards, the sheets S discharged through a discharge roller pair 951, as shown in FIG. 12(d) in a direction indicated by an arrow 952, are brought into contact with a bin warped downwards (alternate long and one short dash line Bd), thus causing a defect to take place in the discharge operation. Accordingly, some bins have somewhat upward warped portions to prevent the same being warped downwards. However, the bin tray B according to the present invention is intended to prevent its deflection due to the deterioration in the rigidity thereof by compensating the degree of deflection (downward warp) due to the deadweight by previously upwards warping (upward warp) the shape thereof when it is accommodated in the bin unit 17, as shown in FIG. 12(a). As a result, when the bin tray B is accommodated in the bin unit 17, the surface for stacking the sheets is made to be horizontal as shown in FIG. 12(b). Therefore, an excellent sheet stacking characteristic can be obtained.
(Sharp Form of Stopper)
Since the bin tray B is set while being inclined in such a manner that the upstream portion thereof is made lower than the downstream portion thereof in the sheet discharge direction when it is accommodated in the bin unit 17, a stopper 158 is provided in the most upstream position for the purpose of maintaining the end of the sheet. The stopper 158 is formed to have a sharp angle θ that is made from the sheet stacking surface (see FIG. 13). As a result, upward projection of the end of the sheet warped after the discharge can be prevented. In a case where the sheet bundle is stapled by the stapler 56 and as well as a guide surface 113a of an upper guide member 113 provided on the upper portion of the stapler 56 is used to downwards push raised point S' at the rear end of the sheet S toward the stacking surface B' of the bin B, the point S' tends to be moved in a direction indicated by an arrow 901. Since the surface 158' of the stopper 158 is formed into a shape that is widened in the downward direction as compared with the right angle stopper, the rear end S' of the raised sheet S can be smoothly pushed upwards and the sheets S can be stapled without disorder of the sheet bundle (see FIGS. 13 and 41(a)). It is preferable that the angle θ be 90 degrees or smaller, more preferably about 80 degrees.
(Friction Member Provided for Stopper)
On the erected surface (the surface that comes in contact with the sheet) of the stopper 158, there is bonded a friction member 159 in order to prevent the end of the sheet being moved upwards. The friction member 159, as shown in FIG. 13, comprises a felt-like member that restricts the movement in the direction indicated by an arrow 905 with respect to the upward movement of the sheet. Specifically, the friction member 159 is made of suede or sponge having a high coefficient of friction. The friction member 159 bonded to the erected surface of the stopper 158 is provided in such a manner that it is continuously attached in the erected surface of the stopper 158 over the widthwise direction of the sheet or it is divided into sections to be bonded. Note that it is preferable that the friction member 159 be a one-way restriction member that can be moved in a direction indicated by an arrow 906 and that cannot be moved in a direction indicated by an arrow 905. For example, it may be a member like a hair-transplant member having downward hairs (see FIG. 41(b) or a ratchet-shape member (see FIG. 41(c)).
(Hooked Portion of Upper Portion of Stopper)
A hooked portion 158a for restricting the end of the sheet warped upwards after it has been discharged is formed in the upper portion of the stopper 158. The hooked portion 158a according to this embodiment is, as shown in FIG. 6, formed in substantially the central portion of the bin tray B in the direction (a direction perpendicular to the sheet discharge direction) of the width of the sheet or formed continuously to cover the overall surface. As a result, the hooked portion 158a is able to correspond to sheets having a variety of sizes. The hooked portion 158a prevents a corner 158b of the sheet adjacent to the stopper, as shown in FIG. 11(d), being placed on the upper surface of the stopper (see FIG. 40(a)). Thus, it is effective to stack a plurality of portions S1, S2, . . . , Sn on the bin (See FIG. 40(b)).
(Shape of Bin Roller)
Each bin tray B accommodated in the bin unit 17 has, at the two ends of the base portion thereof, bin rollers 44a, as shown in FIG. 6. Furthermore, trunnions 44b each having a diameter smaller than that of the bin roller 44a are rotatively disposed on the outside of the bin rollers 44a. The bin rollers 44a and the trunnions 44b project over a slit 45 formed in an erected portion 30a of the bin frame 30, and the bin rollers 44a are introduced in such a manner that they are stacked on the guide rail 16 (see FIGS. 13 and 14).
As shown in FIG. 15(a), each bin roller 44a has, on the outer surface thereof, a projection 44a1 in the upper portion; and a recess 44a2 formed in the lower portion thereof so that the projection and the recess of the upper and lower bin rollers 44a are engaged to each other so as to be secured. The bin roller 44a has a member (not shown) for restricting the rotation in the circumferential direction so that the position in the circumferential direction is maintained as illustrated. As a result, the bin roller 44a is stacked on the guide rail 16 so that the bin B supported by a lead cam surface 51' of a lead cam 51 receives (arrow g1) the load of all upper bins by an upper surface 44a' of the bin roller, as shown in FIG. 15(a). If the projection and recess are not provided, the lowermost bin B is deflected, as shown in FIG. 15(c). However, the engaged portion realized by the projection and the recess receives (arrow g2) the force of deflecting as shown in FIG. 15(a) so that deflection (downward warp) of the bin tray due to the weight is prevented.
Angles α and β made between the projection 44a1 and the recess 44a2 are determined to be substantially 45 degrees to easily introduce the projection 44a1 and the recess 44a2 when the separated bin roller 44a is brought to the contact state (see FIGS. 42(a) and (b)). It is preferable that the angles be 45 deg.±30 deg.
Although the foregoing embodiment according to the present invention has the structure such that the substantially -45 degrees projections and recesses on the outer surface of the bin roller 44a, the projection and the recess may be formed to comprise a substantially right-angle portion 161 and an inclined portion 162, as shown in FIGS. 43(a). As a matter of course, a projection and a recess having the substantially right-angle portion 161 and an rounded portion 163 may be employed to obtain a similar effect.
The lowermost bin roller 441 is brought into contact with the lower guide roller 46a supported by the erected portion 30a of the bin frame 30, while the uppermost bin roller 44a is brought into contact with the upper guide roller 47a supported by the erected portion 30a of the bin frame 30. Thus, each bin tray B is supported by the bin unit 17 in such a manner that the bin intervals are the same as the diameter of the bin roller 44a.
Thus, the upper guide roller 47a and the lower guide roller 46a are introduced into the guide rail 16 so that the bin unit 17 is able to move vertically along the guide rail 16. Furthermore, trunnions 46b and 47b each having a diameter smaller than that of each guide rollers 46a and 47a are rotatively disposed on the outsides of the guide rollers 46a and 47a. The trunnions 46b and 47b are guided by a lead cam 51 to enable the bin unit 17 to be moved vertically.
By making the diameter of the trunnion 44b (and trunnions 46b and 47b) to be smaller than the diameter of the bin roller 44a (and guide rollers 46a and 47a), when the lead cam 51 is used to vertically move each bin tray B maintained at predetermined intervals, that are the same as the diameter of the bin roller 44a, the operation of scooping the trunnion 44b by a spiral cam surface of the lead cam 51 can be performed smoothly (or easily introduced). That is, the vertical movement of the bin tray B by the lead cam can be performed smoothly.
At positions of the front and rear side plates 12 that faces the lower discharge roller pair 22, there are disposed cam shaft holders 48 (see FIG. 2), as shown in FIGS. 2 and 3. Between the cam shaft holder 48 and the base 13, there is rotatively disposed each lead cam shaft 50 through a bearing 49 that bears the thrust lead. Above the lead cam shafts 50, there are disposed lead cams 51 each having a spiral cam surface, while a sprocket 52 is secured below the same. Between the sprocket 52 and a shift motor 53, a chain 54 is arranged so that the lead cam 51 is rotated forwards or rearwards by the shift motor 53 that is selectively rotated forwards or rearwards.
The lead cam 51 is so disposed as to face the lower discharge roller pair 22 disposed in the substantially central portion of the sorter body 15. The lead cam 51 places, on the spiral cam surface thereof, the trunnion 44b of each bin tray B, that is moved to a position to oppose the lower discharge roller pair 22, to guide the trunnion 44b. Thus, the bin roller 44a disposed coaxial with the trunnion 44b is moved vertically along the guide rail 16 (see FIGS. 13 and 14). For example as shown in FIG. 13, on rotation of the lead cam 51 in a direction indicated by an arrow A moves the trunnion 44b23 to an intermediate position of the lead cam 51 (the position 44b22). A further rotation moves the same to a position (position 44b21) that passes the lead cam 51. Between the bin tray B2, that has received the sheet from the lower discharge roller pair 22 at a position that faces the lower discharge roller pair 22 and the bin trays B1 and B3 disposed above and below the bin tray B2, opening portions X1 and X2, each of which is wider than the interval of the other bin trays B, are formed.
(Paper Retaining Means)
After the sheet has been discharged onto the bin tray B2 that has the opening X1 the bin try is usually moved upwards or downwards. In a case where the bin tray is moved upwards, the bin tray B2 is moved upwards to the position of the bin tray B1 shown in FIG. 13 so that a narrow opening X3 is formed. In a case where the bin tray is moved downwards, the bin tray B2 is moved downwards to the positions B3 and B4. When the bin tray has been moved downwards to the position B4, the bin tray forms a narrow opening X4. If a sheet is discharged in such a manner that the end is projected upwards, this sheet interrupts the discharge of the next sheet. Therefore, sheets cannot accurately be discharged and stacked. If the in tray once forms the narrow opening X3 and X4, the projecting end of the sheet is pressed. Thus, the sheet does not interrupt the sheet to be discharged next. The bin trays B1, B2, . . . , Bn when the bin trays whose moving direction is switched, that is, when the bin trays B1, B2, B3, . . . , Bn are used, temporarily form wide opening portions. Thus, the sheet S is undesirably discharged before a narrow opening is formed after the sheet has been discharged.
Accordingly, the present invention comprises a paper retaining means 160 for pressing the sheet on the bin tray in the opening X1 and X2. Thus, even if the direction, in which the bin tray is moved, is changed, the end of the sheet can be held.
In a so-called group mode, in which a plurality of sheets are continuously discharged on to one bin tray, the opening in the bin tray is not narrowed and therefore the next sheet can be discharged. Therefore, the paper retaining means 160 is operated whether the sheet is discharged so as to hold the end of the sheet.
In a case where a sorter is connected to an image processing apparatus in which is sheet is curled considerably, if the end of the sheet is temporarily held by the narrow opening, the end of the sheet is sometimes moved upwards due to vibrations occurring when the bin tray is moved. Accordingly, the present invention has a structure such that, if a sheet, that is curled considerably, is used, the bin tray is moved to operate the paper retaining means 160 before the next sheet is discharged so as to hold the end of the sheet.
As for the sheet in the opening X1 (between the bin trays B1 and B2) of the bin tray B2 and the sheet in the opening X2 (between the bin trays B2 and B3) of the bin tray B3, if the end of the sheet is warped and moved upwards after the sheet has been discharged, the upper and lower jaws of the stapler 56, that is introduced into the openings X1 and X2, undesirably outwards pushes the sheets on the bin trays B2 and B3. In this embodiment, the paper retaining means 160 holds the end of the sheet between the stapler 56 is introduced into the openings X1 and X2.
The paper retaining means 160, as shown in FIG. 16, comprises a solenoid 160a, an arm 160b that is rotated when the solenoid 160a is turned on/off, a sliding member 160c that is moved vertically when the arm 160b is rotated, an upper retaining member 160d and a lower retaining member 160e that are rotated when the sliding member 160c is moved vertically.
Referring to FIG. 16, reference numeral 160f represents a support frame that has a bottom to which the solenoid 160a is secured and which rotatively supports the arm 160b. Furthermore, the support frame 160f has, in the side portion thereof, the retaining members 160d and 160e that are rotatively supported; and the sliding member 160c that is slidably supported by a screw. A portion of the support frame 160f and a portion of the sliding member 160c are connected to each other by a spring 160g so that the sliding member 160c is pulled downwards.
In the paper retaining means 160, when the solenoid 160a is turned on, the sliding member 160c in the state shown by bin trays depicted with the dashed and dotted lines in FIG. 17 is moved upwards against the force of the spring 160g optical system that the retaining members 160d and 160e are rotated to the retaining positions. Thus, as shown in FIG. 16, the ends of the sheet bundles on the bin trays B2 and B3 are held. If the solenoid 160a is turned off, the state shown in FIG. 16 is brought to a state in which the restoring force of the spring 160g downwards moves the sliding member 160c so that the retaining members 160d and 160e are rotated to the relief positions. Thus, as shown by the bin trays depicted with solid lines in FIG. 17, holding of the end of the sheet bundles on the bin trays B2 and B3 is suspended.
Since the paper retaining means 160 holds the sheets in the openings X1 and X2 on the bin trays B2 and B3, sheet jamming occurring due to the end of the sheet mode upwards on the bin tray, and undesirable outward pushing of the sheets on the bin trays B2 and B3 by the upper and lower jaws of the stapler 56, that is introduced into the openings X1 and X2, can be prevented so that the sheet discharge conveyance operation and the stapling operation are performed smoothly.
The paper retaining means 160 having the foregoing structure is disposed adjacent to the stapler 56 so as to be moved in the direction of the width of the sheet (in a direction perpendicular to the sheet discharge direction) together with the stapler 56 (see FIG. 20). As a result, the end of the sheet is always held at a position near the stabling position. Therefore, the effect of outwards pushing the sheet by the stapler 56 can be further improved.
In this embodiment, the paper retaining means is used to improve the conveying and stacking characteristics and to prevent outward pushing by the stapler 56. Individual paper retaining means may be provided for the respectively purposes.
(Stapler)
The sorter body 15 has an electric stapler 56 disposed to face the bin B that opposes the lower discharge roller pair 22 so as to bind the sheets accommodated in the bin B2. A stapler moving mechanism, to be described later, performs one-front-portion binding (binding position: H1) of sheets S1 and S2 discharged onto the bins, two-portion binding of sheet S1 (binding positions: H2 and H3) and one-inner-portion binding of sheet S2 (binding position: H3).
At the positions in each bin tray B at which stapling is performed, cut portions 57, 58 and 59 to prevent interference with the stapler 56 are formed.
The stapler 56 is also to move in directions indicated by arrows Y1 and Y2 shown in FIG. 18 and slides at the respective positions (56a/56c) to perform stapling.
(Stapler Apparatus)
A stapler apparatus 60 will now be described with reference to FIGS. 19 and 20. The direction of the stapler 56 shown in FIG. 19 shows a state where the binding positions H2 and H3 shown in FIG. 18 are stapled.
The stapler 56 is secured to a first support member 62 having a support shaft 62 secured thereto. A second support member 63 rotatively supports the support shaft 61 of the first support member 62 by holes in the two support portions 64a and 64b.
A spring member 65 is disposed at an end of the first support member 62, while another end of the same is secured to the second support member 63. Thus, the first support member 62 is urged on the second support member 63 around the support shaft 61 in a direction indicated by an arrow C and it is located by a stopper 66.
On a portion opposing the spring member 65 and the support shaft 61, a link 68 connected to a solenoid 67 secured to the second support member 63 is connected.
In a lower portion of the second support member 63, a guide member 71, that is engaged in a swinging manner to two rails 70a and 70b and that movably supports the second support member 63 in the direction indicated by an arrow D.
The support holes in the guide member 71 are formed such that the hole to be engaged to either rail (70a or 70b) is formed into a circular hole and the hole to be engaged to the other rail is formed into an elongated round hole so that shakiness of the second support member 63 including the stapler 56 in directions indicated by arrows F1 and F2 is prevented.
The second support member 63 has a rack gear 72, while the third support member 69 has a motor 74 secured to thereto, the motor 74 having a pinion gear 73 to be engaged to the rack gear 72.
When the motor is rotated, the second support member 63 is moved in a direction indicated by an arrow D while being guided by the rails 70a and 70b.
Guide members 77a and 77b that are engaged to two rails 76a and 76b provided for a fourth support member 75 and that movably supports the third support member 69 in a direction indicated by an arrow F2 are disposed below the third support member 69. Hole to be engaged to the rails 76a and 76b of the guide members 77a and 77b are formed such that either hole is formed into a circular hole 78 and the other hole is formed into an elongated round hole 79 so as to prevent shakiness of the third support member 69 in directions indicated by arrows F1 and D.
A motor 81 for rotating a belt pulley 80 and an idler pulley that rotates around a shaft 82 are secured to the fourth support member 75. A belt 84 is arranged between the two pulleys 80 and 83, a portion of the belt 84 being secured to a secured portion 85 that is a potion of the third support member 69. Reference numeral 86 represents a bent tensioner. When the motor 81 is rotated, the belt is rotated so that the third support member 69 is moved in a direction indicated by an arrow F2 while being guided by the rails 76a and 76b.
To detect waiting positions for the first, second, and the third support members 62, 63 and 69, detection means 87, 88 and 89 each comprising a microswitch are provided (see FIG. 20).
The fourth support member 75 is supported by an acculied rail 90 and the like so as to be made detachable with respect to the body of the apparatus when maintenance is performed, the fourth support member 75 being usually located and mounted by a locking mechanism, to be described later, in the sorter body 15.
(Locking Mechanism for Stapler)
The fourth support member 75 is drawn toward (to the left portion of FIG. 20) the operator by the operator when stable cartridge to be mounted on the electric stapler 56 or when jamming of a staple is overcome. If the fourth support member 75 can be drawn in a state where the electric stapler 56 is located at an arbitrary position, the electric stapler 56 and the stopper 158 of the bin interfere with each other and are damaged. Accordingly, a front locking mechanism is provided to prevent drawing of the fourth support member 75 only in a case where the third support member 69 having the stapler 56 mounted thereon is located at the home position.
The front locking mechanism will now be described. Referring to FIG. 20, a lock pin 15a projects over the sorter body 15. A locking member 75a that can be engaged to the locking pin 15a is rotatively attached to the fourth support member 75. The locking member 75a is, by a stopper 75b, usually secured to a position, to which it is engaged to the locking pin 15a. The stopper 75b is structured such that the engagement is suspended when the third support member 69 is moved to the home position. Referring to FIGS. 44(a) and (b) that are views when viewed in a direction indicated by an arrow G shown in FIG. 19, the stopper 75b is secured to the fourth support member 75 in such a manner that the stopper 75b can be swung in the direction indicated by the arrow. If the third support member 69 is not in contact, the stopper 75b is located to engage the locking member 75a as shown in FIG. 44(a). If the third support member 69 has been moved to the home position and brought into contact with the stopper 75b, the engagement of the locking member 75a is suspended. A handle 75c is coaxially provided with the rotational center of the locking member 75a. A twisted coil spring 75d is secured to the handle 75c and the stopper 75b. Therefore, when the handle 75c is pulled in the direction indicated by the dashed-line arrow, the engagement between the stopper 75b and the locking pin 15a as, through the twisted coil spring 75d, suspended.
Therefore, if the third support member 69 is not located at the home position, pulling of the handle 75c cannot rotate the locking member 75a because of the stopper 75b. If the handle 75c is pulled to suspend the engagement of the stopper 75b when the third support member 69 has been moved to the home position, the locking member 75a is rotated to suspend the engagement with the locking pin 15a. Thus, the fourth support member 75 can be drawn to a position in front of the sorter body 15. When the fourth support member 75 is mounted on the sorter body 15, the handle 75c is mounted while being gripped and then the handle 75c is released, the elastic force of the twisted coil spring 75d causes the locking member 75a to be engaged to the locking pin 15a. When the fourth support member 75 is moved, the stopper 75b engages and locks the locking member 75a. Therefore, undesirable drawing of the fourth support member 75 by an operator regardless of the position of the stapler 56. Therefore, the safety and the reliability can be improved.
When the fourth support member 75 is mounted on the sorter body 15, the weights of the electric stapler 56 mounted on the fourth support member 75, the first, second and the third support members 62, 63 and 69 for supporting the electric stapler 56 cause the fourth support member 75 to be brought into contact with the inner end of the sorter body 15, thus causing the foregoing elements to be moved toward inside of the apparatus due to inertia. Therefore, there arise a risk that the electric stapler 56, the leading end passage 26 and the stopper 158 interfere with each other and they are broken. Accordingly, an inner locking mechanism for locking the moving mechanism of the third support member 69 is provided.
The inner locking mechanism will now be described. Referring to FIG. 20, a small-diameter gear 81b of a two-speed gear is engaged to a motor gear 81a attached to the motor 81. A ratchet 81d is attached to a large-diameter gear 81c in such a manner that the ratchet 81d is capable of engaging to the same. The ratchet 81d has a structure that it can be engaged to and separated from the large-diameter gear 81c by a solenoid 81e. The solenoid 81e is usually turned off, and the ratchet 81d and the large-diameter gear 81c are, in the foregoing state, engaged to each other. Only when the motor 81 is turned on, the solenoid 81e is turned on so that the engagement is suspended.
As a result, the belt pulley 80 is not rotated. Therefore, even if the fourth support member 75 is drawn from the sorter body 15 or it is mounted on the sorter body 15, the third support member 69 is not moved. In particular, undesirable inward movement of the third support member 69 having the electric stapler 56 mounted due to inertia when the fourth support member 75 is mounted can be prevented, the undesirable inward movement taking place due to inertia. Therefore, the safety and reliability can be improved.
The specific structure and basic operation of the stapler 56 will now be described. Referring to FIG. 21, the stapler 56 is formed into an alligator-shape and comprises a forming portion 101 in the upper portion thereof; and a staple table 102 in the lower portion thereof. A staple cartridge 103 is detachably mounted in the stapler 56, the staple cartridge 103 including about 5,000 staples H connected in the form of a plate. The plate-like staples H loaded into the staple cartridge 103 are downwards urged by a spring 104 disposed to the uppermost portion of the staple cartridge 103 so that a feeding roller 105 disposed in the lowermost portion is given conveyance force. Each of the staples H fed by the feeding roller 105 is formed into a U-shape facing side when the forming portion 101 is swung.
When a staple motor 106 is rotated, the forming portion 101 causes an eccentric cam gear 107 to be rotated. Thus, an eccentric cam 108 integrally formed with the eccentric cam gear 105 swings the forming portion 101 toward the staple table 102 as indicated by an arrow so that the forming portion 101 performs a clinching operation (a stapling operation).
A state where the staple cartridge 103 has no staple H can be detected by a reflection-type sensor 109 disposed in the lower portion of the staple cartridge 103. The timing, at which the final staple H is detected, is arranged in such a manner that a state where the number of the staples is as expressed by: number (n) of the bin trays B×the number (2) of portions to be stapled, that is, a state where 2n staples exist, can be detected. As a result, if the staple is wanted during the stapling operation, the subject job can be completed.
Detection of jamming of staples H (clogging of a staple) to be fed by the staple cartridge 103 will now be described with reference to FIGS. 22 and 23. Referring to FIG. 22, a cord 106a for supplying an operation electric current is connected to the staple motor 106, the cord 106a having an electric-current sensor (an abnormality detection means) 106b serving as a load detection means for detecting the flowing electric current.
FIG. 23 shows the waveform of an electric current that flows in the staple motor 106 during one stapling process detected by the electric current sensor 106b.
Referring to FIG. 23, W1 indicates the waveform realized when the staple H has been usually ejected to pass through the sheet bundle S and the staple has been bent and the sheet bundle S has been fixed; and W2 indicates the waveform realized when idle stapling (although the stapler 56 has been operated, no staple H has been ejected) has been performed. Since no load acts when the staple H penetrates the sheet bundle S and when the staple H is bent, the level of the electric current is lowered. W3 indicates the waveform when a defective stapling has been performed or a staple jamming has taken place. In the foregoing case, an excess load is usually generated and the level of the electric current is raised extremely.
Therefore, when the level of the electric current is near I0 (the initial value), a discrimination can be made that the stapling operation is being performed normally. If I>I0+C (C represents scattering), a discrimination can be performed that jamming of a staple, defective stapling, or a mechanical problem of the stapler 56 has occurred. If I<I0-C, a discrimination can be made that idle stapling has been performed.
The staple-less state or the staple-jam state of the stapler 56 are respectively displayed on a staple-less display portion (abnormal display means) 15b and a staple-jam display portion (abnormal display means) 15c formed in the portion of the sorter body 15 adjacent to an operator. If the stapler 56 has encountered the staple-less state, the staple-less display portion 15b is flickered. If the stapler 56 has encountered the staple-jam, the staple-jam display portion 15c flickers. Thus, the foregoing problems are notified to the operator.
(Paper Detection Means Provided for Stapler)
As shown in FIGS. 21 and 25, the forming portion 101 and the staple table 102 respectively comprise an upper guide member 113 and a lower guide member 114. The upper guide member 113 is provided with a prism 110, while the lower guide member 114 is provided with a light emitting device 111 comprising an LED or the like; and a light receiving device 112 comprising a phototransistor or the like. The light emitting device 111 and the light receiving device 112 detect whether or not a sheet S exists between the forming portion 101 of the stapler 56 and the staple table 102 so as to prevent idle stapling that is performed by the stapler 56. If the stapler 56 performs the idle stapling operation, the staple H is used wastefully and the idly ejected staple H is dispersed in the apparatus. Thus, the foregoing problems can be prevented.
As shown in FIG. 25, the detection by means of the sheet detection sensor is performed in such a manner that light emitted by the light emitting device 111 is reflected by the prime 110 so as to be detected by the light receiving device 112. Thus, light emitted by the light emitting device 111 is shielded by the sheet S so that whether or not a sheet S exists is detected. If the sheet S has been detected by the sheet detection sensor provided for the upper and lower guide members 113 and 114, the sheet S can reliably by stapled due to the movement of the stapler 56. Thus, idle stapling can be prevented.
As a result of the foregoing structure, a sheet S is detected when the stapling operation is performed within the width of the stapler 56. Thus, a space required to provide a detection means for detecting sheet S individually from the stapler 56 can be eliminated. The width of a cut portion required to be formed in the bin tray B can be minimized so that deterioration in the alignment characteristic of the sheet S and the strength of the bin tray B are prevented. Even if the reverse side (facing the light emitting device and the light receiving device) is black, the existence of the sheet can reliably be detected.
Referring to FIG. 21, the upper guide member 113 and the lower guide member 114 are respectively attached to the forming portion 101 and the staple table 102. The upper guide member 113 and the lower guide member 114 act in such a manner that a tapered surface 114a of the lower guide member 114 is introduced to a portion below the bin tray B when the stapler 56 is moved to a stapling position 56c to staple the sheets S so as to move the staple 56 on to the staple table 102. As a result, the position of stapling the sheet S is determined. The upper guide member 113 guides the stapler 56 into the stapling position 56c between the forming portion 101 and the staple table 102 in such a manner that the end of the contact of sheets stacked on the bin tray B with the guide surface 113a, which causes the stacking characteristic and the aligning characteristic to deteriorate, is prevented.
The guiding operation to be performed by the upper and lower guide members 113 and 114 will now be described. Referring to FIG. 26, when the stapler 56 is moved so the stapling position 56c, the upper paper end Sa of the sheet bundle S indicated by an alternate long and one short dash line is downwards restricted along the tapered surface (the guide surface) 113a of the upper guide member 113 so as to be guided between the upper guide member 113 and the bin tray B as indicated by a dashed line. Then, the bin tray B is gradually moved upwards by the lower guide member 114, and the stapler 56 is further moved so that the bin tray B is supported by the staple table 102. As a result, the stapling position is determined and the stapling operation by the forming portion 101 is performed.
As a result of the foregoing structure, the stapling operation is performed in such a manner that the sheet bundle S is initially introduced between the stapler 56 and the bin tray B by the tapered surface 113a of the upper guide member 113 and the stapling operation can be performed smoothly without deterioration in the sheet stacking characteristic and the aligning characteristic while preventing dislocation of the stapling position. Since the upper guide member 113 holds the end of the sheet and guides the introduction, the stapler 56 can be moved to the stapling position 56c in such a manner that the contact to the end of the sheet that causes the stacking characteristic to deteriorate can be prevented. Thus, the end of the sheet can smoothly be introduced.
The stapling operation of the stapler 56 will now be described specifically. Referring to FIG. 27, the plate-like staples H accommodated in the staple cartridge 103 are, one by one, fed by the feeding roller 105 to a staple bending block 115. Thus, the leading staple H is held in a holding groove 115a of the staple bending block 115. The eccentric cam gear 108 is rotated so that the forming portion 101 is moved downwards to the operation position. As a result, as shown in FIG. 27(b), a drive mechanism (not shown) downwards move a driver 116 so that the plunger 116a is moved downwards. At this time, a pushing claw 116b formed in a portion of the plunger 116a pushes the bending block 117 formed into a U-shape acing side to press the upper surface of the staple bending block 115. The staple H held in the holding groove 15a of the staple bending block 115 is bent into a U-shape facing side, as shown in FIG. 27(a).
The plunger 116a is further moved downwards so that the pushing claw 116b is separated from the bending block 117 formed into a U-shape facing side. Thus, only the plunger 116a is pushed downwards to reach the tapered portion of the staple bending block 115. While pushing aside the staple bending block 115 to a position (in a direction indicated by a dashed-line arrow) indicated by an alternate long and a short dash line, only the leading staple H formed into the U-shape facing side is sheared by a staple shearing member 118 to inject the staple H into the sheet S. Then, the staple H is pushed against the staple table 102 so that the sheet S is stapled. When the further rotation of the eccentric cam gear 108 moves the forming portion 101 to the upper waiting position, the driver 116 is pulled upwards to that the plunger 116a is moved upwards to be restored to the waiting position. Thus, one process of the stapling operation is completed.
(Stable Cartridge)
The structure of the staple cartridge 103 and a method of loading the staple H to be accommodated in the stable cartridge 103 will now be described. The staple cartridge 103, as shown in FIG. 28, comprises an integrally-formed box-like transparent case having an opened bottom and made of plastic or resin. A spring 104 is attached to the upper surface of the staple cartridge 103 to downwards urge the staple H loaded in the staple cartridge 103. The staple H loaded in the staple cartridge 103 is fastened by a fastening means, such as a clicking member, so that the staple H is not dropped through the opening.
A plurality of the staples H are connected to be formed into a plate-like shape, and a plurality of the plate-like structures are stacked before they are loaded into the staple cartridge 103. Before the staples H are loaded, a plurality of the plate-like structures are stacked and held by a wrapping paper 119 in such a manner that the two sides ends are held in the form of a U-shape facing side, and a tape 120 is wound around the plate-like structures. A handle 120a is projected over the tape 120 so that separation is easily performed by pulling the handle 120a.
An arrow 103a indicating the loading direction for the staple H is formed on one side surface of the staple cartridge 103. The arrow 103a can be formed by printing or embossing the case. Also the side surface of the wrapping paper 119 for wrapping the staples H has an arrow 109a that indicates the loading direction for the staples H. The reason for this is that, if the staples H are loaded into the staple cartridge 103 inversely in longitudinal direction or the sides, the stapling operation cannot be performed effectively. Thus, the foregoing problems can be prevented.
When a state where no staple H is in the staple cartridge 103 is detected by the reflection-type sensor 109 disposed in the lower portion of the staple cartridge 103, the operator draws the fourth support member 75 from the sorter body 15 as shown in FIG. 20, and upwards removes the staple cartridge 103 mounted on the stapler 56, as shown in FIG. 21. As shown in FIG. 28, the staples H wrapped by the wrapping paper 119 are loaded into the staple cartridge 103 against the force of the spring 104 in such a manner that the arrows 119a and 103a are made coincide with each other. Then, the handle 120a is pulled to peel off the tape 120 that bundles the staples H. Thus, the loading operation is completed. Then, the staple cartridge 103 accommodating the staples H is again mounted on the stapler 56, and the fourth support member 75 is mounted on the sorter body 15. Thus, the operation is completed.
As a result of the foregoing structure, loading is performed such that the arrow 103a formed on the side surface of the stable cartridge 103 and the arrow 109a formed on the wrapping paper 119 that is warping the staples H are made coincide with each other. Thus, the operator is able to prevent erroneous loading of the staples H inversely in the longitudinal direction or the sides. Thus, sheets S can effectively be stapled.
As shown in FIG. 29, the first support member 62 for supporting the stapler 56 has the cam 62a formed integrally. The plate cam 121 is secured to the frame (not shown) of the sorter body 15. The stapler 56 is set to a position, at which the first support member 62 is pulled by the spring member 65 to correspond to the one-front-portion binding position, that is, to a position (the home position) at which the leading portion diagonally faces the inner portion of the apparatus.
If the stapler 56 encounters jam of a staple, the handle 75c is gripped to draw the fourth support member 75 toward the front portion of the apparatus (the left portion of FIG. 20). Thus, the cam 62a is initially brought into contact with a tin portion 121a of the plate cam 121. As the stapler 56 moves in a direction indicated by the arrow, the cam 62a is brought into a thick portion 121b through the inclined cam surface. The first support member 62 is rotated counterclockwise around the support shaft 61 against the elastic force of the spring member 65 so that the clinching portion of the stapler 56 is rotated in a direction toward the front portion. When the fourth support member 75 has been accommodated in an inner portion (in the first portion of FIG. 20), the cam 62a is initially in contact with the thick portion 121b of the plate cam 121. As the stapler 56 is moved, the first support member 62 is rotated clockwise around the support shaft 61 due to the elastic force of the spring member 65. After the accommodating operation has been completed, it is brought into contact with the thin portion 121a and the stapler 56 is returned to the home position.
As a result of the foregoing structure, since the clinching portion of the stapler 56 is located in a position adjacent to the operator when the fourth support member 75 has been drawn, the operator is able to excellently recognize the staple jam state and therefore the operator is able to easily jam overcoming operation. By using the support shaft 61 of the first support member 62 for use in the stapling operation, such as the one-front-portion binding and two-portion binding operations as the rotational shaft for the staple jam overcoming operation, the necessity of providing a rotational shaft or the like for the stapler 56 can be eliminated. Therefore, the jam overcoming operation can be simplified. Since the stapler 56 can be rotated in synchronization with the drawing and accommodating operations of the stapler unit, excellent operationality can be realized, and the staple jam overcoming operation can be completed quickly.
Although this embodiment has the structure such that the first support member 62 is rotated in synchronization with the drawing and accommodating operations of the fourth support member 75, the first support member 62 is not required to be moved in synchronization with the operation of the fourth support member 75. For example, another structure may be employed in which the first support member 62 is eccentrically supported around the support shaft 61; when the stapler 56 is at the home position, the first support member 62 is secured by a securing member, such as a claw, and the foregoing securing state is suspended by a button or the like after the fourth support member 75 has been removed from the body of the apparatus so that the first support member 62 is rotated around the support shaft 61 due to the dead weight to cause the clinching portion of the stapler 56 to face the front portion of the apparatus. A structure may be employed in which the cam formed on the first support member 62 is brought into contact with the frame of the sorter body in the accommodation state so that the first support member 62 is rotated in the reverse direction, and securing to the securing member is again realized at the position at which the stapler 56 is returned to the home position.
The stapler apparatus 60 has the foregoing structure. The image processing apparatus 1 and the sorter 11 respectively provided with control apparatuses (a CPU) 1A and (a CPU) 11A to control the operations and passing (see FIG. 1).
Since this embodiment has the foregoing structure, the sheet S discharged from the image processing apparatus, such as a copying machine, is, through an introduction port 18, guided by the deflector 24 that is displaced to correspond to the non-sort mode (a mode in which sheets are not classified) and the sort mode (a mode in which sheets are classified) so as to be introduced into the first sheet conveyance passage 19 or the second sheet conveyance passage 20.
(Binding Operation)
The binding operations in a plurality of bins B will now be described with reference to flow charts shown in FIGS. 34 to 38.
<One-Front-Portion Binding>
The binding operation in a plurality of bins B is performed such that the binding operation is performed in the bin B to which the sheets have been finally discharged and accommodated (S113) to obtain the most significant effect.
Initially, the operation to be performed in the case where the one-front-portion binding (binding position: H1) operation is performed will now be described. Referring to FIG. 34, the second support member 63 is, as described above, moved together with the stapler 56 on the first support member 62 so that the stapler 56 is moved from the waiting position 56a to the stapling position 56c. When the operation of stapling the first bin has been completed, the motor 74 is rotated counterclockwise (S117). Then, the stapler 56 is not returned to the position 56a, but it is moved to the intermediate waiting position 56b, and the rotation of the motor 74 is stopped (S119). The foregoing intermediate waiting position 56b is detected by the detection means 91 (S118) (see FIGS. 3 and 30).
In response to a bin-shifting completion signal (S120), sheets in the second bin are subjected to a process such that the stapler 56 is, by the foregoing drive means, moved from the intermediate waiting position 56b to the stapling position 56c. After the stapling operation has been completed, the stapler 56 is returned to the intermediate waiting position 56b. In response to a signal representing the completion of the sequential operations of the stapler 56, a next bin shifting operation is performed, and the operation is repeated. Thus, the stapling operation is automatically completed. After the stapling operation in the final bin has been completed, the second support member 63, first support member 62 and the stapler 56 are returned so that the stapler 56 is returned from the stapling position 56c to the waiting position 56a.
As a matter of course, the required member of shifting of the bins at the time of performing the automatic stapling operation is repeated by the number of bin shifting times at the time of performing the sorting operation.
The distance L1 of movement of the stapler 56 from the stapling position 56c to the intermediate waiting position 56b is shorter than distance L2 of movement from the stapling position 56c to the waiting position 56a (see FIG. 19). The reason for this is that the distance (L1), for which the stapler 56 is relieved when the stapling operation is continuously performed, is minimized so far as the interference with the bin is prevented at the time of shifting the bin. Therefore, the time required to perform the reciprocating operation can be shortened and thus the time taken to complete the stapling operation can be shortened.
<Two-Portion Binding>
Referring to FIGS. 35 and 36, when a signal indicating the two-portion binding operation has been supplied from the control means (S201), the solenoid 67 is turned on (S202) so that the first support member 62 is, together with the stapler 56, rotated counterclockwise around the support shaft 61 so as to be located (at the position indicated by the alternate long and two short dashes line shown in FIG. 31). The completion of the rotation is detected by the detection member 92 (S203). Whether or not the second support member 63 and the third support member 69 are at the waiting positions is detected by the detection means 88 and 89 (S204 and S206). If they are not at their waiting positions, they are returned to the waiting positions (home positions) (S205 and S207).
At the substantially the same time as the foregoing operation, the motor 81 is rotated counterclockwise (S208) so that the third support member 69 is moved from the position 69a to the position 69b, and the motor 81 is stopped (S210).
The position 69b of the third support member 69 is detected by the detection means 92 (S209).
The motor 81 may comprise, for example, a DC motor, and its rotation may be detected by the detection means 93. A stepping motor or the like may be employed so as to be stopped after the movement by a predetermined distance from the detection means 89 that detects the waiting position of the third support member 69. In the foregoing case, the detection means 93 also serves as a means for detecting the stop position.
At the substantially the same time as the foregoing operation, the leading passage 26 in the state detected by the detection means 27 (S211) moved from the usable position 26a (the position indicated by a continuous line shown in FIG. 3) to the relief position 26b (alternate long and two short dashes line shown in FIG. 3) when the drive motor (not shown) of the sheet conveyance system is rotated to rotate the eccentric cam 29a of the foregoing pushing mechanism.
If reaching of the leading passage 26 to the relief position 26b has been detected by the detection means 28 (S213), the drive motor (not shown) is stopped (S214), and the leading passage 26 is maintained at the stopped position.
When the detection means 93, 92, 28 and 88 have supplied signals representing that all elements have been moved to predetermined positions to the control means, the control means, similarly to the one-front-portion binding operation, transmits a signal that permits the movement to the stapling position of the second support member 63 (S215) so that the motor 74 is rotated clockwise (S216). Thus, the stapler 56 is moved from the intermediate waiting position 56 to the stapling position 56c. The detection means 94 performs the detection operation (S217), and then the motor 74 is stopped (S218). Then, staple H is injected at the stapling position H2 for the sheet S (S219) (see FIGS. 31 and 32).
If the detection means 28 does not detect the leading passage 26, that is, if the leading passage 26 has not been moved to the relief position (alternate long and one dashed line shown in FIG. 3), the movement of the second support member 63 is inhibited.
In the foregoing operation, the relief position 26b for the leading passage 26 is determined to a position at which interference can be prevented when the stapler 56 is moved to the stapling position 56c. Since the stapler 56 is operated in such a manner that its respective positions are confirmed by the detection means 28, 93, 92 and 88 (in particular, by the detection means 28), the interference between the stapler 56 and the bin B and the leading passage 26 can be prevented. The movement of the leading passage 26 and the movements of the first support member 62 and the third support member 69 are performed during a period in which the first support member 62 is detected by the detection means 88. Therefore, if the stapler 56 is at the waiting position waiting position 56a, any process may be performed previously or the processes may be performed simultaneously.
Thus, the stapling operation by the stapler 56 is completed.
In a case where one bin is processed (S220), the stapler 56 is moved to the intermediate waiting position 56b because of the same reason as that for the foregoing process, the motor 74 is rotated counterclockwise (S225). After the detection means 91 has detected the stapler 56, the motor 74 is stopped (S227), followed by restoring the stapler 56.
Then, the motor 81 is rotated counterclockwise (S228), and the third support member 69 is moved to the position 69c. The position 69c of the third support member 69 is detected by the detection means 95 (S230) (see FIG. 33).
At the foregoing position, the second support member 63 is moved, and the motor 74 is rotated clockwise (S231) so that the stapler 56 is moved from the intermediate waiting position 56b to the stapling position 56c. After the detection means 94 has performed the detection (S232), the motor 74 is stopped (S233). The staple H is injected to the binding position H3 which is one of the two-portion binding positions (S234). Since binding in one bin is performed (S234), the motor 74 is rotated counterclockwise (S226) to move the staple 56 from the stapling position 56c to the waiting position 56a. After the detection means 88 has performed the detection (S337), the motor 74 is stopped (S338). Thus, binding in one bin is completed.
When the detection means 88 has detected that the second support member 63 is at the waiting position, the drive motor (not shown) of the sheet conveyance system is rotated reversely (S239) so that the leading passage 26 is returned to the usable position 26a (the position indicated by the continuous line shown in FIG. 3). The returned leading passage 26 is detected by the detection means 27 (S240). Thus, the drive motor is stopped (S241).
The operation of binding to be performed in a plurality of bins B will now be described.
Initially, the third support member 69 is moved to the position 69b, and stapling of the stapling position H2 in the final bin is performed (the stapler 56 is moved from the waiting position 56a to stapling position 56c).
In steps S201 to S220, the stapler 56 is moved from the stapling position 56c to the intermediate waiting position 56b by counterclockwise rotating the motor 74 (S221). After the detection means 91 has performed the detection (S222), the motor 74 is stopped (S223).
When shifting of the bins has been completed similarly to the foregoing process (S224), the foregoing operation (intermediate waiting position 56b--stapling position 56c--intermediate waiting position 56b) is repeated so that stapling is performed. Thus, stapling at position H2 of the sheets in the bins, the number of which is the desired number of copies, is completed.
At the position of the in at which stapling at the stapling position H2 is performed, the third support member 69 is moved to the position 69c (S220 to S230) similarly to the foregoing process.
At the foregoing position, the stapler 56 is moved from the intermediate waiting position 56b to the stapling position 56c so that stapling is performed (S231 to S232). Then, the motor 74 is rotated counterclockwise (S242) to move the stapler 56 to the intermediate waiting position 56b. After the detection means 91 has performed the detection (S243), the motor 74 is stopped (S244) to return the stapler 56.
Then, the bin is shifted in a direction opposing the direction, in which the bin has been shifted (S245), and a similar operation (intermediate waiting position 56b--stapling position 56c--intermediate waiting position 56b) is repeated with shifting the bin so that stapling is performed (S231 to S234).
After stapling at the position H3 has been completed in the final bin (the bin in which the stapling at position H2 has been first performed), the stapler 56 is returned to the waiting position 56a so that two places stapling in all bins is completed (S226, S237 and S238).
The third support member 69 is moved from the position 69c to the position 69a at a predetermined timing. If the fact that the stapler 56 is at the waiting position 56a, that is, the fact that the second support member 63 is at the waiting position has been detected by the detection means 88, the leading passage 26 is returned to the usable position 26a (the position indicated by the continuous line shown in FIG. 30). The position 26a is detected by the detection means 27 (S239 to S241).
If the detection means 88 has not detected the second support member 63, movement of the leading passage 26 to the usable position 26a is inhibited.
Referring to FIG. 3, as a matter of course, the detection means 27 and the stapler 56 are disposed not to interfere with each other in the thrusting direction (a front portion of FIG. 3).
<One-Inner-Portion Binding>
If a signal representing the one-inner-portion binding operation (binding position H3) at which sheet S2 is stapled as shown in FIG. 33) has been supplied from the control means (S301), the solenoid 67 is turned on similarly to the foregoing two-portion binding operation (S302). The stapler 56 is brought to a state shown in FIG. 33 (the foregoing position is detected by the detection means 92 (S303)).
Similarly, the initial position for each process is detected by the detection means 89 and 88 (S304 and S306). If the positions have not been detected, the stapler 56 is returned to the waiting position (S305 and S307), and the third support member 69 is moved to the position 69c by counterclockwise rotating the motor 81 (S308). The foregoing position is detected by the detection means 95 so that the motor 81 is stopped (S310).
Also the leading passage 26 is moved to the relief position 26b by rotating the drive motor (not shown) of the sheet conveyance system in a state where the detection means 27 has detected the same (S311) similarly to the two-portion binding operation. The detection means 28 detects it (S313), and the drive motor is stopped (S314).
The operation order of the leading passage 26 and the operations of the first, second and the third support members 62, 63 and 69 may be determined arbitrarily.
Similarly to the foregoing operation, when the detection means 95, 92, 88 and 94 have confirmed all operation positions, a signal permitting the movement is transmitted (S315), and the second support member 63 is moved to the stapling position by rotating the motor 74 clockwise (S316). The stapler 56 is moved from the waiting position 56a to the stapling position 56c. When the detection means 94 has performed the detection (S317), the motor 74 is stopped (S318), stapling at the stapling position H3 is performed (S319). In a case of a one-bin process (S320), the motor 74 is rotated counterclockwise (S321) to move it to the waiting position 56a. After the detection means 88 has performed the detection (S322), the motor 74 is stopped (S323), and thus the stapling operation is completed. If the detection means 28 has not detected it, that is, if the leading passage 26 has not been moved to the relief position 26b, movement of the second support member 63 to the sheet stapling position is inhibited.
If the detection means 88 has detected that the second support member 63 is at the waiting position, the drive motor (not shown) of the sheet conveyance system is rotated reversely (S323) so that the leading passage 26 is returned to the usable position 26a (the position indicated by the continuous line shown in FIG. 3). After the detection means 27 has performed the detection (S324), the drive motor is stopped (S325).
If the detection means 88 has not detected the second support member 63, the movement of the leading passage 26 to the usable position 26a is inhibited.
The stapling operations in a plurality of bins B will now be described.
Similarly to the foregoing process, the third support member 69 is moved to the position 69c, and the leading passage 26 is moved to the relief position 26b. Then, similarly to the one-front-portion binding operation, the stapler 56 is moved from the waiting position 56a to the stapling position 56c so that stapling at the stapling position H3 is performed (S301 to S320). Then, the motor 74 is rotated counterclockwise (S326), followed by returning the stapler 56 to the intermediate waiting position 56b at which it can be detected by the detection means 91 (S327). Then, the motor 74 is stopped (S328).
After sheets in the first bin have been stapled at the position H3, simultaneously with the completion of shifting of the bin (S329), the movement of the stapler 56 (intermediate waiting position 56b--stapling position 56c) and the stapling operation are repeated. After stapling of a predetermined number of bundles has been completed (S316 to S320 and S326 to S329), the stapler 56 is returned to the waiting position 56a (S321 to S323).
Similarly to the foregoing process, when the detection means 88 has detected the stapler 56 at the waiting position 56a, the leading passage 26 is returned to the usable position 26a (the position indicated by the continuous line shown in FIG. 3) (if the detection means 88 has not detected it, the movement of the leading passage 26 is inhibited). Also the third support member 69 is returned to the position 69a (S324 and S325).
Thus, the stapling operation is performed in the case of the one-front-portion binding operation, the two-portion binding operation, and the one-inner-portion binding operation to staple on and a plurality of sheet bundles.
The stapling mode may be an afterward stapling operation in which a stapling start button (not shown) is used after sheets have been distributed and stacked on the bins due to the sorting operation; or a stapling operation in which stapling is automatically started after sorting has been completed.
The foregoing operation may, of course, be performed in a group mode (a mode in which the copies of the same original document are classified and stacked on one bin).
Although the invention has been described in its preferred form with a certain degree of particularly, it is understood that the present disclosure of the preferred form can be changed in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed. | A sheet post processing apparatus includes at least one sheet receiving tray for accommodating sheets; a sheet discharging device for discharging sheets to the said sheet receiving tray; a sheet processing device for processing sheets accommodated on the sheet receiving tray; a reference member for guiding edges of the sheets on the sheet receiving tray and for functioning as a reference for alignment of the sheets to a reference position; an aligning member movable to a predetermined alignment position to urge the sheets on the receiving tray to the reference member; a device for changing a reference position of the reference member to make constant a distance from an edge of the sheet to a position where the sheets are processed by the sheet processing device. | 1 |
FIELD OF THE INVENTION
This invention relates to an extendable surface which can serve as a protective weather shield and more particularly to a surface which can be deployed from a compact, retracted position to an extended position as desired.
BACKGROUND OF INVENTION
Electrical junction boxes such as those used for telecommunications, cable television, control systems and power distribution are often mounted outside where they are constantly exposed to the elements. Such exposure is normally not a problem for the boxes or their contents as the boxes are designed to be weather proof. However, it is often necessary to perform maintenance on or make modifications to the contents of such boxes. For example, to add new lines to a telephone system or to trouble shoot the system for problems, the junction box must be opened and its contents exposed to the weather. If there is rain or snow during servicing, the internal components of the box can be damaged or rendered inoperable if the water is allowed to contact the exposed components. For example, water can cause short circuits in telephone line connectors which disable individual phone lines; it can also cause surge protectors to malfunction and thereby compromise the safety and electrical protection of the entire system.
Currently, technicians servicing junction boxes carry an umbrella which they use to shield themselves and the box when working out of doors during inclement weather. This solution is impractical because the technician typically must hold the umbrella with one hand and work on the box with the other, reducing the efficiency of the technician and increasing fatigue. This solution can be dangerous when the technician must work on a ladder to access the box. Clearly there is a need for an improved means for protecting the contents of an electrical junction box from precipitation when the box is out of doors and being serviced.
SUMMARY AND OBJECTS OF INVENTION
This invention provides an extendable surface which can be mounted above an outdoor junction box containing electrical equipment which is adversely affected by water. The extendable surface is normally stowed in a compact, retracted position and is manually deployed to an extended position when required to shield the contents of the open box from rain, sleet or snow.
The extendable surface comprises a plurality of triangular leaves hingedly mounted one above another for rotation about an axis through the apex of each leaf. In the retracted position the leaves are arranged one atop the other in substantially overlapping relation, and in the extended position the leaves are arranged adjacent to one another to form the extended surface. The leaves are manually rotatable about the apex axis between the retracted and extended positions.
Each leaf has an inside edge and an outside edge terminating at the apex of each leaf. The inside edges of the leaves comprise those edges which are closest to the surface or structure on which the extendable surface is mounted when the extendable surface is in the retracted position. The outside edges on each leaf are arranged respectively opposite the inside edges on each leaf.
The plurality of leaves includes a first leaf and a last leaf, and may also comprise one or more intermediate leaves arranged in between the first and last leaves. The first leaf has a hook on its outside edge, and the last leaf has a hook on its inside edge. Intermediate leaves, if present, will have hooks on both their inside and outside edges. The hooks are interengagable with one another, the outer hook of one leaf interengaging the inner hook of the leaf arranged below it when the leaves are rotated from the retracted to the extended position. The hooks cooperate to keep the leaves arranged adjacent to one another when the leaves are rotated into the extended position.
Preferably, the first leaf is arranged uppermost of the leaves and has a mounting flange extending from its inside edge. The mounting flange is arranged at a right angle to the plane of the first leaf and is used to mount the extendable surface onto a fixed structure. The last leaf is arranged lowermost of the leaves and has a handle extending from its outer edge, the handle affording a place for manually gripping the last leaf in order to rotate the leaves between the retracted and extended positions.
To prevent water from accumulating on the extendable surface at least one leaf, and preferably all of the leaves, have a lip positioned on the third edge extending between the inside and outside edges. The lip comprises a surface segment which extends at an angle downwardly from the plane of the leaves and allows water to run off the extendable surface.
To prevent water from leaking through the extendable surface when the surface is in the extended position the hooks on each leaf are configured as continuous curved extensions of the edge on which each hook is positioned. Each hook is preferably completed by reverse bends which causes each terminal edge portion to project substantially parallel to the plane of its leaf. The hook on the outside edge of each leaf is curved downwardly toward the leaf arranged immediately below while the hook on the inside edge of each leaf is curved upwardly toward the leaf immediately above. In the extended position a hook on the outside edge of a leaf interengages a respective hook on the inside edge of the leaf below it. This configuration of interengaging hooks forms a natural seal along the edges of the leaves which forces water flowing over the surface to cascade over the downwardly curved hook of a leaf without leaking through the joint between the leaves.
It is an object of this invention to provide an extendable surface useable as a shield to protect water sensitive items.
It is an object of this invention to provide an extendable surface which is movable from a compact retracted position into an extended position.
It is yet another object of this invention to provide an extendable surface which can be inexpensively fabricated from common materials.
These and other objects of the invention will become apparent from a consideration of the drawings and the detailed description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front elevational view of an extendable surface in the extended position and mounted above an open building entry protection unit (BEP) type junction box;
FIG. 2 shows a plan view of an extendable surface in the extended position mounted above an open BEP, the BEP and various details of the extendable surface hidden from view being shown by dotted lines;
FIG. 3 shows a plan view of an extendable surface in the retracted position, with various details hidden from view being shown by dotted lines;
FIG. 4 shows a plan view of a first leaf with various details hidden from view being shown by dotted lines;
FIG. 4A shows a side view of a portion of FIG. 4 taken along lines 4A--4A;
FIG. 4B shows a side view of a portion of FIG. 4 taken along lines 4B--4B;
FIG. 5 shows a plan view of an intermediate leaf with various details hidden from view being shown by dotted lines;
FIG. 6 shows a plan view of a last leaf with various details hidden from view being shown by dotted lines; and
FIG. 7 shows a partial sectional view taken along lines 7--7 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show an extendable surface 10 according to the invention mounted above a building entry protection unit (BEP) 2. The BEP 2 is shown in the open position as it would be accessed by a technician for servicing.
BEPs are commonly used to connect the telephone lines within a building to the external lines of a regional telephone system. BEPs typically contain wiring blocks, connectors, and electrical surge protection equipment, all of which can be adversely affected by water. Although extendable surface 10 is shown in conjunction with a BEP, it is understood that the invention is not limited to this use and that extendable surface 10 could be used to protect almost any type of device requiring shielding from the elements.
Extendable surface 10 comprises a plurality of leaves 12 including a first leaf 14, a last leaf 16, and one or more intermediate leaves 18a-18d. FIG. 4 shows first leaf 14 in detail, and as is common to all of the leaves, first leaf 14 has a triangular shape defined by an inside edge 20, an outside edge 22 arranged opposite inside edge 20, and a third radial edge 24 extending between the inside and outside edges 20, 22. Inside edge 20 and of side edge 22 terminate at an apex 26. As seen in FIG. 7, he apexes 26 and 26a-26e of the leaves 26a-26e and 26a-26e provide the mounting ponts whereby the leaves are hingedly connected to each other as described in detail below.
As shown in FIGS. 1 and 4,the extended surface 10 is preferably mounted to a structure, such as a wall, by means of the first leaf 14. A flange 28 is provided for this purpose. The flange 28 (FIG. 1) extends at aright angle to first leaf 14 and provides a surface for mounting screws 32 to engage for mounting to a structure in position above the BEP 2 for example.
FIG. 1 illustrates a downwardly depending lip 34 slopes from the edge surface 24 of each leaf. Lip 34 helps guide water from extendable surface 10 and thereby prevents water from pooling on the surface or accumulating as droplets on its underside as the water runs off of the edge of the leaf.
As seen in FIGS. 1 and 4, outside edge 22 has a hook 38 positioned thereon which is interengagable with a cooperating hook on the inside edge of another leaf, for example leaf 18a (seen in FIGS. 1 and 2), arranged adjacent to first leaf 14. Although hook 38 could take many forms it is preferred that the hook comprise a continuous curved extension 40 of outside edge 22 in the form of a "C" shape as best illustrated in FIG. 4A. A continuous hook along the edges of the leaves forms a natural seal between each leaf which, when properly oriented as described below, will prevent water from leaking through the extendable surface and into the open BEP unit or other water sensitive component.
FIG. 5 shows an intermediate leaf 18a. As the intermediate leaves 18a-18d are essentially identical and similar in shape to leaves 14 and 16, the following description of leaf 18a applies to all of the intermediate leaves. Intermediate leaf 18a is triangular in shape and has an inside edge 20a and an outside edge 22a which are oppositely disposed on the leaf and terminate in an apex 26a. A third or radial edge 24a extends between the inside and outside edges. A lip 34a, like lip 34 in FIG. 4B, is preferably disposed along edge 24a. A cooperating hook 42a is disposed on inside edge 20a. Cooperating hook 42a is substantially like hook 38, except that it is curved opposite to it so that the two hooks will interengage when the extendable surface 10 is in its extended position as seen in FIG. 1.
A second hook 46a disposed along outside edge 22a is curved to cooperate with the hook on the next adjacent leaf 18b in the same way as hooks 38 and 42a cooperate.
As best illustrated in FIG. 1, first leaf 14 is preferably arranged uppermost of all the leaves and has its hook 38 curved downwardly, while the subsequent intermediate leaves 18a-18d have hooks which curve alternately upwardly and downwardly to interengage the cooperating hooks on an adjacent leaf when the leaves are relatively extended. By curving the hook on first leaf 14 downward, a pattern is established wherein all of the hooks on the outside edges on all of the successive leaves are also curved downwardly. This configuration is preferred because the hooks, when engaged one with another, form a natural seal which is proof against water because the water tends to cascade over the outside edge of each leaf and does not readily travel up the curved hook of the inside edge to leak through the extendable surface.
As seen in FIG. 6, last leaf 16 is like leaf 14 with the exception of upwardly curled hook 48 disposed on the inside edge 20e and a handle 50 disposed on outside edge 22e. Hook 48 has the same basic shape as hook 38, shown in FIG. 4A, except for the upward curvature noted.
The leaves are hingedly attached to each other at the apexes 26, and 26a-26e, about a common axis of rotation 54 best illustrated in FIG. 7. Preferably, axis 54 is perpendicular to the plane of the extendable surface. An axle, in the form of a self clinching stud 56 physically defines the axis 54 and provides the mounting for rotatably fastening the hinges at the apexes. Stud 56 is inserted into an aperture 58 in the apex 26 of first leaf 14 whereupon the stud embeds itself flush with the surface of the apex and extends perpendicularly therefrom. Apexes for the intermediate leaves also have apertures denoted as 58a-58d (FIGS. 5 and 7), and last leaf 16 has a similar aperture 58e (FIG. 6) sized to accept stud 56. Stud 56 preferably has a round cross section which allows the leaves to rotate freely on the stud. The stud extends from apex 26 of first leaf 14, and the leaves are retained to the stud by means of a locknut 60. Washers 62 are inserted between the apexes to reduce friction between the leaves as they rotate relative to one another. Preferably the leaves are fabricated from sheet metal and the washers are made of a plastic material, although the invention is not limited to these materials.
In use, the extendable surface according to the invention would be mounted above a BEP unit as seen in FIG. 1, or some other device. The BEP unit may be mounted on the outside wall of a building and provide for connection of the telephone lines in the building to the regional telephone system's lines. A technician performing a task on the building telephone system, for example adding a phone line or trouble shooting for a malfunction, can shield the BEP while working during periods of inclement weather by grasping the handle 50 and moving the leaves from the retracted position seen in FIG. 3, to the extended position seen in FIGS. 1 and 2. As the technician moves last leaf 16 from an overlapping position with leaf 18d, hook 48 on leaf 16 engages cooperating hook 46d on intermediate leaf 18d. As the last leaf is moved further it pulls intermediate leaf 18d from overlapping relation with intermediate leaf 18c, whereupon cooperating hooks 42d and 46c on those leaves interengage. Further movement continues to draw subsequent leaves along as the respective hooks interengage until the extendable surface 10 is fully deployed. The technician may then open BEP 2 which will be shielded by extendable surface 10 as shown in FIG. 1.
The extendable surface according to the invention provides a simple yet effective means for shielding sensitive components from the adverse effects of the elements. It is inexpensive to manufacture, reliable in operation, and versatile in its potential uses.
Although the extendable surface has been described as a weather shield, it is not limited to this use. The extendable surface could also function as a table when mounted beneath a BEP unit to provide a work surface upon which to place tools and small parts. When used as a table, lips 34 would preferably be turned upward to prevent tools and components from rolling off of the surface. | An extendable surface comprising a plurality of triangular leaves is disclosed. The leaves are arranged one above another and are hingedly mounted at the apex of each leaf for rotational motion between a retracted position in which the leaves are arranged in overlapping relation, to an extended position in which the leaves are adjacent to one another. The leaves have interengaging hooks along their edges which link the leaves together in the extended position and seal the surface, preventing water from leaking through the surface. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the transfer of baseband digital data in a hospital environment, and, in particular, to a low cost, efficient, and reliable system for transferring such data among and between central processors and processors located at the beds of individual patients.
2. Description of the Prior Art
The increasing use of computers and microprocessors in hospitals has led to a need for efficient and effective means for transferring digital data between different locations in the hospital. In particular, there has developed a need for two-way digital communication with a patient in his bed over existing coaxial cables. Such communication can, for example, be used to remotely monitor the patient, to request and receive information from the patient, e.g., order entry from the patient's bed, daily menu selections, and the like, to control and monitor the patient's environment, e.g., room lighting, air conditioning, door release, bed controls, smoke detectors, and the like, and to control and monitor the entertainment services and prescription services available to and used by the patient, e.g., forced tuning of TV channels, remote readout of the TV channel being watched at the patient's location, TV channel lockout, adding or skipping of TV channels, and the like.
A possible approach for providing the desired data transfer capability at each patient's bed would be to use a dedicated pair of conductors for each bed. Although this approach might be practical for new hospitals and for some existing hospitals, it is obviously expensive and, for existing hospitals, installation would involve a major interruption of on-going hospital activities. Also, for many existing hospitals, there is insufficient space in existing electrical conduits to add additional wiring. Accordingly, for these hospitals, in addition to the basic wiring, more conduits would also have to be added.
In an attempt to deal with the wiring problem, efforts have been made to transmit digital data on the coaxial cable network which hospitals normally use to carry RF television signals to the television receivers at each patient's bed. This cable network has in the past been adapted to provide DC power to the patient's television set. See Bunting, U.S. Pat. No. 3,699,250.
The approach generally considered to date has been to add additional RF bands to the existing bands already on the cable to carry the digital data. See, for example, European Patent Publication No. 103,438. The inventors of the present invention have worked with this approach and have developed prototype systems employing such additional RF bands. Surprisingly, the added RF bands approach has been found to be significantly more expensive to implement in practice and less reliable in use than the baseband digital data transfer system of the present invention. Also, the RF approach was found to suffer more attenuation than the present system in conducting digital signals over long distances and to be less noise immune than the present system.
The use of frequency-coded and pulse-coded control signals, as well as DC control signals, to activate selected equipment or serve a "nurse call" function has been disclosed in various patents. For example, Friesen et al., U.S. Pat. No. 3,534,161, discloses the use of frequency-coding or pulse-coding to connect the audio portion of a patient's television to a nurse's station. Fay, U.S. Pat. No. 3,946,159, discloses a nurse call system using DC control voltages of different magnitudes. Bunting, U.S. Pat. No. 3,517,120, discloses a nurse call system using a 100 kilohertz control signal. See also Tanner, U.S. Pat. No. 3,492,418; Damoci, U.S. Pat. No. 4,630,313: and U.K. Patent Application Ser. No. 2,022,963.
Along these same lines, Bunting, Inc., the assignee of the present invention, has in the past used interruption of the flow of DC current in a coaxial cable leading to a patient's television set as a control signal for controlling, inter alia, the position of a patient's bed. See also Hempell, U.S. Pat. No. 4,443,815, which discloses a system for detecting tampering with a cable TV system by sensing an interruption of the DC path through the cable.
In the former Bunting system, a coaxial cable carrying RF television signals and DC power for the patient's television set was supplied to the patient's hospital room. The cable was passed through a decoder circuit which was designed to sense interruptions in the flow of DC current in the cable. The decoder circuit was connected to a relay bank which determined the position of the patient's bed. From the decoder circuit, the cable was passed through an encoding circuit which interrupted the flow of DC current through the cable a preselected number of times at a preselected rate depending on the bed position selected by the patient. Finally, the cable was connected to the patient's television set, where it provided RF signals and DC power.
In operation, the patient would press a button on his television set corresponding to the position he desired for his bed, the pressing of the button would cause the encoder to generate a series of DC current interruptions corresponding to the selected button, and the interruptions would cause the appropriate relays to be activated to move the bed into the position selected by the patient.
Significantly, with regard to the present invention, the foregoing systems were concerned with the communication of simple control signals, not with the two-way transmission of streams of digital data at high baud rates. In addition, none of these systems addressed the problem of distinguishing between data being received at a station and data being sent from that station.
SUMMARY OF THE INVENTION
In view of the foregoing state of the art, it is an object of the present invention to provide an efficient, reliable, and low cost system for transferring baseband digital data at high baud rates between diverse locations in hospitals, hotels, motels, schools, apartment houses, and similar buildings which have been wired with coaxial cable.
It is an additional object of the invention to provide such a data transfer system which can be readily used with coaxial cable systems wherein the cable also carries RF television signals and DC power for television sets.
It is a further object of the invention to provide baseband digital data transfer systems which can serially transmit data through a coaxial cable in two directions and which can distinguish between data being transmitted and data being received.
To achieve the foregoing and other objects, the invention provides a baseband, 2-way, digital data transfer system comprising:
(a) a DC voltage source;
(b) a load;
(c) a direct current path between the DC voltage source and the load comprising:
(i) a coaxial cable having a central conductor which has a first end and a second end:
(ii) a first end conductive path for connecting the DC voltage source to the first end of the central conductor; and
(iii) a second end conductive path for connecting the load to the second end of the central conductor;
(d) a first end switch, e.g., a DC pass transistor, in the first end conductive path having an open state in which the flow of DC current from the DC voltage source to the load is interrupted and a closed state in which the flow of DC current is uninterrupted:
(e) a first end bit processor for receiving baseband digital bits from, for example, a central computer and switching the first end switch into its open state for a period of time corresponding to the duration of each bit:
(f) a second end switch in the second end conductive path having an open state in which the flow of DC current from the DC voltage source to the load is interrupted and a closed state in which the flow of DC current is uninterrupted;
(g) a second end bit processor for receiving baseband digital bits from, for example, a remote microprocessor and switching the second end switch into its open state for a period of time corresponding to the duration of each bit;
(h) a first end bit generator for sensing an interruption in the flow of DC current through the first end conductive path and generating a baseband digital bit in response thereto; and
(i) a second end bit generator for sensing an interruption in the flow of DC current through the second end conductive path and generating a baseband digital bit in response thereto.
In certain preferred embodiments, the coaxial cable carries RF signals between its first and second ends in both directions, the load is a television receiver, the coaxial cable carries DC power to the television receiver, and the system includes a storage capacitor in parallel with the television receiver for supplying power to the receiver during times when the direct current path from the DC power source to the receiver is interrupted through the opening of either the first end switch or the second end switch.
In other preferred embodiments, the system inhibits the first end bit generator from generating bits in response to the opening of the first end switch and similarly inhibits the second end bit generator from generating bits in response to the opening of the second end switch.
In additional preferred embodiments, the system includes short circuit and open circuit sensors, as well as a temperature sensor for monitoring the temperature of the first end switch. In connection with these embodiments, the system also preferably limits the rate at which charging current is supplied to the storage capacitor during startup or resetting of the system so as to avoid erroneous triggering of the short circuit sensor due to high inrush current flows into the storage capacitor.
In further preferred embodiments, a plurality of remote processors are connected to a central processor through baseband digital data transfer systems of the above type. For these embodiments, the connection of a particular remote processor to the central processor is established through the use of addressable switches which connect the central processor to the first end bit processor and first end bit generator associated with the particular remote processor to which or from which data is to be transferred.
The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate the preferred embodiments of the invention, and together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the overall structure of a baseband, serial, digital data distribution and processing system employing the digital data transfer system of the present invention.
FIG. 2 is a circuit diagram showing suitable electronic components which can be used for the first end portion of the baseband digital data transfer system of the present invention.
FIG. 3 a circuit diagram showing suitable electronic components which can be used for the second end portion of the baseband digital data transfer system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the figures, wherein like reference characters designate like or corresponding parts throughout the several drawings, there is shown in FIG. 1 a baseband digital data distribution system constructed in accordance with the present invention for use in a hospital or similar building which has been wired with coaxial cable.
For purposes of illustration, it is assumed in FIG. 1 that central processor 10 communicates with eight remote processors 12. FIG. 1 shows the components connecting the central processor to one of the eight remote processors. Identical components are used between the central processor and each of the other remote processors. The eight remote processors could, for example, be located in different rooms or at the bedsides of different patients in a hospital ward. More or less processors, of course, could be connected to the central processor. Also, the data distribution system of FIG. 1 could be part of a hierarchial distribution system wherein digital data flows between central processors, hospital wings, hospital wards, and processors in the rooms of individual patients.
In FIG. 1, it is further assumed that there is a television receiver 14 associated with each remote processor and that in addition to transferring baseband data, coaxial cable 13 provides DC power and RF signals to the receiver. The RF signals are supplied to the cable through TV 8-split 46 which receives its input from the hospital's master antenna system. If desired, coaxial cable 13 can also be used to carry RF signals from the patient's room to a nurse's station, central monitoring station, or the like. Television receiver 14 functions as a load for the baseband data transfer system and will typically draw 200 milliamps when off and 1,000 milliamps when on. Other loads, such as, a simple resistor, can be used in place of the television receiver.
As shown in FIG. 1, the baseband digital data transfer system comprises a first end portion 16 and a second end portion 18. First end portion 16 is connected to DC power supply 20 by conductor 22, to addressable switch 24 by conductor 26, to addressable switch 28 by conductor 30, and to first end 32 of central conductor 31 of coaxial cable 13. Second end portion 18 is connected to remote processor 12 by conductors 34 and 36 and to second end 38 of the central conductor of coaxial cable 13.
When neither first end portion 16 nor second end portion 18 is transferring digital data, DC current flows from DC power supply 20 to television receiver 14 by means of the direct current path consisting of first end conductive path 40 in first end portion 16, central conductor 31, and second end conductive path 42 in second end portion 18. When the direct current path is interrupted during the transferring of baseband digital data, storage capacitor 44 supplies power to the television receiver. For a storage capacitor having a capacitance of approximately 2,000 microfarads and a television receiver which draws approximately 1,000 milliamps when on and which has an internal capacitance of approximately 1,000 microfarads, data transfer rates on the order of 4,800 baud can be easily achieved without any noticeable effect on the performance of the television receiver. Transmission rates as high as 38,000 baud have been tested with the system again with no degradation of television performance.
First end portion 16 of the data transfer system includes: (1) DC pass transistor 48, which has an open state in which the flow of DC current through conductive path 40 is interrupted and a closed state in which the flow of DC current is uninterrupted; (2) source voltage switcher 50, which receives baseband digital bits from addressable switch 24 and switches transistor 48 into its open state for the durations of the received bits: and (3) interruption sensor 52 and processor 54 which sense interruptions in the flow of DC current through conductive path 40 and generate a baseband digital bit in response to each interruption. As discussed in detail below, the operation of source voltage switcher 50 and processor 54 are coordinated so that digital bits are not generated on conductor 30 in response to interruptions in conductive path 40 by transistor 48.
In addition to the foregoing components, first end portion 16 can include: open circuit sensor 56 for sensing a break in the conductive (load) path to ground, including a break resulting from the disconnecting of television receiver 14 from cable 13: RF filter 58 for isolating first end portion 16 from the RF signals applied to cable 13 by TV 8-split 46 (see inductor L101 and capacitors C106 and C106A in FIG. 2); and two overcurrent safety (protection) devices, namely, short circuit sensor 60, which is triggered when the current in conductive path 40 exceeds a predetermined level, e.g., 6 amps, and heat sensor 62, which is triggered when the temperature of transistor 48 exceeds a predetermined level, e.g., 138° F. Short circuit sensor 60 and heat sensor 62 are each connected to short circuit timer 64 which causes source voltage switcher 50 to switch transistor 48 into its open state.
Second end portion 18 of the baseband data transfer system includes: (1) DC pass transistor 78, which has an open state in which the flow of DC current through conductive path 42 is interrupted and a closed state in which the flow of DC current is uninterrupted; (2) load current switcher 66, which receives baseband digital bits from remote processor 12 and switches transistor 78 into its open state for the durations of the received bits: (3) interruption sensor 68 which senses interruptions in the flow of DC current through conductive path 42 and generates a baseband digital bit in response to each interruption; and (4) a load, such as, television receiver 14. As discussed in detail below, the operation of load current switcher 66 and interruption sensor 68 are coordinated so that digital bits are not generated on conductor 36 in response to interruptions in conductive path 42 by transistor 78.
In addition to the foregoing components, second end portion 18 can include RF filter 70 which passes DC signals to conductor 42 and RF signals to conductor 80 which is connected to the tuner of television receiver 14 (see inductor 102 and capacitors 104 and 105 in FIG. 3). Also, as discussed above, the second end portion can include storage capacitor 44 after diode 43 for providing stored DC current to television receiver 14 when the direct current path from power source 20 has been interrupted by the transmission of baseband digital data through coaxial cable 13.
In operation, central processor 10 causes addressable switches 24 and 28 to switch to a selected (addressed) one of the eight baseband digital data transmission systems. The switching can be performed using switching cable 76 or, depending on the design of the addressable switches, the same conductors used for carrying data to and from the central processor, i.e., conductors 74 and 72, can be used to perform the switching. Suitable components for the addressable switches are a 74LS138 chip for addressable switch 24 and a 74LS251 chip for addressable switch 28.
After the connections between the central processor 10 and first end portion 16 have been established, baseband digital data is transmitted from the central processor to source voltage switcher 50 by means of conductor 74, addressable switch 24, and conductor 26. For each digital bit, the source voltage switcher causes transistor 48 to switch to its open state, thus interrupting the flow of DC current in conductive path 40, central conductor 31 and conductive path 42. This interruption in current flow is sensed by interruption sensor 68 which generates and transmits a baseband digital bit to remote processor 12. In this way, baseband digital bits are transferred from central processor 10 to remote processor 12.
Baseband digital bits are transferred in the reverse direction in a similar manner. In this case, baseband digital data is transmitted from the remote processor to load current switcher 66 by means of conductor 34. For each digital bit, the load current switcher causes transistor 78 to switch to its open state, thus interrupting the flow of DC current in conductive path 42, central conductor 31 and conductive path 40. This interruption in current flow is sensed by interruption sensor 52 and processor 54 which generate and transmit a baseband digital bit to central processor 10 by means of conductor 30, addressable switch 28 and conductor 72.
Since the central processor and the remote processor are connected by a single cable 13, data transfer between the processors must be done serially, i.e., the central processor sends baseband data to the remote processor, followed by the remote processor sending baseband data to the central processor, etc. In general, the central processor will control the flow of data through the cable by sending appropriate control signals to the remote processor, although other traffic controlling approaches can be used if desired.
Referring now to FIG. 2, this figure shows specific components which can be used to construct first end portion 16. For simplicity of illustration, central processor 10 is shown directly connected to first end portion 16 by conductors 82 and 84.
Conductor 82 is normally high so that inverting buffer U5 pulls the base of PNP transistor Q101 low thus turning on the transistor. Conductor 82 temporarily goes low to transmit a digital bit to first end portion 16. The low state of conductor 82 causes the base of transistor Q101 to go high, thus shutting off the transistor. As discussed in more detail below, the low state of conductor 82 is also transmitted to the base of transistor U101D by conductor 86 to inhibit that transistor from generating a digital bit on conductor 84 in response to the interruption of current flow on conductor 40 caused by the opening of transistor Q101.
The turning off of transistor Q101 produces an interruption in the flow of current through conductor 40, cable 13, and conductor 42 (see FIG. 1) which is sensed by second end portion 18 (see below). Note that a complete cessation of current is not necessary, but rather the current flow only needs to be reduced to a level which will trigger the second end's current interruption sensor.
Interruptions in the flow of current through conductor 40 produced by second end portion 18 are sensed by transistor Q102. Due to the voltage drop across diode CR101 and resistor R104, transistor Q102 is on when current is flowing in conductor 40. Accordingly, capacitor C105 is charged, transistor U101A is on and transistor U101D is off since its base is connected to ground through transistor U101A. When current flow through conductor 40 is temporarily interrupted by second end 18, transistor Q102 temporarily turns off, which temporarily turns off transistor U101A, which causes the base of transistor U101D to temporarily go high, thus temporarily turning on this transistor and producing a digital bit on conductor 84.
As discussed above, digital bits which are transmitted to first end portion 16 by central processor 10 are fed to the base of transistor U101D by conductor 86. These low bits prevent the base of transistor U101D from going high when transistor Q102 turns off in response to the interruption in current flow through conductor 40 caused by transistor Q101 turning off. Accordingly, an outgoing digital bit is not produced on conductor 84 in response to an incoming digital bit on conductor 82.
For an interruption of current through conductor 40 of an extended duration, e.g., because of an open circuit condition in the overall conductive path to ground such as would occur if someone were to remove, e.g., steal, the patient's television set, transistor U101D eventually turns off as capacitor C105 discharges through the base of the transistor U101D and through resistors R110, R119, R109, R108, and R118. The turning off of transistor U101D occurs at a time determined by the time constant of the RC circuit formed by capacitor C105 and resistors R110, R119, R109, R108, and R118. The turning off of this transistor is of value since many central processors and addressable switches are not designed to receive a high input over an extended period of time as would occur if transistor U101D was to remain conductive for the full duration of the open circuit condition.
Transistor Q102, in addition to sensing interruptions in the current flow in conductor 40 produced by second end portion 18, also forms part of the first end portion's open circuit sensor. Specifically, when transistor Q102 is on, i.e., when current is flowing in conductor 40, transistor U101E is on, and thus LED 102 is on. An open circuit condition causes transistors Q102 and U101E to turn off, thus turning off LED 102. LED 102 also turns off each time a digital bit is transmitted through cable 13, but the duration of this turning off is generally too short to be visible.
The short circuit sensor of first end portion 16 comprises one-shot timer U102 and transistors Q103, U101B, and U101C. When the current through diode CR101 and resistor R104 exceeds a predetermined value, e.g., 6 amps, transistor Q103 turns on, which turns on transistor U101B, which triggers timer U102 and causes the output of the timer at pin 3 to go high for a period of time determined by the values of resistor R113 and capacitor C102. The high output from the timer turns on LED 101 and transistor U101C. Transistor U101C connects the input of inverting buffer U5 to ground, which makes the output of the buffer high, thus turning off transistor Q101. Transistor Q101 remains off until timer U102 times out. If the short has been removed, normal operation will then resume. If the short has not been removed, transistor Q103 and thus timer U102 will again turn on to again shut down current flow through the system as a result of transistor Q101 being turned off.
One-shot timer U102 also forms part of the heat sensor of first end portion 16. Specifically, thermistor RT101 is mounted on the heat sink for transistor Q101. When the temperature of transistor Q101 and thus of the heat sink exceeds a threshold temperature, e.g., 138° F., thermistor RT101 becomes sufficiently conductive to trigger timer U102. Once triggered, timer 102 turns off transistor Q101 and turns on LED 101 in the same manner as when triggered by the short circuit sensor.
When transistor Q101 has been off for a substantial period of time, e.g., when it has been shut off by timer U102 or at initial startup, capacitor 44 in second end portion 18 will be at least partially discharged. The charging current flowing into this discharged capacitor may be great enough to trigger the short circuit sensor, i.e., transistor Q103. Accordingly, startup of first end portion 16 may be erratic and the first end portion may not reliably restart after either the short circuit sensor or the heat sensor has been triggered.
To eliminate these possibilities, two paths are used to supply base current to transistor Q101: (1) resistor R102, which is sized so that it does not supply enough base current to fully turn on transistor Q101; and (2) resistor R1 and transistor Q1, which, in combination with resistor R102, do supply enough base current to fully turn on transistor Q101. The base of transistor Q1 is connected to an RC network consisting of resistor R3 and capacitor C1. Accordingly, during restart or initial startup, transistor Q101 is not fully turned on until capacitor C1 has become charged. This arrangement has been found to prevent erroneous triggering of the short circuit sensor due to high charging currents flowing into capacitor 44 upon restart and initial startup.
Referring now to FIG. 3, this figure shows specific components which can be used to construct second end portion 18. Conductor 88 is normally low so that transistor 90 is off, transistor 92 is on, and transistor 78 is on since its base is low. Conductor 88 temporarily goes high to transmit a return digital bit from remote processor 12 to second end portion 18. The high state of conductor 88 causes transistor 90 to turn on, which turns off transistor 92, which causes the base of transistor 78 to go high, thus shutting off transistor 78 and causing an interruption in the flow of current through conductor 42 which is sensed by first end portion 16. As with transistor 48, transistor 78 does not have to completely stop all current flow through conductor 42, but only needs to reduce the current flow to a level which can be sensed by the first end portion.
Interruptions in the flow of current through conductor 42 produced by first end portion 18 are sensed by transistor 94. Transistor 94 is normally on which causes transistor 98 to be normally off, so that conductor 100 is normally high. When current flow through conductor 42 is temporarily interrupted, transistor 94 temporarily turns off, which temporarily turns on transistor 98, which causes conductor 100 to temporarily go low thus transmitting a digital bit to remote processor 12.
Transistor 96 prevents transistor 98 from generating an outgoing digital bit on conductor 100 in response to a return digital bit on conductor 88 from remote processor 12. Specifically, a return digital bit from remote processor 12 on conductor 88 turns on transistor 96 so that transistor 98 remains off even though transistor 94 is turned off by an interruption of current on conductor 42 resulting from the turning off of transistor 78 by the return digital bit.
Although specific embodiments of the invention have been described and illustrated, it is to be understood that modifications can be made without departing from the invention's spirit and scope. For example, components and component configurations other than those shown can be used for each of first end portion 16 and second end portion 18. | A digital data transfer system for transferring baseband digital data between a central location and a patient's room is provided. The system employs the existing coaxial cable network found in hospitals and other institutions. The coaxial cable carries power from a DC power source to the patient's television receiver or other device. Digital data is addressed and transmitted from the central location to the individual patient's room on the coaxial cable by temporarily disconnecting the DC power source from the coaxial cable for each bit which is to be transferred (source switching) and detecting, in the patient's room, the interruption in the flow of DC current through the cable. Digital data is transmitted from the patient's room back to the central location on the same single coaxial cable by temporarily disconnecting the load, e.g., the patient's television receiver or other device, from the coaxial cable for each bit which is to be transferred back (load switching) and detecting, at the central location, the interruption in the flow of DC current through the cable. A storage capacitor is placed in parallel with the load to provide power for the load while the flow of DC current is interrupted. The system can readily achieve transmission rates on the order of 38 kilobaud and above. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of allowed patent application Ser. No. 10/940,360, filed on Sep. 14, 2004, published as U.S. patent application Ser. No. 2005-0137391, which is a continuation of patent application Ser. No. 10/760,940, filed on Jan. 20, 2004, now U.S. Pat. No. 7,041,816, which is a continuation of U.S. application Ser. No. 10/232,881, filed on Aug. 30, 2002, now U.S. Pat. No. 6,858,715, which is a continuation of patent application Ser. No. 10/288,679, filed on Apr. 9, 1999, now U.S. Pat. No. 6,465,628, and claims priority benefit of U.S. provisional application Ser. No. 60/118,564, filed on Feb. 4, 1999, entitled “Improved Synthesis of Oligonucleotides.” The entire contents of each of the foregoing patents and patent applications are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to improved methods for the preparation of oligomeric compounds having phosphodiester, phosphorothioate, phosphorodithioate or other linkages. In preferred embodiments, the methods of the invention provide oligomers that have reduced amounts of unwanted side-products.
BACKGROUND OF THE INVENTION
Antisense and other oligonucleotide therapies have gone beyond academic publications to the level of approved drug as shown by the recent FDA approval of an antisense oligonucleotide therapeutic for ocular cytomegalovirus infections. More and more oligonucleotides are entering the clinic for the treatment of a variety of diseases such as inflammation, cancer, viral disease and others. There is an urgent need for improved methods for the synthesis of oligonucleotides in high quantity and with high quality. Solid phase chemistry is the present method of choice. Typical synthons now used are O-cyanoethyl protected nucleoside phosphoamidite monomers. At the end of the synthesis, the oligonucleotide product is treated typically with 30% aqueous ammonium hydroxide to deprotect the cyanoethyl groups on the phosphorothioate backbone as well as exocyclic amino groups. During this deprotection step, one molecule of acrylonitrile is produced for every cyanoethyl group present.
It is now known that acrylonitrile is a rodent carcinogen and that, at pH 7, it can react with T, dC, dG, dA and dI, resulting in the formation of a variety of adducts. See, Solomon et al., Chem .- Biol. Interactions , 51, 167-190 (1984). it is greatly desired to eliminate these impurities in synthesis of oligonucleotides, especially phosphorothioate oligonucleotides.
Eritja et al. ( Tetrahedron , 48, 4171-4182 (1992)) report the prevention of acrylonitrile adduct formation of nucleobase moieties during deprotection of β-cyanoethyl protected oligomers by 40% triethylamine in pyridine for 3 hours followed by treatment with 0.5 M DBU/pyridine. However, as will be seen infra, their conditions failed to eliminate adduct formation to a suitable extent.
Given the demand for oligonucleotides and analogs thereof for clinical use, and the known toxicity of acrylonitrile nucleobase adducts, methods of preparing phosphate linked oligomers having reduced amount of such adducts are greatly desired. The present invention is directed to this, as well a other, important ends.
SUMMARY OF THE INVENTION
The present invention provides an improved method for the preparation of phosphate-linked oligomers that have significantly reduced amounts of exocyclic nucleobase adduct resulting from the products of removal of phosphorus protecting groups. In one aspect of the invention, methods are provided comprising:
a) providing a sample containing a plurality of oligomers of the Formula I:
wherein:
R 1 is H or a hydroxyl protecting group; B is a naturally occurring or non-naturally occurring nucleobase that is optionally protected at one or more exocyclic hydroxyl or amino groups;
R 2 has the Formula III or IV:
wherein
E is C 1 -C 10 alkyl, N(Q 1 )(Q 2 ) or N═C(Q 1 )(Q 2 ); each Q 1 and Q 2 is, independently, H, C 1 -C 10 alkyl, dialkylaminoalkyl, a nitrogen protecting group, a tethered or untethered conjugate group, a linker to a solid support, or Q 1 and Q 2 , together, are joined in a nitrogen protecting group or a ring structure that can include at least one additional heteroatom selected from N and O;
R 3 is OX 1 , SX 1 , or N(X 1 ) 2 ;
each X 1 is, independently, H, C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C(═NH)N(H)Z 8 , C(═O)N(H)Z 8 or OC(═O)N(H) Z 8 ;
Z 8 is H or C 1 -C 8 alkyl;
L 1 , L 2 and L 3 comprise a ring system having from about 4 to about 7 carbon atoms or having from about 3 to about 6 carbon atoms and 1 or 2 hetero atoms wherein said hetero atoms are selected from oxygen, nitrogen and sulfur and wherein said ring system is aliphatic, unsaturated aliphatic, aromatic, or saturated or unsaturated heterocyclic; Y is alkyl or haloalkyl having 1 to about 10 carbon atoms, alkenyl having 2 to about 10 carbon atoms, alkynyl having 2 to about 10 carbon atoms, aryl having 6 to about 14 carbon atoms, N(Q 1 )(Q 2 ), O(Q 1 ), halo, S(Q 1 ), or CN; each q 1 is, independently, from 2 to 10; each q 2 is, independently, 0 or 1; m is 0, 1 or 2; pp is from 1 to 10; and q 3 is from 1 to 10 with the proviso that when pp is 0, q 3 is greater than 1;
R t is a phosphorus protecting group of formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p —C(R 10 ) 2 —W
each R 10 is independently H or lower alkyl;
W is an electron withdrawing group;
p is 0 to 3;
each Y 2 is independently, O, CH 2 or NH;
each Z is independently O or S;
each X is independently O or S;
Q is a linker connected to a solid support, —OH or
O—Pr where Pr is a hydroxyl protecting group; and
n is 1 to about 100;
b) contacting said sample with a deprotecting reagent for a time and under conditions sufficient to remove substantially said R t groups from said oligomers; and
c) reacting said oligomers with a cleaving reagent;
wherein said deprotecting reagent comprises at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents.
Preferably, the methods further comprises a washing step before step (c).
In some preferred embodiments, Q is a linker connected to a solid support. In further preferred embodiments, said deprotecting reagent does not cleave said oligomers from said solid support.
In some preferred embodiments, the deprotecting reagent comprises an aliphatic amine, which is preferably triethylamine or piperidine.
In further preferred embodiments, the deprotecting agent comprises a haloalkyl solvent or a cyanoalkyl solvent, which is preferably acetonitrile or methylene chloride.
In particularly preferred embodiments, the phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —(CH═CH) p —CH 2 —C≡N, where p is an integer from 1 to 3, with —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N being preferred, and —CH 2 —CH 2 —C≡N being particularly preferred.
In some preferred embodiments, the deprotecting reagent or cleaving reagent further comprises a scavenger, which is preferably a purine, a pyrimidine, inosine, a pyrrole, an imidazole, a triazole, a mercaptan, a beta amino thiol, a phosphine; a phosphite, a diene, a urea, a thiourea, an amide, an imide, a cyclic imide, a ketone, an alkylmercaptan, a thiol, ethylene glycol, a substituted ethylene glycol, 1-butanethiol, S-(2-amino-4-thiazolylmethyl)isothiourea hydrochloride, 2-mercaptoethanol, 3,4-dichlorobenzylamine, benzylamine, benzylamine in the presence of carbon disulfide, hydroxylamine, 2-phenylindole, n-butylamine, diethyl ester of acetaminomalonic acid, ethyl ester of N-acetyl-2-cyanoglycine, 3-phenyl-4-(o-fluorophenyl)-2-butanone, 3,4-diphenyl-2-butanone, desoxybenzoin, N-methoxyphthalimide, p-sulfobenzenediazonium chloride, or p-sulfamidobenzenediazonium chloride.
In some preferred embodiments, the scavenger is a resin containing a suitable scavenging molecule bound thereto. Exemplary scavenger resins include polymers having free thiol groups and polymers having free amino groups, for example a polymer-bound amine resin wherein the amine is selected from benzylamine, ethylenediamine, diethylamine triamine, tris(2-aminoethyl)amine, methylamine, methylguanidine, polylysine, oligolysine, Agropore™ NH 2 HL, Agropore™ NH 2 LL (available from Aldrich Chem. Co. St. Louis. Mo.), 4-methoxytrityl resin, and thiol 2-chlorotrityl resin.
In some preferred embodiments, Q is —OH or O—Pr.
In some preferred embodiments, the cleaving reagent comprises an aqueous methanolic solution of a Group I or Group II metal carbonate, preferably aqueous methanolic CaCO 3 . In further preferred embodiments, the cleaving reagent comprises an aqueous metal hydroxide. In yet further preferred embodiments, the cleaving reagent comprises a phase transfer catalyst. Preferred phase transfer catalysts include quaternary ammonium salts, quaternary phosphonium salts, crown ethers and cryptands (i.e., crown ethers which are bicyclic or cycles of higher order). It is more preferred that the phase transfer catalyst be t-Bu 4 N + OH, or t-Bu 4 N + F − .
In further preferred embodiments, the cleaving reagent comprises NaNH 2 .
In preferred embodiments, the oligomers produced by the methods of the invention have from 0.001% to about 1% acrylonitrile adduct, with from about 0.1% to about 1% acrylonitrile adduct being more preferred, from about 0.1% to about 0.75% acrylonitrile adduct being even more preferred, and from about 0.1% to about 0.5% acrylonitrile adduct being even more preferred. In even more preferred embodiments, the oligomers are substantially free of detectable acrylonitrile adduct.
In some preferred embodiments, steps b) and c) are performed simultaneously.
In some particularly preferred embodiments, Q is a linker connected to a solid support; said aliphatic amine is triethylamine or piperidine; said solvent is acetonitrile or ethylene chloride; and said phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N, and wherein the deprotecting reagent, said cleaving reagent, or both preferably further comprises a scavenger.
In further preferred embodiments, the deprotecting reagent comprises a secondary alkyl amine which is preferably piperidine, and said cleaving reagent comprises an alkali metal carbonate, which is preferably potassium carbonate.
Also provided by the present invention are methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of protected phosphorus linkages of Formula II:
wherein:
Each X is O or S;
R t is a phosphorus protecting group of the formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p—C(R 10 ) 2 —W
each R 10 is independently H or lower alkyl; W is an electron withdrawing group; p is 1 to 3;
comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers;
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers, said deprotecting reagent containing at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(c) reacting said oligomers with a cleaving reagent.
Preferably, the methods further comprises a washing step before step (c).
In some preferred emboidiments, the oligomers are in solution. In other preferred embodiments, the oligomers are linked to a solid support.
In some preferred embodiments, said deprotecting reagent does not cleave said oligomers from said solid support.
In some preferred embodiments, the deprotecting reagent comprises an aliphatic amine, which is preferably triethylamine or piperidine.
In further preferred embodiments, the deprotecting agent comprises a haloalkyl solvent or a cyanoalkyl solvent, which is preferably acetonitrile or methylene chloride.
In particularly preferred embodiments, the phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —(CH═CH) p —CH 2 —C≡N, where p is an integer from 1 to 3, with —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N being preferred, and with —CH 2 —CH 2 —C≡N being particularly preferred.
In some preferred embodiments, the deprotecting reagent or cleaving reagent further comprises a scavenger, which is preferably a purine, a pyrimidine, inosine, a pyrrole, an imidazole, a triazole, a mercaptan, a beta amino thiol, a phosphine, a phosphite, a diene, a urea, a thiourea, an amide, an imide, a cyclic imide, a ketone, an alkylmercaptan, a thiol, ethylene glycol, a substituted ethylene glycol, 1-butanethiol, S-(2-amino-4-thiazolylmethyl)isothiourea hydrochloride, 2-mercaptoethanol, 3,4-dichlorobenzylamine, benzylamine, benzylamine in the presence of carbon disulfide, hydroxylamine, 2-phenylindole, n-butylamine, diethyl ester of acetaminomalonic acid, ethyl ester of N-acetyl-2-cyanoglycine, 3-phenyl-4-(o-fluorophenyl)-2-butanone, 3,4-diphenyl-2-butanone, desoxybenzoin, N-methoxyphthalimide, p-sulfobenzenediazonium chloride, or p-sulfamidobenzenediazonium chloride.
In some preferred embodiments, the scavenger is a resin containing a suitable scavenging molecule bound thereto. Exemplary scavenger resins include polymers having free thiol groups and polymers having free amino groups, for example a polymer-bound amine resin wherein the amine is selected from benzylamine, ethylenediamine, diethylamine triamine, tris(2-aminoethyl)amine, methylamine, methyiguanidine, polylysine, oligolysine, Agropore™ NH 2 HL, Agropore™ NH 2 LL, 4-methoxytrityl resin, and thiol 2-chlorotrityl resin.
In some preferred embodiments, the cleaving reagent comprises an aqueous methanolic solution of a Group I or Group II metal carbonate, preferably aqueous methanolic potassium carbonate. In further preferred embodiments, the cleaving reagent comprises an aqueous metal hydroxide. In yet further preferred embodiments, the cleaving reagent comprises a phase transfer catalyst. Preferred phase transfer catalysts include quaternary ammonium salts, quaternary phosphonium salts, crown ethers and cryptands (i.e., crown ethers which are bicyclic or cycles of higher order). It is more preferred that the phase transfer catalyst be t-Bu 4 N + OH, or t-Bu 4 N + F − .
In further preferred embodiments, the cleaving reagent comprises NaNH 2 .
In preferred embodiments, the produced by the methods of the invention oligomers have from about 0.001% to about 1% acrylonitrile adduct, with from about 0.001% to about 0.5% acrylonitrile adduct being more preferred, from about 0.001% to about 0.1% acrylonitrile adduct being even more preferred, and from about 0.001% to about 0.05% acrylonitrile adduct being even more preferred. In even more preferred embodiments, the oligomers are substantially free of acrylonitrile adduct.
In some preferred embodiments, steps b) and c) are performed simultaneously.
In some particularly preferred embodiments, said aliphatic amine is triethylamine or piperidine; said solvent is acetonitrile or methylene chloride; and said phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N, and wherein the deprotecting reagent, said cleaving reagent, or both preferably further comprises a scavenger.
In further preferred embodiments, the deprotecting reagent comprises a secondary alkyl amine which is preferably piperidine, and said cleaving reagent comprises an alkali metal carbonate, which is preferably potassium carbonate.
Also provided by the present invention are methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of protected phosphorus linkages of Formula II:
wherein:
Each X is O or S;
R t is a phosphorus protecting group of formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p —C(R 10 ) 2 —W
each R 10 is independently H or lower alkyl; W is an electron withdrawing group; p is 1 to 3;
comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers;
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers;
(c) washing said deprotected oligomers with a washing reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(d) reacting said oligomers with a cleaving reagent.
In some preferred embodiments, the oligomers are in solution. In other preferred embodiments, the oligomers are linked to a solid support.
In some preferred embodiments, the deprotecting reagent does not cleave said oligomers from said solid support.
In further preferred embodiments, the deprotecting reagent comprises an aliphatic amine, which is preferably triethylamine or piperidine. In still further preferred embodiments, the deprotecting agent comprises a haloalkyl solvent or a cyanoalkyl solvent which is preferably acetonitrile or methylene chloride.
In particularly preferred embodiments, the phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —(CH═CH) p —CH 2 —C≡N, where p is an integer from 1 to 3, with —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N being preferred, and with —CH 2 —CH 2 —C≡N being particularly preferred.
In some preferred embodiments, the deprotecting reagent, the cleaving reagent or the washing reagent further comprises a scavenger, which is preferably a purine, a pyrimidine, inosine, a pyrrole, an imidazole, a triazole, a mercaptan, a beta amino thiol, a phosphine, a phosphite, a diene, a urea, a thiourea, an amide, an imide, a cyclic imide a ketone, an alkylmercaptan, a thiol, ethylene glycol, a substituted ethylene glycol, 1-butanethiol, S-(2-amino-4-thiazolylmethyl)isothiourea hydrochloride, 2-mercaptoethanol, 3,4-dichlorobenzylamine, benzylamine, benzylamine in the presence of carbon disulfide, hydroxylamine, 2-phenylindole, n-butylamine, diethyl ester of acetaminomalonic acid, ethyl ester of N-acetyl-2-cyanoglycine, 3-phenyl-4-(o-fluorophenyl)-2-butanone, 3,4-diphenyl-2-butanone, desoxybenzoin, N-methoxyphthalimide, p-sulfobenzenediazonium chloride, or p-sulfamidobenzenediazonium chloride.
In some preferred embodiments, the scavenger is a resin containing a suitable scavenging molecule bound thereto. Exemplary scavenger resins include polymers having free thiol groups and polymers having free amino groups, for example a polymer-bound amine resin wherein the amine is selected from benzylamine, ethylenediamine, diethylamine triamine, tris(2-aminoethyl)amine, methylamine, methylguanidine, polylysine, oligolysine, Agropore™ NH 2 HL, Agropore™ NH 2 LL, 4-methoxytrityl resin, and thiol 2-chlorotrityl resin.
In some preferred, embodiments, the cleaving reagent comprises an aqueous methanolic solution of a Group I or Group II metal carbonate, preferably aqueous methanolic potassium carbonate. In further preferred embodiments, the cleaving reagent comprises an aqueous metal hydroxide. In yet further preferred embodiments, the cleaving reagent comprises a phase transfer catalyst. Preferred phase transfer catalysts include quaternary ammonium salts, quaternary phosphonium salts, crown ethers and cryptands (i.e., crown ethers which are bicyclic or cycles of higher order). It is more preferred that the phase transfer catalyst be t-Bu 4 N + OH, or t-Bu 4 N + F − .
In further preferred embodiments, the cleaving reagent comprises NaNH 2 .
In preferred embodiments, the oligomers produced by the methods of the invention have from 0.001% to about 1% acrylonitrile adduct, with from about 0.1% to about 1% acrylonitrile adduct being more preferred, from about 0.1% to about 0.75% acrylonitrile adduct being even more preferred, and from about 0.1% to about 0.5% acrylonitrile adduct being even more preferred. In even more preferred embodiments, the oligomers are substantially free of is detectable acrylonitrile adduct.
In some particularly preferred embodiments, said aliphatic amine is triethylamine or piperidine; said solvent is acetonitrile or methylene chloride; and said phosphorus protecting group is —CH 2 —CH 2 —C≡N or —CH 2 —CH═CH—CH 2 —C≡N, and wherein the deprotecting reagent, the washing reagent, the cleaving reagent, or each preferably further comprise a scavenger.
In further preferred embodiments, the deprotecting reagent comprises a secondary alkyl amine which is preferably piperidine, and said cleaving reagent comprises an alkali metal carbonate, which is preferably potassium carbonate.
The present invention also provides methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of phosphorus linkages of Formula II:
wherein:
Each X is O or S;
R t is a phosphorus protecting group of the formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p —C(R 10 ) 2 —W
each R 10 is independently H or lower alkyl; W is an electron withdrawing group; p is 1 to 3;
comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers; and
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers, said deprotecting reagent comprising gaseous ammonia.
Also provided in accordance with the present invention are compositions comprising phosphodiester, phosphorothioate, or phosphorodithioate oligonucleotides produced by the methods of the invention.
The present invention also provides compositions comprising phosphodiester, phosphorothioate, or phosphorodithioate oligonucleotides, said oligonucleotides having from about 0.001% to about 1% acrylonitrile adduct, with from about 0.1% to about 1% acrylonitrile adduct being more preferred, from about 0.1% to about 0.75% acrylonitrile adduct being even more preferred, and from about 0.1% to about 0.5% acrylonitrile adduct being even more preferred. In particularly preferred embodiments, compositions comprising phosphodiester, phosphorothioate, or phosphorodithioate oligonucleotides, said oligonucleotides are provided that are substantially free of detectable acrylonitrile adduct.
The present invention also provides composition comprising oligonucleotides that are substantially free of acrylonitrile adduct prepared by the methods of the invention.
Further provided in accordance with the present invention are methods of preparing a sample of a phosphate linked oligonucleotide having a substantially reduced content of acrylonitrile adduct comprising:
(a) providing a sample containing a plurality of oligomers, said oligomers having a plurality of phosphorus protecting groups;
(b) contacting said oligomers with a deprotecting agent to remove substantially all of said phosphorus protecting groups from said oligomers;
said deprotecting reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents;
(c) optionally washing said oligomers; and
(d) reacting said oligomers with a cleaving reagent. Further provided in accordance with the present invention are methods of preparing a sample of a phosphate linked oligonucleotide having a substantially reduced content of acrylonitrile adduct comprising:
(a) providing a sample containing a plurality of oligomers, said oligomers having a plurality of phosphorus protecting groups;
(b) contacting said oligomers with a deprotecting agent to remove substantially all of said phosphorus protecting groups from said oligomers;
(c) washing said oligomers with a washing reagent, said washing reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(d) reacting said oligomers with a cleaving reagent.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention provides methods for the preparation of oligomeric compounds having phosphodiester, phosphorothioate, phosphorodithioate, or other internucleoside linkages, and to composition produced by the methods.
The methods of the invention are applicable to both solution phase and solid phase chemistries. Representative solution phase techniques are described in U.S. Pat. No. 5,210,264, which is assigned to the assignee of the present invention. in some preferred embodiments, the methods of the present invention are employed for use in iterative solid phase oligonucleotide synthetic regimes. Representative solid phase techniques are those typically employed for DNA and RNA synthesis utilizing standard phosphoramidite chemistry, (see, e.g., Protocols For Oligonucleotides And Analogs, Agrawal, S., ed., Humans Press, Totowa, N.J., 1993. A preferred synthetic solid phase synthesis utilizes phosphoraroidites as activated phosphate compounds. In this technique, a 5′-protected phosphoramidite monomer is reacted with a free hydroxyl on the growing oligorner chain to produce an intermediate phosphite compound, which is subsequently oxidized to the P V state using standard methods. This technique is commonly used for the synthesis of several types of linkages including phosphodiester, phosphorothioate, and phosphorodithioste linkages.
Typically, the first step in such a process is attachment of a first monomer or higher order subunit containing a protected 5′-hydroxyl to a solid support, usually through a linker, using standard methods and procedures known in the art. See for example, Oligonucleotides And Analogues A Practical Approach , Eckstein, F. Ed., IRL Press, N.Y., 1991. The support-bound monomer or higher order first synthon is then treated to remove the 5′-protecting group. The solid support bound monomer is then reacted with an activated phosphorous monomer or higher order synthon which is typically a nucleoside phosphoramidite, which is suitably protected at the phosphorus atom, and at any vulnerable exocyclic amino or hydroxyl groups. Typically, the coupling of the phosphoramidite to the support bound chain is accomplished under anhydrous conditions in the presence of an activating agent such as, for example, 1H-tetrazole, 5-(4-nitrophenyl)-1H-tetrazole, or diisopropylamino tetrazolide.
The resulting linkage is a phosphite or thiophosphite, which is subsequently oxidized prior to the next iterative cycle. Choice of oxidizing or sulfurizing agent will determine whether the linkage will be oxidized or sulfurized to a phosphodiester, thiophosphodiester, or a dithiophosphodiester linkage.
At the end of the synthetic regime, the support-bound oligomeric chain is typically treated with strong base (e.g., 30% aqueous ammonium hydroxide) to cleave the completed oligonucleotide form the solid support, and to concomitantly remove phosphorus protecting groups (which are typically β-cyanoethyl protecting groups) and exocyclic nucleobase protecting groups. Without intending that the invention be bound by any particular theory, it is believed that the loss of the cyanoethyl phosphorus protecting group occurs via a β-elimination mechanism, which produces acrylonitrile as a product. The acrylonitrile is believed to react in a Michael addition with nucleobase exocyclic amine and/or hydroxyl moieties, and in particular the N 3 position of thymidine residues, to form deleterious adducts. The methods of the present invention significantly reduce the content of such adducts formed during the removal of phosphorus protecting groups that are capable of participating in such adduct-forming addition reactions.
Thus, in one aspect, the present invention provides synthetic methods comprising:
a) providing a sample containing a plurality of oligomers of the Formula I:
wherein:
R 1 is H or a hydroxyl protecting group; B is a naturally occurring or non-naturally occurring nucleobase that is optionally protected at one or more exocyclic hydroxyl or amino groups;
R 2 has the Formula III or IV:
wherein
E is C 1 -C 10 alkyl, N(Q 1 )(Q 2 ) or N═C(Q 1 )(Q 2 ); each Q 1 and Q 2 is, independently, H, C 1 -C 10 alkyl, dialkylaminoalkyl, a nitrogen protecting group, a tethered or untethered conjugate group, a linker to a solid support, or Q 1 and Q 2 , together, are joined in a nitrogen protecting group or a ring structure that can include at least one additional heteroatom selected from N and O;
R 3 is OX 1 , SX 1 , or N(X 1 ) 2 ;
each X 1 is, independently, H, C 1 -C 8 alkyl, C 1 -C 8 haloalkyl, C(═NH)N(H)Z 8 , C(═O)N(H)Z 8 or OC(═O)N(H)Z 8 ;
Z 8 is H or C 1 -C 8 alkyl;
L 1 , L 2 and L 3 comprise a ring system having from about 4 to about 7 carbon atoms or having from about 3 to about 6 carbon atoms and 1 or 2 hetero atoms wherein said hetero atoms are selected from oxygen, nitrogen and sulfur and wherein said ring system is aliphatic, unsaturated aliphatic, aromatic, or saturated or unsaturated heterocyclic;
Y is alkyl or haloalkyl having 1 to about 10 carbon atoms, alkenyl having 2 to about 10 carbon atoms, alkynyl having 2 to about 10 carbon atoms, aryl having 6 to about 14 carbon atoms, N(Q 1 )(Q 2 ), O(Q 1 ), halo, S(Q 1 ), or CN;
each q 1 is, independently, from 2 to 10; each q 2 is, independently, 0 or 1; m is 0, 1 or 2; pp is from 1 to 10; and q 3 is from 1 to 10 with the proviso that when pp is 0, q 3 is greater than 1;
R t is a phosphorus protecting group of formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p —C(R 10 ) 2 —W
each R 10 is independently H or lower alkyl; W is an electron withdrawing group; p is 0 to 3;
each Y 2 is independently, O, CH 2 or NH;
each Z is independently O or S;
Each X is independently O or S;
Q is a linker connected to a solid support, —OH or O—Pr where Pr is a hydroxyl protecting group; and
n is 1 to about 100;
b) contacting said sample with a deprotecting reagent for a time and under conditions sufficient to remove substantially said R t groups from said oligomers; and
c) reacting said oligomers with a cleaving reagent;
wherein said deprotecting reagent comprises at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents.
Also provided by the present invention are methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of protected phosphorus linkages of Formula II:
wherein X and R t are as defined above, comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers;
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers, said deprotecting reagent containing at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(c) reacting said oligomers with a cleaving reagent.
In further embodiments, the present invention provides methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of protected phosphorus linkages of formula II comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers;
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers;
(c) washing said deprotected oligomers with a washing reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(d) reacting said oligomers with a cleaving reagent.
The present invention also provides methods for deprotecting a phosphate-linked oligomer, said oligomer having a plurality of phosphorus linkages of formula II comprising:
(a) providing a sample containing a plurality of said phosphate linked oligomers; and
(b) contacting said oligomers with a deprotecting reagent for a time and under conditions sufficient to remove substantially all of said R t groups from said oligomers, said deprotecting reagent comprising gaseous ammonia.
Further provided in accordance with the present invention are methods of preparing a sample of a phosphate. linked oligonucleotide having a substantially reduced content of acrylonitrile adduct comprising:
(a) providing a sample containing a plurality of oligomers, said oligomers having a plurality of phosphorus protecting groups;
(b) contacting said oligomers with a deprotecting agent to remove substantially all of said phosphorus protecting groups from said oligomers;
said deprotecting reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents;
(c) optionally washing said oligomers; and
(d) reacting said oligomers with a cleaving reagent.
Further provided in accordance with the present invention are methods of preparing a sample of a phosphate linked oligonucleotide having a substantially reduced content of acrylonitrile adduct comprising:
(a) providing a sample containing a plurality of oligomers, said oligomers having a plurality of phosphorus protecting groups;
(b) contacting said oligomers with a deprotecting agent to remove substantially all of said phosphorus protecting groups from said oligomers;
(c) washing said oligomers with a washing reagent, said washing reagent comprising at least one amine, the conjugate acid of said amine having a pKa of from about 8 to about 11; said deprotecting reagent optionally further comprising one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents; and
(d) reacting said oligomers with a cleaving reagent.
Thus, in some preferred methods of the invention, a support-bound or solution phase oligomer having a plurality of phosphorus protecting groups that are capable of producing acrylonitrile, or a structurally similar product that can form an adduct with nucleobase amino groups, is contacted with a deprotecting reagent that includes at least one amine. The amine is selected such that it is a sufficiently strong base to effect the removal of a substantial majority of the phosphorus protecting groups, but insufficiently strong to cause deprotonation the thymidine N 3 position, and hence activation of that position to adduct formation. It has been found that suitable amines include those whose conjugate acids have a pKa of from about 8 to about 11, more preferably from about 9 to about 11, even more preferably from about 10 to about 11. In general, it is preferred that the amine be an aliphatic amine of the formula (R) 3 N, (R) 2 NH, or RNH 2 where R is alkyl. Two particularly suitable amines are triethylamine and piperidine.
As used herein, the term “deprotect” or deprotection” is intended to mean the removal of the vast majority, and more preferably substantially all phosphorus protecting groups from the oligomers of interest.
In preferred embodiments, the deprotecting reagent can be either an aliphatic amine, or a solution of one or more amines aliphatic as described above. In more preferred embodiments, the deprotecting reagent further comprises one or more solvents selected from the group consisting of alkyl solvents, haloalkyl solvents, cyanoalkyl solvents, aryl solvents and aralkyl solvents. Preferably, the solvent is a haloalkyl solvent or a cyanoalkyl solvent. Examples of particularly suitable solvents are acetonitrile and methylene chloride.
In the practice of the present invention, it is greatly preferred that the vast majority of the cyanoethyl groups be removed before the oligomer is treated with the relatively strong conditions of the cleavage reagent (e.g., 30% aqueous ammonium hydroxide). The rate of deprotection of β-cyanoethyl groups from oligonucleotides has been shown to exhibit a marked solvent effect. For example, the half-life of a dimer containing a single cyanoethyl group in a 1:1 v/v solution of triethylamine in acetonitrile or methylene chloride is, very approximately, 10 min. at 25° C., whereas the half-life of the same compound in triethylamine-pyridine (1:1, v/v) is about ten times longer. Eritja et al. ( Tetrahedron , 48, 4171-4182 (1992)) recommend a three hour treatment with a 40% solution of triethylamine in pyridine as sufficient to avoid formation of acrylonitrile adduct to thymidine residues in oligonucleotides subsequently treated with DBU. However, it has been discovered that under the conditions described by Eritja, many of the cyanoethyl protecting groups would remain intact. While not wishing to be bound by a specific theory, it is believed that subsequent treatment with ammonium hydroxide (or any other strong base such as DBU) would lead to the formation of unacceptable levels of residues having acrylonitrile adducts. Thus, in the present invention it is preferred that the solvent which is contained in the deprotection reagent not include pyridine, or similar heterocyclic base solvents that could extend the time for removal of oligomer-bound β-cyanoethyl or other electronically similar protecting groups.
At present, the detectable limit of acrylonitrile adduct by HPLC methodologies is believed to be about 0.1%. However, it is believed that the present methods provide oligomers having as little as 0.001% of such adduct. Thus, in preferred embodiments, the oligomers produced by the methods of the invention have from 0.001% to about 1% acrylonitrile adduct, with from about 0.1% to about 1% acrylonitrile adduct being more preferred, from about 0.1% to about 0.75% acrylonitrile adduct being even more preferred, and from about 0.1% to about 0.5% acrylonitrile adduct being even more preferred. In even more preferred embodiments, the oligomers are substantially free of detectable acrylonitrile adduct.
As used herein, the term “acrylonitrile adduct” refers to adducts to exocyclic nucleobase adducts that result from the acrylonitrile formed during removal of β-cyanoethyl phosphorus protecting groups, or similar adducts formed by removal of protecting groups that form electronically similar products upon removal. Representative examples of such protecting groups are those having the formula:
—C(R 10 ) 2 —C(R 10 ) 2 —W or —C(R 10 ) 2 —(CH═CH) p —C(R 10 ) 2 —W
wherein each R 10 is independently H or lower alkyl, W is an electron withdrawing group, and p is 1 to 3. The term “electron withdrawing group” is intended to have its recognized meaning in the art as a chemical moiety that attracts electron density, whether through resonance or inductive effects. Examples of electron withdrawing groups are cyano, nitro, halogen, phenyl substituted in the ortho or para position with one or more halogen, nitro or cyano groups, and trihalomethyl groups. Those of skill in the art will readily recognize other electron withdrawing groups, as well as other phosphorus protecting groups that have similar potential to form adducts with exocyclic amino or hydroxyl functions.
After contact with the deprotecting reagent, the oligomers can be further washed prior to reaction with a cleavage reagent, or reacted with the cleaving reagent directly. The cleaving reagent is a solution that includes a single reagent or combination of reagents that effect the cleavage of the deprotected oligomer from a solid support, and/or, where the oligomer is in solution, effects cleavage of exocyclic protecting groups, for example 30% aqueous ammonium hydroxide.
In the methods of the invention, it is generally advantageous to effect removal of substantially all phosphorus protecting groups from the oligomers, and separating the acrylonitrile or acrylonitrile-like products from the oligomers prior to exposing oligomers to the more severe basic conditions that effect cleavage from the solid support, or removal of exocyclic and/or hydroxyl protecting groups. Thus, in some preferred embodiments, a washing step is utilized in between contact with deprotecting reagent and cleaving reagent. In some preferred embodiments the washing step is performed using one or more suitable solvents, for example acetonitrile or methylene chloride. In other preferred embodiments, washing is performed with a washing reagent that contains one or more amines as is employed in the deprotecting reagent.
In some particularly preferred embodiments, a scavenger can be included in the deprotection reagent, cleaving reagent, washing reagent, or combinations thereof. In general, the scavenger is a molecule that reacts with the acrylonitrile or acrylonitrile-like products of deprotection, lowering the possibility of nucleobase adduct formation. Suitable scavengers include purines, pyrimidines, inosine, pyrroles, imidazoles, triazoles, mercaptans, beta amino thiols, phosphines, phosphites, dienes, ureas, thioureas, amides, imides, cyclic imides and ketones. Further useful scavengers include alkylmercaptans, thiols, ethylene glycol, substituted ethylene glycols, 1-butanethiol, S-(2-amino-4-thiazolylmethyl)isothiourea hydrochloride, 2-mercaptoethanol, 3,4-dichlorobenzylamine, benzylamine, benzylamine in the presence of carbon disulfide, hydroxylamine, 2-phenylindole, n-butylamine, diethyl ester of acetaminomalonic acid, ethyl ester of N-acetyl-2-cyanoglycine, 3-phenyl-4-(o-fluorophenyl)-2-butanone, 3,4-diphenyl-2-butanone, desoxybenzoin, -methoxyphthalimide, p-sulfobenzenediazonium chloride, p-sulfamidobenzenediazonium chloride.
In some preferred embodiments, the scavenger is a resin containing a suitable scavenging molecule bound thereto. Exemplary scavenger resins include polymers having free thiol groups and polymers having free amino groups, for example a polymer-bound amine resin wherein the amine is selected from benzylamine, ethylenediamine, diethylamine triamine, tris(2-aminoethyl)amine, methylamine, methylguanidine, polylysine, oligolysine, Agropore™ NH 2 HL, Agropore™ NH 2 LL, 4-methoxytrityl resin, and thiol 2-chlorotrityl resin.
The methods of the present invention are useful for the preparation of oligomeric compounds containing monomeric subunits that are joined by a variety of linkages, including phosphite, phosphodiester, phosphorothioate, and/or phosphorodithioate linkages.
As used herein, the terms “oligomer” or “oligomeric compound” are used to refer to compounds containing a plurality of nucleoside monomer subunits that are joined by internucleoside linkages, preferably phosphorus-containing linkages, such as phosphite, phosphodiester, phosphorothioate, and/or phosphorodithioate linkages. The term “oligomeric compound” therefore includes naturally occurring oligonucleotides, their analogs, and synthetic oligonucleotides.
In some preferred embodiments of the compounds of the invention, substituent W can be an electron withdrawing group selected such that it facilitates attack by a nucleophile. Accordingly, W can be any of a variety of electron withdrawing substituents, provided that it does not otherwise interfere with the methods of the invention. Preferred non-silyl electron withdrawing W groups include cyano, NO 2 , alkaryl groups, sulfoxyl groups, sulfonyl groups, thio groups, substituted sulfoxyl groups, substituted sulfonyl groups, or substituted thio groups, wherein the substituents are selected from the group consisting of alkyl, aryl, or alkaryl. Particularly preferred are alkanoyl groups having the formula R—C(═O)— where R is an alkyl group of from 1 to six carbons, with acetyl groups being especially preferred. W can also be a trisubstituted silyl moiety, wherein the substituents are alkyl, aryl or both.
In some preferred embodiments, the scavenger is a resin containing a suitable scavenging molecule bound thereto. Exemplary scavenger resins include polymers having free thiol groups and polymers having free amino groups, for example a polymer-bound amine resin wherein the amine is selected from benzylamine, ethylenediamine, diethylamine triamine, tris(2-aminoethyl)amine, methylamine, methylguanidine, polylysine, oligolysine, Agropore™ NH 2 HL, Agropore™ NH 2 LL (available from Aldrich Chem. Co. St. Louis. Mo.), 4-methoxytrityl resin, and thiol 2-chlorotrityl resin.
When used as part of the cleaving reagent, contact with fluoride ion preferably is effected in a solvent such as tetrahydrofuran, acetonitrile, dimethoxyethane, or water. Fluoride ion preferably is provided in the form of one or more salts selected from tetraalkylammonium fluorides (e.g., tetrabutylammonium fluoride (TBAF)), potassium fluoride, cesium fluoride, or triethylammonium hydrogen fluoride.
The present invention is applicable to the preparation of phosphate linked oligomers having a variety of internucleoside linkages including phosphite, phosphodiester, phosphorothioate, and phosphorodithioate linkages, and other linkages known in the art
In preferred embodiments, the methods of the invention are used for the preparation of oligomeric compounds including oligonucleotides and their analogs. As used herein, the term “oligonucleotide analog” means compounds that can contain both naturally occurring (i.e. “natural”) and non-naturally occurring (“synthetic”) moieties, for example, nucleosidic subunits containing modified sugar and/or nucleobase portions. Such oligonucleotide analogs are typically structurally distinguishable from, yet functionally interchangeable with, naturally occurring or synthetic wild type oligonucleotides. Thus, oligonucleotide analogs include all such structures which function effectively to mimic the structure and/or function of a desired RNA or DNA strand, for example, by hybridizing to a target. The term synthetic nucleoside, for the purpose of the present invention, refers to a modified nucleoside. Representative modifications include modification of a heterocyclic base portion of a nucleoside to give a non-naturally occurring nucleobase, a sugar portion of a nucleoside, or both simultaneously.
Representative nucleobases useful in the compounds arid methods described herein include adenine, guanine, cytosine, uracil, and thymine, as well as other non-naturally occurring and natural nucleobases such as xanthine, hypoxanthine, 2-aminoadenine, 6-methyl and other alkyl derivatives of adenine and guanine, 2-propyl and other alkyl derivatives of adenine and guanine, 5-halo uracil and cytosine, 6-azo uracil, cytosine and thymine, 5-uracil (pseudo uracil), 4-thiouracil, 8-halo, oxa, amino, thiol, thioalkyl, hydroxyl and other 8-substituted adenines and guanines, 5-trifluoromethyl and other 5-substituted uracils and cytosines, 7-methylguanine. Further naturally and non naturally occurring nucleobases include those disclosed in U.S. Pat. No. 3,687,808 (Merigan, et al.), in chapter 15 by Sanghvi, in Antisense Research and Application , Ed. S. T. Crooke and B. Lebleu, CRC Press, 1993, in Englisch et al., Angewandte Chemie , International Edition, 1991, 30. 613-722 (see especially pages 622 and 623, and in the Concise Encyclopedia of Polymer Science and Engineering , J. I. Kroschwitz Ed., John Wiley & Sons, 1990, pages 858-859, Cook, P.D., Anti-Cancer Drug Design , 1991, 6, 585-607. The ‘term nucleosidic base’ is further intended to include heterocyclic compounds that can serve as like nucleosidic bases including certain ‘universal bases’ that are not nucleosidic bases in the most classical sense but serve as nucleosidic bases. Especially mentioned as a universal base is 3-nitropyrrole.
As used herein, the term “alkyl” includes but is not limited to straight chain, branch chain, and alicyclic hydrocarbon groups. Alkyl groups of the present invention may be substituted. Representative alkyl substituents are disclosed in U.S. Pat. No. 5,212,295, at column 12, lines 41-50, hereby incorporated by reference in its entirety.
As used herein, the term “aralkyl” denotes alkyl groups which bear aryl groups, for example, benzyl groups. The term “alkaryl” denotes aryl groups which bear alkyl groups, for example, methylphenyl groups. “Aryl” groups are aromatic cyclic compounds including but not limited to phenyl, naphthyl, anthracyl, phenanthryl, pyrenyl, and xylyl.
As used herein, the term “alkanoyl” has its accustomed meaning as a group of formula —C(═O)-alkyl. A preferred alkanoyl group is the acetoyl group.
In general, the term “hetero” denotes an atom other than carbon, preferably but not exclusively N, O, or S. Accordingly, the term “heterocycloalkyl” denotes an alkyl ring system having one or more heteroatoms (i.e., non-carbon atoms). Preferred heterocycloalkyl groups include, for example, morpholino groups. As used herein, the term “heterocycloalkenyl” denotes a ring system having one or more double bonds, and one or more heteroatoms. Preferred heterocycloalkenyl groups include, for example, pyrrolidino groups.
In some preferred embodiments of the invention oligomers can be linked connected to a solid support. Solid supports are substrates which are capable of serving as the solid phase in solid phase synthetic methodologies, such as those described in Caruthers U.S. Pat. Nos. 4,415,732; 4,458,066; 4,500,707; 4,668,777; 4,973,679; and 5,132,418; and Koster U.S. Pat. No. 4,725,677 and U.S. Pat. No. Re. 34,069. Linkers are known in the art as short molecules which serve to connect a solid support to functional groups (e.g., hydroxyl groups) of initial synthon molecules in solid phase synthetic techniques. Suitable linkers are disclosed in, for example, Oligonucleotides And Analogues A Practical Approach , Eckstein, F. Ed., IRL Press, N.Y., 1991, Chapter 1, pages 1-23. Other linkers include the “TAMRA” linker described by Mullah et. al., Tetrahedron Letters , 1997, 38, 5751-5754, and the “Q-linker” described by Pon et. al., Nucleic Acid Research, 1997, 25, 3629-3635.
Solid supports according to the invention include those generally known in the art to be suitable for use in solid phase methodologies, including, for example, controlled pore glass (CPG), oxalyl-controlled pore glass (see, e.g., Alul, et al., Nucleic Acids Research 1991, 19, 1527, TentaGel Support—an aminopolyethyleneglycol derivatized support (see, e.g., Wright, et al., Tetrahedron Letters 1993, 34, 3373) and Poros—a copolymer of polystyrene/divinylbenzene.
In some preferred embodiments of the invention hydroxyl groups can be protected with a hydroxyl protecting group. A wide variety of hydroxyl protecting groups can be employed in the methods of the invention. Preferably, the protecting group is stable under basic conditions but can be removed under acidic conditions. In general, protecting groups render chemical functionalities inert to specific reaction conditions, and can be appended to and removed from such functionalities in a molecule without substantially damaging the remainder of the molecule. Representative hydroxyl protecting groups are disclosed by Beaucage, et al., Tetrahedron 1992, 48, 2223-2311, and also in Greene and Wuts, Protective Groups in Organic Synthesis , Chapter 2, 2d ed, John Wiley & Sons, New York, 1991. Preferred protecting groups used for R 2 , R 3 and R 3a include dimethoxytrityl (DMT), monomethoxytrityl, 9-phenylxanthen-9-yl (Pixyl) and 9-(p-methoxyphenyl)xanthen-9-yl (Mox). The hydroxyl protecting group can be removed from oligomeric compounds of the invention by techniques well known in the art to form the free hydroxyl. For example, dimethoxytrityl protecting groups can be removed by protic acids such as formic acid, dichloro-acetic acid, trichloroacetic acid, p-toluene sulphonic acid or with Lewis acids such as for example zinc bromide. See for example, Greene and Wuts, supra.
In some preferred embodiments of the invention amino groups are appended to alkyl or to other groups such as, for example, to 2′-alkoxy groups. Such amino groups are also commonly present in naturally occurring and non-naturally occurring nucleobases. It is generally preferred that these amino groups be in protected form during the synthesis of oligomeric compounds of the invention. Representative amino protecting groups suitable for these purposes are discussed in Greene and Wuts, Protective Groups in Organic Synthesis , Chapter 7, 2d ed, John Wiley & Sons, New York, 1991. Generally, as used herein, the term “protected” when used in connection with a molecular moiety such as “nucleobase” indicates that the molecular moiety contains one or more functionalities protected by protecting groups.
Sulfurizing agents used during oxidation to form phosphorothioate and phosphorodithioate linkages include Beaucage reagent (see e.g. Iyer, R.P., et.al., J. Chem. Soc ., 1990, 112, 1253-1254, and Iyer, R.P., et.al., J. Org. Chem ., 1990, 55, 4693-4699); 3-methyl-1,2,4-thiazolin-5-one (MEDITH; Zong, et al., Tetrahedron Lett . 1999, 40, 2095); tetraethylthiuram disulfide (see e.g., Vu, H., Hirschbein, B.L., Tetrahedron Lett ., 1991, 32, 3005-3008); dibenzoyl tetrasulfide (see e.g., Rao, M.V., et.al., Tetrahedron Lett ., 1992, 33, 4839-4842); di(phenylacetyl)disulfide (see e.g., Kamer, P.C.J., Tetrahedron Lett ., 1989, 30, 6757-6760); Bis(O,O-diisopropoxy phosphinothioyl)disulfides (see Stec et al., Tetrahedron Lett ., 1993, 34, 53 17-5320); 3-ethoxy-1,2,4-dithiazoline-5-one (see Nucleic Acids Research , 1996 24, 1602-1607, and Nucleic Acids Research , 1996 24, 3643-3644); Bis(p-chlorobenzenesulfonyl)disulfide (see Nucleic Acids Research , 1995, 23, 4029-4033); sulfur, sulfur in combination with ligands like triaryl, trialkyl, triaralkyl, or trialkaryl phosphines.
Useful oxidizing agents used to form the phosphodiester or phosphorothioate linkages include iodine/tetrahydrofuran/water/pyridine or hydrogen peroxide/water or tert-butyl hydroperoxide or any peracid like m-chloroperbenzoic acid. In the case of sulfurization the reaction is performed under anhydrous conditions with the exclusion of air, in particular oxygen whereas in the case of oxidation the reaction can be performed under aqueous conditions.
Oligonucleotides or oligonucleotide analogs according to the present invention hybridizable to a specific target preferably comprise from about 5 to about 100 monomer subunits. It is more preferred that such compounds comprise from about 5 to about 50 monomer subunits, more preferably 10 to about 30 monomer subunits, with 15 to 25 monomer subunits being particularly preferred. When used as “building blocks” in assembling larger oligomeric compounds, smaller oligomeric compounds are preferred. Libraries of dimeric, trimeric, or higher order compounds can be prepared by the methods of the invention. The use of small sequences synthesized via solution phase chemistries in automated synthesis of larger oligonucleotides enhances the coupling efficiency and the purity of the final oligonucleotides. See for example: Miura, K., et al., Chem. Pharm. Bull ., 1987, 35, 833-836; Kumar, G., and Poonian, M.S., J. Org. Chem ., 1984, 49, 4905-4912; Bannwarth, W., Helvetica Chimica Acta , 1985, 68, 1907-1913; Wolter, A., et al., nucleosides and nucleotides , 1986, 5, 65-77.
The present invention is amenable to the preparation of oligomers that can have a wide variety of 2′-substituent groups. As used herein the term “2′-substituent group” includes groups attached to the 2′ position of the sugar moiety with or without an oxygen atom. 2′-Sugar modifications amenable to the present invention include fluoro, O-alkyl, O-alkylamino, O-alkylalkoxy, protected O-alkylamino, O-alkylaminoalkyl, O-alkyl imidazole, and polyethers of the formula (O-alkyl)m, where m is 1 to about 10. Preferred among these polyethers are linear and cyclic polyethylene glycols (PEGs), and (PEG)-containing groups, such as crown ethers and those which are disclosed by Ouchi, et al., Drug Design and Discovery 1992, 9, 93, Ravasio, et al., J. Org. Chem . 1991, 56, 4329, and Delgardo et. al., Critical Reviews in Therapeutic Drug Carrier Systems 1992, 9, 249, each of which are hereby incorporated by reference in their entirety. Further sugar modifications are disclosed in Cook, P.D., Anti-Cancer Drug Design , 1991, 6, 585-607. Fluoro, O-alkyl, O-alkylamino, O-alkyl imidazole, O-alkylaminoalkyl, and alkyl amino substitution is described in U.S. patent application Ser. No. 08/398,901, filed Mar. 6, 1995, entitled Oligomeric Compounds having Pyrimidine Nucleotide(s) with 2′ and 5′ Substitutions, now U.S. Pat. No. 6,166,197, hereby incorporated by reference in its entirety.
Representative 2′—O— sugar substituents of formula XII are disclosed in U.S. patent application Ser. No. 09/130,973, filed Aug. 7, 1998, entitled Capped 2′-Oxyethoxy Oligonucleotides, now U.S. Pat. No. 6,172,209, hereby incorporated by reference in its entirety.
Sugars having O-substitutions on the ribosyl ring are also amenable to the present invention. Representative substitutions for ring O include S, CH 2 , CHF, and CF 2 , see, e.g., Secrist, et al., Abstract 21, Program & Abstracts, Tenth International Roundtable, Nucleosides, Nucleotides and their Biological Applications, Park City, Utah, Sep. 16-20, 1992.
Representative 2′—O— sugar substituents of formula XIII are disclosed in U.S. patent application Ser. No. 09/123,108, filed Jul. 27, 1998, now U.S. Pat. No. 6,271,358, entitled RNA Targeted 2′-Modified Oligonucleotides that are Conformationally Preorganized, hereby incorporated by reference in its entirety.
In one aspect of the invention, the compounds of the invention are used to modulate RNA or DNA, which code for a protein whose formation or activity it is desired to modulate. The targeting portion of the composition to be employed is, thus, selected to be complementary to the preselected portion of DNA or RNA, that is to be hybridizable to that portion.
The oligomeric compounds and compositions of the invention can be used in diagnostics, therapeutics and as research reagents and kits. They can be used in pharmaceutical compositions by including a suitable pharmaceutically acceptable diluent or carrier. They further can be used for treating organisms having a disease characterized by the undesired production of a protein. The organism should be contacted with an oligonucleotide having a sequence that is capable of specifically hybridizing with a strand of nucleic acid coding for the undesirable protein. Treatments of this type can be practiced on a variety of organisms ranging from unicellular prokaryotic and eukaryotic organisms to multicellular eukaryotic organisms. Any organism that utilizes DNA-RNA transcription or RNA-protein translation as a fundamental part of its hereditary, metabolic or cellular control is susceptible to therapeutic and/or prophylactic treatment in accordance with the invention. Seemingly diverse organisms such as bacteria, yeast, protozoa, algae, all plants and all higher animal forms, including warm-blooded animals, can be treated. Further, each cell of multicellular eukaryotes can be treated, as they include both DNA-RNA transcription and RNA-protein translation as integral parts of their cellular activity. Furthermore, many of the organelles (e.g., mitochondria and chloroplasts) of eukaryotic cells also include transcription and translation mechanisms. Thus, single cells, cellular populations or organelles can also be included within the definition of organisms that can be treated with therapeutic or diagnostic oligonucleotides.
As will be recognized, the steps of the methods of the present invention need not be performed any particular number of times or in any particular sequence. Additional objects, advantages, and novel features of this invention will become apparent to those skilled in the art upon examination of the following examples thereof, which are intended to be illustrative and not intended to be limiting.
EXAMPLES
Example 1
Comparative Example
Present Invention Versus Prior Art Method of Erjita et al.
Treatment of cyanoethyl protected oligonucleotide phosphorothioates with ammonium hydroxide results in the generation of one equivalent of acrylonitrile (AN) per phosphorothioate linkage. In the presence of ammonium hydroxide a small percentage of thymidine residues react with the liberated AN to form N 3 -cyanoethylthymidine (CN-T) residues.
Nonadecathymidinyloctadecaphosphorothioate (T-19 P═S) was synthesized and deprotected under three sets of conditions:
(a) Ammonium hydroxide, 60° C., 16 h; (b) Triethylamine-pyridine (2:3 v/v), 25° C., 3 h then ammonium hydroxide, 60° C., 16 h; (c) Triethylamine-acetonitrile (1:1, v/v), 25° C., 12 h, then ammonium hydroxide, 60° C., 16 h.
The second set of conditions are those recommended by Erijta. The crude oligonucleotides obtained by evaporation of the ammonium hydroxide lysates were detritylated and inspected by liquid chromatography-mass spectroscopy (LC-MS) in order to quantify the amount of CN-T present. It was shown that the levels of CN-T in T-19 P═S samples subjected to conditions a), b) and c) were ca. 15%, 2% and less than 0.1%, respectively.
The results demonstrate that the conditions proposed by Erijta lead to the formation of oligonucleotides that still contain high levels of CN-T residues, where as the methods of the present invention suppress CN-T formation to a level below the detection limit of the assay.
Example 2
Synthesis of fully-modified 5′-d (TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20 mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 1 minute. At the end of synthesis, the support was washed with a solution of triethylamine in acetonitrile (1:1, v/v) for 12 h, cleaved, deprotected and purified in the usual manner.
Example 3
Synthesis of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 160 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was washed with a solution of triethylamine in acetonitrile (1:1, v/v) for 12 h, cleaved, deprotected and purified in the usual manner.
Example 4
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 1 minute. At the end of synthesis, the support was transferred to a container, stirred with a solution of triethylamine in acetonitrile (1:1, v/v) for 12 h, filtered, then treated with 30% aqueous ammonium hydroxide, cleaved, deprotected and purified in the usual manner.
Example 5
Synthesis of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 160 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was transferred to a container, stirred with a solution of triethylamine in acetonitrile (1:1, v/v) for 12 h, filtered, then treated with 30% aqueous ammonium hydroxide, cleaved, deprotected and purified in the usual manner.
Example 6
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazolc in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 1 minutes. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with thymidine, cleaved, deprotected and purified in the usual manner.
Example 7
Synthesis of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 160 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with thymidine, cleaved, deprotected and purified in the usual manner.
Example 8
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 1 minute. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with uridine, cleaved, deprotected and purified in the usual manner.
Example 9
Synthesis of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 160 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with uridine, cleaved, deprotected and purified in the usual manner.
Example 10
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile: 3-picoline (1:1 v/v) for 1 minutes. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with imidazole, cleaved, deprotected and purified in the usual manner.
Example 11
Synthesis of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 160 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.45 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was taken in 30% aqueous ammonium hydroxide along with imidazole, cleaved, deprotected and purified in the usual manner.
Example 12
GMP Manufacture of fully-modified 5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′ phosphorothioate 20-mer [SEQ ID NO: 2] (ISIS 2302) on OligoProcess ISIS 2302 [5′-d(GCC-CAA-GCT-GGC-ATC-CGT-CA)-3′] [SEQ ID NO: 2] was manufactured under Good Manufacturing Practice (GMP) conditions on a Pharmacia OligoProcess Synthesizer on a 150 mmole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was washed with a solution of triethylamine in acetonitrile (1:1, v/v) for 30 minutes and then let stand at room temperature overnight, filtered, washed with acetonitrile solvent and then treated with 30% aqueous ammonium hydroxide, cleaved, deprotected and purified in the usual manner. The oligonucleotide was analyzed by mass spectroscopy to confirm the elimination of acrylonitrile adduct.
Example 13
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with thymidine nucleoside (20 equivalents), deprotected and purified in the usual manner.
Example 14
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with uridine nucleoside (20 equivalents), deprotected and purified in the usual manner.
Example 15
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with inosine nucleoside (20 equivalents), deprotected and purified in the usual manner.
Example 16
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichioroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with thymine (25 equivalents), deprotected and purified in the usual manner.
Example 17
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with uracil (25 equivalents), deprotected and purified in the usual manner.
Example 18
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with imidazole (50 equivalents), deprotected and purified in the usual manner.
Example 19
Synthesis of fully-modified 5′-d(TTT-TTT-TTT-TTT-TTT-TTT-T)-3′ phosphorothioate 20-mer [SEQ ID NO: 1]
The synthesis of the above sequence was performed on a Pharmacia OligoPilot I Synthesizer on a 30 micromole scale using the cyanoethyl phosphoramidites obtained from Pharmacia and Pharmacia's HL 30 primary support. Detritylation was performed using 3% dichloroacetic acid in toluene (volume/volume). Activation of phosphoramidites was done with a 0.4 M solution of 1H-tetrazole in acetonitrile. Sulfurization was performed using a 0.2 M solution of phenylacetyl disulfide in acetonitrile:3-picoline (1:1 v/v) for 2 minutes. At the end of synthesis, the support was incubated with benzyl mercaptan (50 equivalents), deprotected and purified in the usual manner.
Examples 20-27
Oligonucleotide Synthesis.
Oligodeoxynucleotides were assembled on an ABI 380B DNA Synthesizer using 5′—O—(4,4′-dimethoxytrityl)nucleoside 3′—O—(carboxymethyloxy)acetate derivatized CPG 1 (shown in Scheme 1 below) phosphoramidite chemistry, and either commercial oxidizer or 3H-1,2-benzodithiol-3-one 1,1-dioxide (0.05 M in MeCN) as the sulfur-transfer reagent.
Deoxynucleoside CE phosphoramidites protected in a standard manner (A bz , C bz , G ib ) were used to synthesize oligonucleotides presented in Examples 21, 23-27. Those used for the preparation of oligonucleotides presented in Examples 20 and 22 were uniformly protected with either phenoxyacetyl (PAC) or 4-(t-butyl)phenoxyacetyl (tBPA) groups.
Example 20
Two Step Deprotection of Oligonucleotideas with Secondary Amines in an Organic Solvent Followed by Methanolic K 2 CO 3 .
Deprotection procedure is exemplified on Scheme 2 for dodecathymidylate 5. After completeness of oligonucleotide synthesis a solid support-bound 2 was decyanoethylated with either 2M diethylamine or 1M piperidine in MeCN, dioxane, THF, or DMF (3 mL) for 2 to 12 h. The column was washed with dioxane (10 mL) to give 3. Other amines, for instance, morpholine, pyrrolidine, or dimethylamine can also be used on this step.
The oligonucleotide 4 was released from the solid support 3 by treatment with 0.01 to 0.05 M K 2 CO 3 in MeOH (2′5 mL and 2′20 mL for 1 and 15 mmol syntheses, respectively). Each portion was passed forth and back through the column for 45 min, neutralized by passing through short column with Dowex 50W′8 (PyH + ; ca. 1 mL). The combined eluates were evaporated to dryness, co-evaporated with MeCN (10 mL), and dissolved in water. Target oligonucleotide 4 was isolated by RP HPLC on a Delta Pak 15 mm C18 300Å column (3.9×300 mm and 7.8×300 mm for 1 and 15 mmol syntheses, respectively), using 0.1 M NH 4 OAc as buffer A, 80% aq MeCN as buffer B, and a linear gradient from 0 to 60% B in 40 min at a flow rate 1.5 and 5 mL min −1 , respectively. Collected fractions were evaporated and detritylated with 80% aq AcOH for 30 min at room temperature. The solvent was evaporated, the product was re-dissolved in water and desalted by injecting on to the same column, then washing with water (10 min) and eluting an oligonucleotide 5 as an ammonium salt with 50% aq MeCN (20 min). Homogeneity of 5 was characterized by RP HPLC and capillary electrophoresis. ESMS: 3764.2 (found); 3765.1 (calculated)
The efficiency of the deprotection method was verified in preparation of oligonucleotide phosphorothioates 6 and 7 (Isis 1939) and phosphodiester oligonucleotide 8 in 1 to 15 mmol scale.
6: C 5 A 2 T 11 [SEQ ID NO: 3] thioate. ESMS: 5628.3 (found); 5629.6 (calculated). 7: C 5 AC 2 ACT 2 C 4 TCTC [SEQ ID NO: 4] thioate. ESMS: 6438.6 (found); 6440.2 (calculated). 8: C 5 A 2 T 11 . [SEQ ID NO: 3] ESMS: 5355.8 (found); 5356.4 (calculated).
Example 21
Two step deprotection of oligonucleotide TGCATC 5 AG 2 C 2 AC 2 AT [SEQ ID NO: 5] (9) with secondary amines in an organic solvent followed by ammonolysis.
A solid support-bound oligonucleotide was decyanoethylated with either 2M diethylamine or 1M piperidine, morpholine, or diethylamine in MeCN, dioxane, THF, or DMF as described in Example 20. Other amines, for instance, morpholine, pyrrolidine, or dimethylamine can also be used on this step.
The solid support was treated with conc. aq ammonia for 2 h at room temperature, the solution was collected and kept at 55° C. for 8 h. On removal of solvent, the residue was re-dissolved in water and purified as described in Example 20.
9: ESMS: 5980.9 (found); 5982.8 (calculated). 10: TGCATC 5 AG 2 C 2 AC 2 AT [SEQ ID NO: 5] thioate. ESMS: 6287.8 (found); 6288.0 (calculated).
Example 22
Deprotection of Synthetic Oligonucleotides with Aqeous Amines.
Deprotection procedure is exemplified for oligonucleotide 10. A solid support-bound material (20 μmol) was treated with 1 M aq piperidine for 2 h at room temperature. Other amines, for instance, morpholine, pyrrolidine, diethylamine, dimethylamine, ethylamine, or methylamine can also be used on this step. The solid support was washed with another portion of the deprotecting reagent, and combined solutions were evaporated under reduced pressure. Crude 5′-DMTr protected oligonucleotide was dissolved in water (5 mL) and purified by semipreparative HPLC on a DeltaPak C18 column (Waters, 15 mm; 300 Å; 25′100 mm) using 0.1 M NH 4 OAc as buffer A, 80% aq MeCN as buffer B, and a linear gradient from 0 to 40% B in 50 min at a flow rate 15 mL min −1 . Collected fractions were evaporated, the residue was treated with 80% aq AcOH for 30 min and evaporated to dryness. The obtained material was dissolved in 50% aq DMSO and loaded onto the same column. The column was washed with 0.05 M aq NaOAc (15 min) and water (15 min) at a flow rate 15 mL min −1 . Elution with 60% aq MeCN and evaporation to dryness gave 23.0 mg (20%) of desalted oligonucleotide 10 (Na + salt), ESMS: 6286.4 (found); 6288.0 (calculated).
Example 23
Deprotection of Synthetic Oligonucleotides with Aqueous Secondary Amines.
On completeness of oligonucleotide synthesis, a solid support-bound material (20 mmol) was treated with an aq amine as described in Example 22. On evaporation of the solution of the deprotecting reagent, the residue was treated with ammonium hydroxide for 8 h at 55° C., and the solvent was evaporated. The product, 6, was isolated and characterized as described in Example 22.
Example 24
Deprotection of Synthetic Oligonucleotides with Ammonia in the Presence of Aminoalkyl Resins as Acrylonitrile Scavengers. Method A.
On completeness of oligonucleotide synthesis, a solid support-bound material (20 mmol) is mixed with an aminoalkyl resin [for instance, aminoalkyl CPG or polymer-bound tris(2-aminoethyl)amine] and treated with conc. aq ammonia for 2 h at room temperature. The solid phase is filtered off, and the deprotection is completed by keeping the solution at 55° C. for 8 h. The solvent was evaporated, and the product is isolated and characterized as described in Example 22.
Example 25
Deprotection of Synthetic Oligonucleotides with Ammonia in the Presence of Aminoalkyl Resins as Acrylonitrile Scavengers. Method B.
A solid support-bound material (20 mmol) is treated with a flow of conc. aq ammonia for 2 h at room temperature. On leaving the reaction vessel, the solution is passed through a second column that contained an aminoalkyl resin as in Example 24, and collected. Optionally, the collected solution may be recycled by passing again through both columns. When the releasing of oligonucleotide from CPG is complete, the oligonucleotide solution is collected and treated as in Example 24.
Example 26
Deprotection of Synthetic Oligonucleotides with Ammonia in the Presence of Morcaptanes as Acrylonitrile Scavengers.
A solid support-bound oligonucleotide was treated with conc. aq ammonia and thiocresol (0.1 M) for 2 h at room temperature, the solution was collected and kept at 55° C. for 8 h. On removal of solvent, the residue was re-dissolved in water and extracted twice with methylene chloride. The aqueous layer was collected, and the product, 5, was isolated and characterized as described in Example 20. Other thiols, for instance, thiophenol, mercaptoethanol, 1,3-ethanedithiol, or ethanethiol can also be used as acrylonitrile scavengers.
Example 27
Deprotection of Synthetic Oligonucleotides with Ammonia in the Presence of Mercaptoalkylated Resins as Acrylonitrile Scavengers.
A solid support-bound oligonucleotide is treated as in Example 25, but the second column contains a mercaptoalkylated resin (for instance, reported previously mercaptoalkylated resins 1 or NovaSyn 0 TG thiol resin). The product is isolated and characterized as described in Example 20.
Those skilled in the art will appreciate that numerous changes and modifications may be made to the preferred embodiments of the invention and that such changes and modifications may be made without departing from the spirit of the invention. It is therefore intended that the appended claims cover all such equivalent variations as fall within the true spirit and scope of the invention. | Synthetic processes are provided wherein oligomeric compounds are prepared having phosphodiester, phosphorothioate, phosphorodithioate, or other covalent linkages. The oligomers have substantially reduced exocyclic adducts deriving from acrylonitrile or related contaminants. | 8 |
FIELD OF THE INVENTION
This invention relates to the process of manufacturing micro-electro-mechanical systems (MEMS), and, in particular, to MEMS devices having sealed cavities or encapsulated movable parts.
BACKGROUND OF THE INVENTION
This disclosure builds on prior art describing a method for constructing micro-electro-mechanical systems by using multiple sacrificial thin film layers removed using a liquid etch.
It is known in the prior art to create sealed cavities on an integrated circuit for a variety of applications, for example, as a speaker or microphone. It is also known to encapsulate movable mechanical components on an integrated circuit within a sealed cavity. The encapsulation of micro-electro-mechanical structures in a sealed cavity is desirable for several reasons. First, the tolerance of the structures to ambient conditions, such as high humidity, is greatly improved. Second, the dicing and packaging of the MEMS devices is greatly facilitated. Third, when the cavity is at a low or very low ambient pressure, the Brownian noise due to the motion of gas molecules can be significantly reduced.
Processes to create sealed cavities on the surface of a silicon wafer using only thin film deposition and etching techniques have already been developed to create MEMS microphones and speakers for sound and ultrasound. Starting with a silicon substrate, which could in principle have CMOS devices and interconnects already patterned onto it, a protective layer is placed over the entire wafer. Next a sacrificial layer is deposited. Then, the sacrificial layer is patterned to remove it over all parts of the wafer that are not going to be microencapsulated. Next, an encapsulating layer is deposited over the entire wafer. Very small holes are then patterned and etched through the encapsulating layer at selected positions over the sacrificial layer, and the wafer is immersed in a liquid chemical bath containing an etchant that is highly selective, to dissolve the sacrificial layer while not attacking the encapsulating layer or the protective layer. Finally, an insulating or conducting layer that will act to seal the membrane must be deposited onto the wafer. The etch access hole can be sealed off either by material accumulating up from or by material depositing laterally on the sides of the hole growing inward and sealing off the hole. In either case, the final layer serves to both plug the etch holes and to seal the cavity created when the sacrificial material was etched away.
It is also known to create MEMS microstructures within sealed cavities such as the one described above. See, for example, U.S. Pat. Nos. 5,285,131 and 5,493,177 (both to Muller, et al.) in which methods to create an incandescent lamp and a vacuum tube respectively are disclosed. The method disclosed is as follows. A silicon substrate is covered with a non-etchable protective layer that is selectively removed, thereby exposing the silicon wafer in the region to be encapsulated. Then, a layer of poly-silicon is deposited and patterned to cover the exposed silicon window and extending up onto the silicon nitride protection layer in selected positions that will be used as entry points for the liquid etching agents. Non-etchable conductors are then deposited and patterned on top of both the non-etchable mask layer and on top of the silicon substrate in the window. Next, a sacrificial layer is deposited and etched so that it only covers the structures in the region to be encapsulated. The encapsulation process proceeds with the deposition of an encapsulation layer and the etching of small holes in the encapsulation layer located over the poly-silicon above the protection layer that will guide the etching agents into the cavity. In this case, the etching step requires two different liquid etchants—the first one to selectively etch away silicon and poly-silicon and a second one to etch away the sacrificial layer. The encapsulation process is completed by depositing a seal layer to seal up the etch entry holes in the diaphragms.
It is desirable to use a wet etchant, in many cases hydro-fluoric acid, because of its high degree of selectivity, that is, the ability to selectively etch away the sacrificial layers, leaving behind the microstructure and cavity walls. However, one unfortunate problem when working with a “wet” etchant is that the surface tension generated as the liquid evaporates can be strong enough to bend or even break delicate MEMS microstructures. Therefore, the use of liquid etching agents severely limits the complexity of the MEMS microstructures that can be released from sacrificial layers in the cavity because only simple MEMS microstructures can tolerate the surface tension forces exerted by typical liquid etching agents as the surface is drying. MEMS devices having suspended structures have been developed using a wet release etch. However, the structures were quite simple, for example, wires supported at both ends with a small number of meanders. However, in order to create a wide range of MEMS devices, for example, acceleration sensors, quite flexible MEMS structures are necessary. These flexible structures would most likely be destroyed by the surface tension effects of a wet etch.
It is therefore desirable to create MEMS structures with out the wet etch step, eliminating potential damage to delicate MEMS structures by the surface tension created by the wet etchant. Such a process would improve yields of the devices, thereby making their production more economical. Additionally, more complex structures could be developed.
SUMMARY OF THE INVENTION
The disclosed invention specifies improvements to the known MEMS fabrication process by selecting a combination of layers for the MEMS structural layers, seal layer and the sacrificial layers that allows release of the microstructures using a dry plasma etchant. Ideally, the dry etchant would have a high etch rate for the material composing the sacrificial layers and a low etch rate with respect to the material composing the structural and seal layers. This eliminates the undesirable liquid surface tension inherent in the wet etch process.
DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show a top view and a side cross-sectional view respectively of the silicon CMOS wafer used as the base of the MEMS micro-encapsulated structure.
FIGS. 2A and 2B show a top view and a cross-sectional view respectively of the wafer of the FIG. 1A with a sacrificial layer deposited thereon.
FIGS. 3A and 3B show a top view and a cross-sectional view respectively of the wafer of FIGS. 2A and 2B having a structural layer added thereon.
FIGS. 4A and 4B show a top view and a cross-sectional view respectively of the wafer of FIGS. 3A and 3B having a second sacrificial layer deposited thereon.
FIGS. 5A and 5B show a top view and a cross-sectional view respectively of the wafer of FIGS. 4A and 4B having a seal layer applied thereon.
FIGS. 6A and 6B show a top view and a cross-sectional view respectively of the wafer of FIGS. 5A and 5B having etch holes drawn therein.
FIGS. 7A , 7 B and 7 C show a top view, a cross-sectional view along line 7 B and a cross-sectional view along line 7 C respectively of the wafer having the sacrificial layers removed by an enchant.
FIGS. 8A and 8B show a top view and a cross-sectional view respectively of the wafer having a second seal layer applied thereon, thereby sealing the etch holes.
FIGS. 9A and 9B show a top view and a cross-sectional view respectively of the second seal layer having been removed from the contact pad on the base wafer.
DETAILED DESCRIPTION
In general, the invention disclosed refers to gas phase release of any number of microstructure layers whose movement is independent or coupled and which are encapsulated in the thin film seal layer. However, in order to explain the invention, one specific embodiment will be described in detail below, namely a microstructure that can be utilized as a Z-axis accelerometer. This device consists of a paddle shaped MEMS microstructure anchored at one point by a thin supporting member such that it can move vertically within the sealed cavity.
FIGS. 1–9 illustrate the sequence of steps comprising the fabrication of the proposed encapsulated integrated microstructure CMOS process. We start by obtaining or fabricating a silicon CMOS wafer 2 coated with a layer of silicon nitride 4 and having metal pads interfacing to the original CMOS integrated circuit 6 , 8 and 10 present as shown. Openings appear in the silicon nitride layer 4 to allow access to metal pads 6 and 8 . In the preferred embodiment, the metal pads would be aluminum, but may alternatively be copper or any other conductive material.
To begin the fabrication process, a sacrificial layer 12 is deposited on top of the passivation layer of the standard CMOS wafer 2 , which in this case is silicon nitride layer 4 . The MEMS device fabrication steps are all performed at low temperature on top of the complete CMOS wafer 2 , leaving the circuitry therein undisturbed. Cuts in the passivation layer 4 are left during the CMOS IC design and sacrificial layer 12 is removed over these cuts if access to the metal contacts is desired. The exposed metal contacts 6 and 8 are then used to make connections between the MEMS microstructure and the CMOS circuitry in silicon CMOS wafer 2 below. This is illustrated in FIG. 2A .
In the preferred embodiment the microstructure may be composed of any metal, for example, Al, W, Ti, Ta, Cu, Ni, Mo, etc., but in the preferred embodiment would be made of aluminum. The selection of material for a particular microstructure layer is dictated by two factors. First, how much residual stress gradient in the material is acceptable for a particular application and, second, by the availability of a selective etchant that removes the portions of the microstructure which are undesired, while stopping on or having a low etch rate for the silicon nitride passivation layer 4 and the sacrificial layer 12 .
The deposition of the MEMS layer is shown in FIG. 3A and in cross section in FIG. 3B . MEMS microstructure 14 is deposited by methods known by those with ordinary skill in the art and the undesirable portions are etched away, thereby leaving the desired shape of the microstructure behind. The top view of FIG. 3B clearly shows the shape of the microstructure as being a paddle having a long thin beam attached to an anchor point, which in this case is metal contact 8 .
Next, as shown in FIG. 4A , and in cross section in FIG. 4B , a second sacrificial layer 16 is deposited over the microstructure. It can be seen from the top view that portions of the top sacrificial layer 16 will come into contact with portions of the bottom sacrificial layer 12 , in particular, those areas near the edges of the paddle-shaped main body of the microstructure and those areas on either side of the thin connecting beam portion of the microstructure.
In the preferred embodiment, and, if possible as dictated by the shape of microstructure 14 , sacrificial layers 12 and 16 will be of the same material and will have a connection to each other, such that when etchant is introduced, both layers will be etched away without the need to etch additional etchant entry holes. Alternatively, sacrificial layers 12 and 16 may be of different materials. Although not necessary in the construction of the microstructure of this example, more complex microstructures, or multiple microstructures in the same cavity may require etching away of various sacrificial layers at different times, making it necessary to use different materials for the sacrificial layers and different etchants.
The preferred material for sacrificial layers 12 and 14 is photoresist. Photoresist is chosen for this reason because it can be etched with an oxygen plasma gas, which is not destructive of aluminum microstructure 14 , silicon nitride passivation layer 4 or seal layer 18 . FIGS. 4A and 4B show the deposition of second sacrificial layer 16 .
If sacrificial layers 12 and 16 are of different materials it is possible to etch them separately by selecting an etchant that is selective to one and not the other. It is even possible that a wet etch could be used with one of the sacrificial layers. For example, sacrificial layer 16 may be phosphorous-doped glass and the etchant may be hydrofluoric acid. This may be desirable because the wet etchants are generally faster acting than the dry etchants. As long as the microstructure is held in place by one or more other sacrificial layers, the surface tension problem will be avoided. In this case, it is only necessary that the last sacrificial layer binding the microstructure in place be removed using the dry-etchant process.
FIGS. 5A and 5B show the deposition of seal layer 18 . This layer may be composed of an insulator or a conductor, depending on the desired electrical operation of the microstructure. Additionally, the seal layer must have a low enough residual stress and must be thick enough that the membrane created by the seal layer 18 will not buckle after the sacrificial layers 12 and 16 have been removed. In the preferred embodiment, seal layer 18 is the same metal as was chosen for the microstructure layer 14 , but in alternate embodiments may be made of any material resistant to the etchant chosen. In the event an insulating material is chosen for seal layer 18 , it may be patterned and removed to give access to the non-MEMS parts of the integrated circuit, such as bond pads 6 and 8 . If seal layer 18 is a conductor, it may be contacting one or both of bond pads 6 or 8 .
Next, one or more etchant access holes 20 , shown in FIGS. 6A and 6B are etched into seal layer 18 such that communication can be established with sacrificial layers 12 and 16 . This etch is done by any means well known to anyone of ordinary skill in the art. Preferably etch holes 20 will be as far away as possible from the actual MEMS microstructure. Next, as shown in FIGS. 7A , 7 B and 7 C, the etchant is introduced into holes 20 and sacrificial layers 12 and 16 are etched away, leaving void 22 . FIG. 7B shows a cross-sectional view of the device through the center, while FIG. 7C shows a cross-sectional view through one of the etchant access holes. A dry plasma etchant is used to avoid problems created by the surface tension of a wet etchant. In the preferred embodiment, the etchant is oxygen plasma. Oxygen plasma was chosen because it is highly selective with respect to the etching sacrificial layers 12 and 14 , which may be photoresist or other organic polymers, while having an extremely low etching rate for a wide variety of metals and insulators.
At this point, microstructure 14 is able to move vertically within the cavity created by open space 22 previously occupied by sacrificial layers 12 and 16 , with beam 15 acting as a spring and contact pad 8 acting as an anchor point. Depending upon the distance from the etch access holes to the furthest point of sacrificial layers 12 or 16 to be removed, etching time using the oxygen plasma may be quite long. It is preferred for this reason that a barrel etcher be used in the etching process such that a plurality of wafers may be etched at the same time.
The final step, shown in FIG. 8A , is the application of a second seal layer 26 to seal etch holes 20 . In the preferred embodiment, seal layer 26 is the same metal as seal layer 18 and MEMS microstructure 14 . As shown in FIG. 9 , if the second seal layer is not a conductor then it may be etched away using well known methods from the area over contact pad 6 , or it may be left in electrical contact with compact pad 6 . Final seal layer 26 may be etched away from contact pad 6 , or, if seal layer 26 is composed of a conductor, may be left in place.
A simple microstructure that could be utilized as a Z-axis accelerometer has been described to show the general process of creating a microstructure in a sealed cavity using a dry-etch process. However, as realized by one or ordinary skill in the art, and as contemplated by the scope of this patent, the process may be used to build microstructures of more complexity, involving many combinations of sacrificial and structural layers, as long as the last sacrificial layers binding any microstructure component are removed with the dry-etch process. Additionally, alternative combinations of material may be utilized for the dry etchant and sacrificial layer combinations, as long as the etchant selected has a low etch rate with respect to the microstructure material and the material utilized for the passivation and seal layers. Additionally, movable structures consisting of many layers of stacked sacrificial and structural materials are within the scope of this invention. | The disclosed fabrication methodology addresses the problem of creating low-cost micro-electro-mechanical devices and systems, and, in particular, addresses the problem of delicate microstructures being damaged by the surface tension created as a wet etchant evaporates. This disclosure demonstrates a method for employing a dry plasma etch process to release encapsulated microelectromechanical components. | 1 |
FIELD OF THE INVENTION
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 62/050,645 filed on Sep. 15, 2014, which is included herein in its entirety by this reference thereto.
[0002] This invention relates generally to a solar powered charging station configured for recharging cell phones, tablets, laptops and other electronic devices. More particularly, it pertains to an environmentally friendly device and method for the provision of a charging station for electronic devices providing comfortable shaded seating from an overhead shade structure adapted with an angle to increase shade and maximize the output of rooftop solar energized panels producing electrical current to power the device.
BACKGROUND
[0003] In recent years, the popularity of portable electronic devices employed for computing, communications, presentations, mapping and navigation and for other functions has expanded exponentially. In recent years, with the expansion of wireless network capabilities of both public and private networks, smartphones, pad computers, and a plethora of other devices populate the electronics market. All of which have rechargeable batteries which must frequently be charged.
[0004] This need to maintain an operable charge on such portable electronic devices will only increase with the ever expanding number of wireless devices and available wireless networks and mobile hotspots to service such devices. By nature, such devices employ electrical power for the broadcast and receipt of data during network connections. Concurrently, with the battery drain caused by RF wireless communications, the display screen and the electronic computing components of the devices all use electrical power to produce the displayed indicia on the engaged display screen and to process the data using software on the computer component of such devices. This results in a continuous plurality of sources of power drain from the batteries on portable wireless devices as well as portable devices which may be hard-wired to a network connection since the onboard network card employs electric power to transmit and receive data over the network.
[0005] Other larger devices use onboard electrical power stored in batteries. Such include for example golf carts, wheel chairs, powered coolers for food and other contents, and a host of portable devices which use electricity to function and draw such from batteries. Just as with smaller devices, these large devices using power must be recharged to continue to function.
[0006] Conventionally, users of portable electronic devices, both small and large, must plug electric chargers into their electronic portable devices. These charging devices generally are connected to the local electric grid and after a duration of connection will provide a recharge of electric power to onboard batteries of small and large portable devices. Alternatively, many users have vehicle-engageable chargers which may be employed to charge their portable device using a connection to the vehicle in which they may be riding such as a car, truck, airplane, or train or the like, which has an electric generating capability.
[0007] However, many public places where users of portable electronic devices may traverse, such as airports, beaches, recreation areas and the like, have severely limited connections to the power grid for recharging portable electronic devices. This lack of grid power results in users of small and larger portable battery-powered electronic devices being unable to recharge their power supplies when such is invariably required.
[0008] Additionally, many airlines and train lines do not provide connections for device chargers during travel, or offer connections which are not compatible with the charger employed by many users. Thus, the electronic portable devices of users can frequently discharge onboard batteries to the point the portable device becomes inoperable.
[0009] The problem for electronic device users having trouble charging their battery-powered electronic devices is not limited to traveling. Average users frequently forget to charge their device at home or the office, and then find themselves located with their electronic phone or pad computer or other battery-powered device is in danger of losing function when they are visiting a shopping center, mall, campus, beach, outdoor venue such as a zoo or concert, or other venues lacking a connection to the local grid or another power supply.
[0010] While there are charging stations inside many such venues such as airports and campuses, such charging stations are at best inconvenient. This is because they require the user to stand proximate to their slowly charging device, or leave it to charge and risk the potential their device might not be at the charging station when they return. Some such charging stations will provide an exchange of a portable charging component engageable with the user's device. However, most such charging stations generally charge very high rates to use the provided power connections, and use grid-power produced by fossil fuels and therefor not environmentally friendly, and not positionable in locations where such grid power is not easily connected.
[0011] As such, there is an unmet need for a device and method which will provide for the charging of electronic devices for users who may be situated at airports and train stations, outdoor concert venues, shopping centers, campuses, hotels, spas, parks and other public places not proximate to an electrical grid power connection. Such a device should be adapted to both capture and employ electrical power from a regenerative source which is environmentally friendly. Further, such a device and method should not only provide the users with electrical power, but also provide users a comfortable and preferably shaded and climate controlled area to sit while their device is being re-energized, which also takes advantage of regenerative power sources. Finally, such a device should be configured with electrical storage capacity and sufficient solar electrical generation to allow the charging station device to be located at any outdoor venue without the need for a connection to a power grid, thereby significantly increasing the number of venues where the charging station device may be placed.
[0012] With respect to the above, before explaining at least one preferred embodiment of the device and method for recharging portable electronic devices in detail or in general, it is to be understood that the invention is not limited in its application to the details of employment and to the arrangement of the components or the steps set forth in the following description or illustrated in the drawings. The various apparatus and methods of the herein disclosed invention for capturing solar power and providing both charging and cool shaded areas for sitting is capable of other embodiments, and of being practiced and carried out in various ways, all of which will be obvious to those skilled in the art once the information herein is reviewed.
[0013] Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 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 other charging devices and methods. It is important, therefore, that the embodiments, objects and claims herein, be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.
SUMMARY OF THE INVENTION
[0014] The charging station device and method herein solve the shortcomings of the prior art, through the provision of an easily loadable combination including a charging station with user seating which is configured for positioning anywhere an adequate sunlight supply is available to generate electrical power. Thus, the device herein may be situated outside in malls or shopping centers, outdoor concert and other arenas, outdoor areas adjacent airports and train stations, beaches, national parks, and virtually anywhere the sun rises for a sufficient time to charge the onboard batteries using the roof-positioned solar cells.
[0015] The roof-mounted photovoltaic solar panel or a solar array of such solar panels, includes sufficient solar cells to generate electric power when contacted with the anticipated sunlight in the geographic area which the device is to be located, to charge one or a plurality of onboard eclectic storage batteries operatively engaged to the solar array. The slanted roof, supported by opposing sidewalls, doubles as a shade structure and rain shield for users of the device who may be seated on an underlying bench or seat which is situated to cover a lower housing atop a battery compartment therein. Operative wiring from the solar array to the underlying eclectic storage batteries within the battery compartment is routed through passages within the roof and the supporting sidewalls and thereby communicate to operative engagement with the batteries located in the battery compartment.
[0016] The opposing sidewalls engaged to the base on opposite sides of the seating bench are unequal in length to thereby impart a determined slant to the roof and engaged solar array, when operatively situated over the underlying bench. This angle or slant of the roof may be changed to maximize the communication of sunlight to the solar array when the device is operatively postponed on the ground or support surface at a venue. This determined angle of the roof relative to a level roof may change depending on the latitude in which the device is located for operation. A greater incline or slant may be imparted to the roof of devices located at latitudes closer to the North or South poles to better provide for sunlight contact with the solar panel and such may be accommodated by changing the length of extension above the bench of one or both sidewalls which may be configured for independent replacement to accommodate such a change in angular disposition of the roof.
[0017] Wired in operative communication with the batteries are a plurality of charging ports, and/or power sockets such as AC power sockets, and/or inductive charging components, which are operatively engaged with power plates positioned on the sidewalls. Appropriate electric transformers and power invertors if needed and other components well known in the art to convert DC solar panel voltage to the desired AC or DC power and voltage, will be situated between the batteries which are charged by the solar panel, as well as in-between the storage batteries and one or a plurality of user-engageable connectors for charging wires located in the power plates.
[0018] One or a plurality of power plates will be populated with such electrical connectors which may vary in mechanical configuration for allowing for engagement for any of multiple power cords which users may employ to communicate electric power from the charging station device, to charge the battery on their respective electronic device, or to power for instance an AC powered device such as a drill or charging of electric vehicles.
[0019] Inductive charging connection areas may also be provided for wireless charging. Such will allow users having differing power cord connectors to operatively connect their electronic device to the system herein for charging or to power the device in real time. The connectors are of course adapted for replacement to allow for engagement of new connecters as standards change over time.
[0020] Additionally, provided to facilitate easy transport and location is a recess or passage formed at a bottom edge of opposing sidewalls of the lower housing section of the charging station device. A passage communicating between and through the recesses in the bottom edges of the opposing sidewalls will allow for the operative communication of forks from a pallet jack or forklift or the like to elevate the charging station device for easy rolling transport to a desired position at a venue or geographic location.
[0021] Further provided in the favored mode of the device, is an LED illuminated overhead panel to provide lighting to the area of the charging station under the roof. Such will run on electrical power generated by the solar panels or array and will use minimal electrical power to provide maximum illumination of the seating area under the roof when required.
[0022] Employing the onboard electric power generated by the solar array and stored in the onboard batteries located within the lower housing, and employing electric components operatively engaged for the interfacing electric power to the component or purpose, the device may also be configured for:
[0023] security camera monitoring of surrounding areas employing WiFi or other wireless communication to communicate captured images;
[0024] providing cooling fans and/or water misting for users positioned under the roof;
[0025] providing a potable water supply to users through the employment of solar powered water condensing;
[0026] providing an emergency medical station where patients may be provided care remotely;
[0027] providing a safe haven wherein operative RF monitoring components and software running on a computing device powered by the power from the device would ascertain any emergency call made within 100 feet and emit a light and sound beacon to dissuade attackers and or alert first responders to the area of the situation;
[0028] providing cold water and other products using solar powered refrigeration;
[0029] using onboard wireless communications equipment powered by the charging station device, providing weather information from an onboard display and speakers or interactive sports odds/betting;
[0030] using an onboard display powered by the batteries of the charging station device to operatively engaged wireless media electronic components to generate a feed to the display and/or sound, provide a news feed, sports scores, interactive news, a stock ticker, a local events calendar, a photo booth, a video calling station, a Lo-jack/find my phone interface, an emergency telephone call station or beacon, or other media which may be generated by the onboard electronic equipment operatively powered by the power generated by the device.
[0031] Additionally, employing the onboard power generated by the batteries or solar panels of the charging station device, and operative electronic components also thereby powered, the charging station device may also function as an emergency broadcast system warning device to warn people proximate thereto of an immediate emergency, and to emit a visual and/or audio warning and safety instructions in such an event, for example an approaching tsunami at a beach location.
[0032] Finally, the device and system may function using the onboard power as an Amber/Silver Alert notification system to operative electronic phones and computers of people proximate to the charging station device in the event of an Amber Alert or Silver Alert. In such an event, operative well known electronic components operatively engaged with the charging station device would emit a visual and audio signal, as well as provide images on the onboard display of those missing, their last known whereabouts and any vehicle information pertinent to the bulletin.
[0033] As can be discerned, the charging station device herein, through the provision of onboard electrical power generation and storage capacity, can provide any or all of the above functions in a single unit, all of which are enabled wirelessly thereby allowing the positioning of the device virtually anywhere sufficient sunlight is available to provide the electrical power from the onboard solar array, to charge onboard electric storage such as a battery or batteries, to power the electronic components needed for the included functions.
[0034] It is an object of this invention to provide an electric power generation charging station device in combination with a roofed seating area for users to occupy during use.
[0035] Another object of the invention is to provide such a power generation device and user occupied roofed housing which includes power connections and wireless communications to operate a plurality of electronic components and video displays and audio producing components to enable the device for multi functions without the need for a connection to the power grid or a hard wired connection to a network.
[0036] The foregoing has outlined some of the more pertinent objects of the invention provided by the device and system herein. These objects should be construed to be merely illustrative of some of the more prominent features and applications of the intended invention. Many other beneficial results can be attained by applying the disclosed device and system in a different manner or by modifying the invention within the scope of the disclosure.
[0037] Accordingly, other objects and a fuller understanding of the invention may be had by referring to the summary of the invention and the detailed description of the preferred embodiment in addition to the scope of the invention defined by the claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is perspective view of a preferred mode of the charging station device showing a housing formed of a lower section or bench portion covered by an engaged upper section having an angled roof supported by opposing support walls defining a tilt to the roof.
[0039] FIG. 2 depicts a mode of the charging station device of FIG. 1 also showing multiple charging connections which may be differently configured for different plug configurations and an optional area for video display and/or payment interfaces such as credit card readers if necessary, and an optional tilting solar panel axis.
[0040] FIG. 3 is a cut-away sectional view of the charging station device of FIG. 1 or 2 , showing the engagement of the lower section of the housing of the charging station device to the upper section.
[0041] FIG. 4 shows a elevation view of the lower section of the housing having a passage communicating thereunder between opposing sides.
[0042] FIG. 5 is a sectional view through the lower section of the housing of FIG. 4 showing the interior compartment within the lower section defining the bench portion and enclosing the battery, electronic interface components.
[0043] FIG. 6 depicts another sectional view through the lower section of the housing providing the base for the charging station device and storage compartment.
[0044] FIG. 7 shows one mode of a mating surface providing a removable engagement between the support walls of the upper section and the lower section of the housing, and as could also be used on inserts if also employed to raise or lower the angle of the solar panel.
[0045] FIG. 8 depicts a depiction of a side view of the upper section of the housing showing the support walls which can be varied in length to change the roof angle by changing their lengths and/or using engageable inserts of differing widths.
[0046] FIG. 9 shows a mode of the power plate employed for operative engagement of power chord sockets and engagement components.
[0047] FIG. 10 depicts one preferred mode of the layered configuration of the LED lighting and diffusers.
DETAILED DESCRIPTION OF THE INVENTION
[0048] Referring now to FIGS. 1-10 herein, wherein similar components are identified by the same numerals, there can be seen in one favored view of the charging station device 10 showing an assembled view showing the structural and ornamental aspects of the unique configuration of the assembled device 10 . The device 10 has a housing 11 formed of an upper section 13 in a removable engagement to a lower section 15 which provides for ease of configuration the tilt of the roof 14 to adjust an angle of the solar panel 12 thereon. The device 10 is lightweight and easily loadable thereby providing a combination charging station and user shelter and seating apparatus which is adapted for positioning anywhere an adequate sunlight supply is available for the solar panel 12 .
[0049] Shown in FIGS. 1-3 are a roof-mounted photovoltaic solar panel 12 or solar array, which includes sufficient solar cells to generate electric power for the intended use of the device 10 taking into consideration the geographic area which the device 10 is to be located. The roof 14 , providing the mount for the solar panel 12 , is supported by opposing support walls 16 and 18 , and so supported, forms a shade structure within the user cavity between the roof 14 and the bench 20 as well as a rain shield for users who may be seated on the underlying bench 20 positioned on top of a lower section 15 of the housing 11 .
[0050] Shown in FIG. 3 , the lower section 11 of the housing 11 has an interior cavity 24 underneath the bench 20 which may be padded with a cushion 19 . Supports 21 support users seated on the upper wall of the cavity 24 defining the bench 20 and which defines a top area of the interior cavity 24 which is sized for the operative positioning of a plurality of one or a plurality of batteries 26 therein.
[0051] Operative wiring (not shown but well known) communicates through both the lower section 15 and upper section 13 of the housing 11 such as running through supports 41 in the support wall 18 along a race therein, from the solar array or solar panel 12 . This allows communication of electric power to the underlying batteries 26 within the interior cavity 24 . The wiring for both the batteries 26 , and any electronic interfaces, wireless communications, inventors, transformers, and to and from video displays and charging connections, and the like, is routed through passages within the roof 14 and the supporting sidewalls 16 and 18 and the interior cavity 24 and is well known in the art and need not complicate the drawings by depiction thereof.
[0052] As shown in FIGS. 1-3 the opposing support walls 16 and 18 are engaged to the lower section 15 of the housing 11 on opposite sides of the formed bench 20 using removable mating connections between both components such as plates 39 operatively positioned on both the support walls 16 and 18 and opposite ends of the lower section 13 of the housing 11 .
[0053] The sidewalls 16 and 18 as shown, are purposely formed unequal in length to thereby impart a determined slant to the roof 14 providing the mount for the solar array 12 . This angle of the roof 14 can be changed, by changing the respective length of one or both sidewalls 16 and 18 . The angle of the roof 14 being changeable is particularly preferred so as to maximize the communication of sunlight to the solar panel 12 of the device 10 , depending on the latitude in which the device 10 is positioned for operation.
[0054] Wired in operative communication with the batteries 26 are a one or preferably a plurality of charging ports engaged with the housing 11 with plates or power plates 27 . The plates 27 are configured to engage with the housing 11 with one surface exposed which has an electric connector therein such as such as AC or DC power sockets, and/or inductive charging components, which are operatively engaged with power plates 27 positioned on the sidewalls 16 and 18 or roof 12 interior. Such connectors might also include USB cord connectors, plug receptacles for AC power cords, or any other connector configured to engage and existing or future connector used for charging a portable electrically powered device. The plurality of power plates 27 can be populated with a plurality of differing electrical connectors adapted to engage a plurality of different power cords which users may employ to communicate electric power from the device 10 , to their respective electrical device for charging, or to power for instance an AC powered device.
[0055] Additionally preferred in the device 10 , as shown in FIGS. 1 - 3 for example, to facilitate easy transport, is a recess 30 formed in opposing sidewalls of the lower section 15 of the housing 11 . As noted the opposing recesses 30 form a passage therethrough and therebetween, underneath the lower section 15 configured for engagement of a lifting component such as forks from a pallet jack or forklift or similar lifting component which may be employed to elevate the device 10 for easy rolling transport to the desired position.
[0056] As shown in FIG. 2 , the device 10 may also include an engagement of the solar panel 12 to the roof 14 on a rotatable member or axis 21 . The axis 21 may be engaged to an electrically operated or mechanical rotating component 23 such as an electric motor. With the included axis 21 engagement of the solar panel 12 , it may be tilted around the axis 21 to optimize the angle of contact of sunlight with the solar panel 12 , in addition to adjusting the tilt of the roof 14 . By including the axis 21 and rotating component 23 the solar panel 12 will thus be angularly adjustable in two different planes. Additionally, shown in FIG. 2 are an optional video display 31 and the inclusions of means for electronic payment by a user such as a credit card reader 33 or other means for digitally authorizing payment.
[0057] Shown in FIG. 3 , and additionally preferred for inclusion in the favored mode of the device 10 herein, is an LED illuminated panel 32 . The illuminated panel 32 is preferred to provide illumination to the area under the roof 12 which is a low power draw from generated power from the solar panel 12 . A diffuser 33 is situated to provide even directed light from the LED panel 32 .
[0058] As noted, using the electric power generated by the solar panel 12 and stored in a plurality of batteries 26 within the lower section 15 of the housing 11 , and employing electric components operatively engaged for the purpose, the device may also be configured with a digital video camera for security camera monitoring of surrounding areas. The camera may employ hard wiring or wireless communication to send captured images to a remote location. A fan may be engaged to the roof 14 of support walls 16 and 18 , to provide a cooling breeze to users positioned under the roof 14 .
[0059] In other modes a water filtering component might be powered and engaged and provide a potable water supply to users or such might be supplied using solar powered water condensing. Using RF communication equipment 41 such as transceivers the device 10 may be configured for RF monitoring and software running on a computing device 43 having electronic memory and electronic computing processors powered by the power from the device 10 can operate as a cellular antenna and re broadcaster and also operate to monitor RF traffic and ascertain any emergency call made within 100 feet of the device 10 . Thereafter, it may be configured to emit a discernable alarm, such as a light and sound beacon to dissuade attackers and or alert first responders to the area of the situation.
[0060] Additionally, the computing device 43 and the onboard wireless RF communications equipment 41 powered by the device 10 and the video display 31 the device 10 can be enabled to provide weather information from the onboard display 41 and speakers (not shown). Or the device 10 can be configured as an informational stand using an onboard display 31 powered by the device and operatively engaged electronic components of the computing device 43 to generate a video display feed to the display 31 and/or sound, and thereby provide users with a news feed, sports scores, interactive news, a stock ticker, a local events calendar, a photo booth, a video calling station, a Lo-jack/find my phone interface, an emergency telephone call station or beacon, or other media which may be generated by the onboard electronic equipment operatively powered by the power generated by the device.
[0061] Additionally, employing the onboard power generated by the device 10 , and operative electronic components of the computing device 43 powered by the device 10 , the device may also function as an emergency broadcast system warning device to warn people proximate thereto of an immediate emergency, and emit the alarm as a visual and/or audio warning and safety instructions in such an event. Further, the device 10 using the onboard power may be configured to function as an Amber/Silver Alert notification system for people proximate to the device 10 in the event of an Amber Alert or Silver Alert communicated wirelessly to the device.
[0062] As can be discerned, the device 10 , through the provision of onboard electrical power generation and storage capacity, can be easily configured by those skilled in the art, with wiring and computing devices 43 and RF wireless communications 41 and display screen 31 and audio, to provide any or all of the above functions in a single unit. Consequently, such components need not be shown in detail.
[0063] Seen in FIGS. 4-6 are differing views of the lower section 15 which is removably engageable to the upper section 13 forming the housing 11 of the device 10 . Currently preferred dimensions of the device 10 lower section 15 are shown in FIG. 4 , including the three inch wide passage 49 communicating underneath the lower section 15 .
[0064] Also shown in FIGS. 4-6 and in FIG. 7 , are the removably engageable mating connections for the lower section 15 of the housing 11 to the support walls 16 and 18 of the upper portion 13 of the housing 11 . The plates 39 on both the support walls 16 and 18 and the lower section 15 of the housing 11 , have apertures 43 which are aligned when the plates 39 are mated. Thereafter, removable connectors such as a nuts and bolts can be engaged through the aligned mated apertures 43 . A wiring aperture 43 is also shown for passage of operative wiring engagements therethrough.
[0065] In FIG. 8 is shown a side view of an upper portion 13 of the housing 11 which can be engaged to any lower portion 15 having the mating connections therefor. As shown the opposing support walls 16 and 18 , can be configured with a gap 50 for insertion of wall inserts 51 in-between the roof 14 and the support walls 16 and 18 . The wall inserts 51 would engage with mating connections as noted above or other mating connections such as a sliding engagement of each wall insert 51 in between a support wall 16 or 18 , and the roof 14 . Such can be by a slots formed in the mating surfaces of both the roof 14 and the top of each support wall 16 and 18 engageable by projections on each side surface of the wall insert 51 , or other means of engagement therebetween known in the art.
[0066] Consequently, the angle of the roof 14 and attached solar panel 12 is abusable relative to a level surface such as the depicted bench 20 . The angle of the roof 14 may be adjusted by changing the length of either of the support walls 16 and 18 to thereby change the angle of the roof 14 when the upper section 13 is engaged to the lower section 15 of the housing 11 . Or inserts 51 of differing widths can be engaged into the formed gap 50 in the support walls 16 and 18 . The gaps 50 themselves may be two engaged surfaces of a support wall 16 and 18 and the roof 14 , which are disengageable for removable engagement of an insert 51 therein using the same connection between mating surfaces as the roof 14 and the sidewalls 18 .
[0067] The device 10 being portable and solar powered is adapted for positioning anywhere sufficient sunlight is available, and as such may be provided to users as an accommodation by venue owners such as shopping centers, or can be positioned as part of plurality of available charging and communication stations available to subscribing members who would log in upon starting use of a device 10 at a location and have an account which is paid by the subscriber for access to the devices 10 in the plurality of locations available.
[0068] FIG. 9 is a depiction of one mode of the power plates 27 which may be employed herein. Also shown are the one or a plurality of openings 29 which can be fitted with differing electrical connections for differing charging cords.
[0069] Shown in FIG. 10 is the layered configuration for the light for the device to illuminate the user cavity between the roof 14 and bench 20 .
[0070] While all of the fundamental characteristics and features of the disclosed power generating portable structure have been shown and described, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure. It will be apparent that in some instance, some features of the invention may be employed without a corresponding use of other features, or steps may be rearranged for operations, without departing from the scope of the invention as set forth. It should be understood that any such substitutions, modifications, and variations, may be made by those skilled in the art, without departing from the spirit or scope of the invention. Consequently, all such modifications and variations are included within the scope of the invention as defined herein. | A solar powered charging station device is provided which is configured for recharging mobile devices using battery power such as cell phones, tablets, laptops and other electronic devices. A housing of the device is formed of an upper section having an angled roof with solar panels therein engaged to a lower section having storage batteries and electronic interface equipment. Users may engage charging cords for devices to a charging connector configured for such engagement to the device for charging. A bench provides seating which is shaded by the roof and protected from rain during use. | 7 |
[0001] This application claims the benefit of priority to U.S. Provisional Application No. 60/479,469 filed on Jun. 19, 2003, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a snowmobile, and more particularly to a cover structure of a belt transmission system of a snowmobile.
BACKGROUND OF THE INVENTION
[0003] A snowmobile generally includes an engine, a ski and steering assembly, a drive track assembly, a belt transmission system for transmitting power from the engine to the drive track assembly, and a chassis as a supporting base of the snowmobile. The belt transmission system includes an endless belt surrounding a pair of spaced-apart pulleys. The engine and the belt transmission system are enclosed within a fairing shell at a front portion of the snowmobile. The fairing shell usually includes a hood and at least one side panel which are openable to allow for inspection and maintenance of the engine and the belt transmission system.
[0004] In a belt-breaking accident, pieces of a broken belt could be thrown around due to the angular momentum of the turning belt, particularly if the hood or side panel of the snowmobile were open during such an occurrence, as is required under certain circumstances such as engine or belt transmission system inspection, maintenance, or the like.
[0005] Conventionally, a pulley cover which is an elongate and curved metal panel, is positioned above the belt and the pulleys in order to prevent pieces of a broken belt from being thrown around to potentially cause injury to persons. Conventional pulley covers also offer a certain amount of protection such that a person cannot easily place his/her hands on the turning belt or pulleys. The conventional pulley cover is conveniently mounted to the chassis of the snowmobile and can be completely removed. However, it is apparent that the protection provided by this type of conventional pulley covers can, in some circumstances, be limited. In particular, the conventional pulley cover cannot prevent catching clothing in the pulleys in all situations.
[0006] Efforts have been made to develop pulley covers offering better protection. For example, some prior art vehicles provide a pulley cover with a complete housing. However, while those pulley covers provide some protection they, are inconvenient to remove or open for allowing access to the belt transmission system when required. Therefore, there is a need for an alternative belt transmission system covering structure to address these problems.
SUMMARY OF THE INVENTION
[0007] It is one object of the present invention to provide a belt transmission system cover structure for snowmobiles which not only helps to prevent accidental access to the belt transmission system while it is turning, but also conveniently allows for access to the belt transmission system when required.
[0008] In accordance with one aspect of the present invention, an apparatus for covering a belt transmission system which is operatively supported on a chassis of a snowmobile and includes an endless belt surrounding a pair of spaced apart pulleys, comprises an upper cover portion and a side cover portion. The upper cover portion is adapted for preventing access to the pulleys and belt from a top of the snowmobile. The side cover portion is attached to an outer side edge of the upper cover portion, extending downwardly therefrom, and is adapted for preventing access to the pulleys and belt from a side of the snowmobile. Means are positioned at an end of the upper cover portion for pivotally mounting the upper cover portion to the chassis, thereby permitting the upper and side cover portions to pivot away from the belt transmission system about an axis transverse to a longitudinal centerline of the snowmobile, when access to the pulleys and belt is required.
[0009] The pivotal mounting means preferably comprises a pin pivotally interconnecting a front end of the upper cover portion and a mounting portion of the chassis. The upper cover portion preferably comprises a locking device located at a rear end thereof for releasably securing the apparatus in a closed position.
[0010] The side cover portion preferably comprises a noise absorption structure. In one embodiment of the present invention the side cover portion includes a foam material attached to an inner side thereof.
[0011] In accordance with another aspect of the present invention, there is provided a snowmobile having an engine, a ski and steering assembly, a drive track assembly, a belt transmission system for transmitting power from the engine to the drive track assembly, and a chassis as a supporting base of the snowmobile. The snowmobile further comprises a belt transmission system cover including an upper cover portion and a side cover portion attached to an outer side edge of the upper cover portion and extending downwardly therefrom. Means are provided for pivotally mounting the belt transmission system cover at a front end of the upper cover portion, to the chassis, thereby permitting the belt transmission system cover to pivot about an axis transverse to a longitudinal centerline of the snowmobile, between a first position in which the upper cover portion is disposed above the belt transmission system and the side portion is disposed at an outer side of the belt transmission system, and a second position in which the belt transmission system cover is pivoted away from the first position allowing for access to the belt transmission system when required.
[0012] The snowmobile preferably comprises means for releasably securing the belt transmission system cover in the first position. The upper cover portion is preferably shaped to correspond with an upper contour of the belt transmission system. The side cover portion preferably includes a lower edge positioned at a bottom surface of the chassis when the belt transmission system cover is in the first position. It is also preferable that the snowmobile includes an external shell for enclosing the engine and belt transmission system and that the belt transmission system cover is disposed within the external shell.
[0013] The belt transmission system cover according to the present invention not only effectively helps to prevent pieces of a broken belt from being thrown around in a belt-breaking event but also effectively prevents injuries caused by people placing their hands or catching their clothing on the turning belt and pulleys, and further advantageously provides a simple structure for easy installation and convenient opening when access to the belt transmission system is required.
[0014] The present invention still further advantageously improves suppression of the noise produced by the belt transmission system.
[0015] Other features and advantages of the present invention will be better understood with reference to the preferred embodiment described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Having thus generally described the nature of the present invention, reference will now be made to the accompanying drawings by way of illustration showing a preferred embodiment, in which:
[0017] [0017]FIG. 1 is a schematic side view of a snowmobile incorporating one embodiment of the present invention;
[0018] [0018]FIG. 2 is a rear, side perspective view of a belt transmission system cover according to the embodiment of the present invention, incorporated in the snowmobile of FIG. 1;
[0019] [0019]FIG. 3 is a front, side perspective view of the belt transmission system cover of FIG. 2;
[0020] [0020]FIG. 4 is a partial perspective view of FIG. 1, with fairings of the snowmobile removed, showing the belt transmission system cover of FIG. 2 installed in position, with a side cover portion being partially cut away for illustrative purposes; and
[0021] [0021]FIG. 5 is a partial cross-sectional view of the side cover portion, showing a layer of foam material attached thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring now in detail to the drawings, and primarily to FIGS. 1 and 4, a snowmobile incorporating an embodiment of the present invention is identified generally by the reference numeral 10 . Although certain facets of the present invention might be applicable in other types of vehicles, the present invention has particular utility in connection with snowmobiles.
[0023] The snowmobile 10 includes a forward end 12 and a rearward end 14 which are defined consistently with the travel direction of the vehicle. The snowmobile 10 includes a chassis 16 which normally includes a rear tunnel 18 , an engine cradle portion 20 and a front suspension assembly portion 22 . An engine 24 which is schematically illustrated in FIG. 1, is carried by the engine cradle portion 20 of the chassis 16 . A ski and steering assembly (not indicated) is provided, in which two skis 26 are positioned at the forward end 12 of the snowmobile 10 and are attached to the front suspension assembly portion 22 of the chassis 16 through a front suspension assembly 28 . The front suspension assembly 28 includes ski legs 30 , supporting arms 32 and ball joints (not shown) for operatively joining the respective ski legs 30 , supporting arms 32 and a steering column 34 . The steering column 34 at its upper end is attached to a steering device such as a handlebar 36 which is positioned forward of a rider and behind the engine 24 to rotate the ski legs 30 and thus the skis 26 , in order to steer the vehicle.
[0024] An endless drive track 38 is positioned at the rear end 14 of the snowmobile 10 and is disposed under tunnel 18 , being connected operatively to the engine 24 through a belt transmission system 40 which is schematically illustrated by broken lines in FIG. 1. Thus, the endless drive track 38 is driven to run about a rear suspension assembly 42 for propulsion of the snowmobile 10 . The rear suspension assembly 42 includes a pair of slide rails 44 in sliding contact with the endless drive track 38 . The rear suspension assembly 42 also includes one or more shock absorbers 46 which may further include a coil spring (not shown) surrounding the individual shock absorbers 46 . Front and rear suspension arms 48 and 50 are provided to attach the slide rails 44 to the chassis 16 . One or more idler wheels 52 are also provided in the rear suspension assembly 42 .
[0025] At the front end 12 of the snowmobile 10 , there are provided fairings 54 that enclose the engine 24 and the belt transmission system 40 , thereby providing an external shell that not only protects the engine 24 and the belt transmission system 40 , but can also be decorated to make the snowmobile 10 more aesthetically pleasing. Typically, the fairings 54 include a hood (not indicated) and one or more side panels which are both openable to allow for access to the engine 24 and the belt transmission system 40 when this is required, for example, for inspection or maintenance of the engine 24 and/or the belt transmission system 40 . In the particular snowmobile 10 shown in FIG. 1, the side panels can be opened along a vertical axis to swing away from the snowmobile 10 . A windshield 56 may be connected to the fairings 54 near the front end 12 of the snowmobile 10 or directly to the handlebar 36 . The windshield 56 acts as a wind screen to lessen the force of the air on the rider while the snowmobile 10 is moving.
[0026] A seat 58 extends from the rear end 14 of the snowmobile 10 to the fairings 54 . A rear portion of the seat 58 may include a storage compartment or can be used to accept a passenger seat (not indicated). Two footrests 60 are positioned on opposed sides of the snowmobile 10 below the seat 58 to accommodate the rider's feet.
[0027] The engine 24 is a type of internal combustion engine that is supported on the chassis 16 and is located at the engine cradle portion 20 . The internal construction of the engine 24 may be of any known type, however the engine 24 drives an engine output shaft (not shown) that rotates about a horizontally disposed axis that extends generally transversely to a longitudinal centerline 61 of the snowmobile 10 . Best seen in FIG. 4, the engine output shaft drives the belt transmission system 40 and in the illustrated embodiment, the belt transmission system 40 includes a drive pulley 62 . The drive pulley 62 , in turn, drives a driven pulley 64 by way of an endless belt 66 which surrounds the pair of pulleys 62 , 64 . The driven pulley 64 is, in turn, coupled in an appropriate manner to a drive shaft (not shown) which transmits the torque power generated by the engine 24 in a well known manner, to the endless drive track 38 for propulsion of the snowmobile 10 .
[0028] Referring now to FIGS. 2-4, a transmission system cover 68 is provided to prevent pieces of a broken belt from being thrown around in a belt-breaking event, particularly when the hood and side panels of the fairings 54 of FIG. 1 are opened while the engine 24 is running. The transmission system cover 68 includes an upper cover portion 70 preferably made of aluminium. The upper cover portion 70 is formed as an elongate panel and is curved to correspond with the upper contours of the belt transmission system 40 . Thus, the upper cover portion 70 can be placed in a close relationship to the belt 66 and the pulleys 62 , 64 when being disposed thereabove and being attached to the engine cradle portion 20 of the chassis 16 . The upper cover portion 70 when in place, can effectively prevent access to the pulleys 62 , 64 and the belt 66 from a top of the snowmobile 10 .
[0029] The transmission system cover 68 further includes a side cover portion 72 attached to an outside edge 74 of the upper cover portion 70 and extending downwardly therefrom such that access from a side of the snowmobile 10 to the pulleys 62 , 64 and the belt 66 , is effectively prevented. The side cover portion 72 is preferably made of a plastic material. A pin 75 is received in a sleeve 76 formed at the front end of the upper cover portion 70 , with opposed ends projecting laterally therefrom. The opposed laterally projecting ends of the pin 75 are pivotally received in a pair of holes (not indicated) in a bracket 78 which is part of the chassis 16 and is disposed in the engine cradle portion 20 forward of the drive pulley 62 . The pin 75 is secured in place by well known fastening mechanisms such as clips 80 , and its longitudinal axis extends transversely to the longitudinal centerline 61 of the snowmobile 10 of FIG. 1. Thus, the transmission system cover 68 is permitted to pivot about the pin 75 between a first position (as shown in FIG. 4) in which the upper cover portion 70 is disposed above the belt transmission system 40 and the side cover portion 72 is disposed at an outer side of the belt transmission system 40 , and a second position in which the transmission system cover 68 is pivoted away from the first position thereof, as indicated by the arrow P in order to permit access to the belt transmission system 40 when required, for example, when maintenance work needs to be done on the belt 66 and/or the pulleys 62 , 64 . Optionally, reinforcing ridges 82 can be formed at the front end of the upper cover portion 70 in order to increase the rigidity of the upper cover portion 70 .
[0030] A plurality of clips 84 are fixed to the rear end of the upper cover portion 70 and are releasably engagable with complimentary components (not shown) disposed on a section of a vertical panel 86 which, as part of the chassis 16 , extends upwardly from a bottom surface 88 of the chassis 16 and is disposed immediately behind the driven pulley 64 . The clips 84 with their complimentary components provide a means for releasably securing the transmission system cover 68 in the first position. Alternatively, a securing pin (not shown) can replace clips 84 and can selectively lock the rear end of the upper cover portion 70 to the vertical panel 86 with appropriate mechanisms which are well known in the art and will not therefore be further discussed herein. Other well known types of locking devices can also be alternatively used.
[0031] The side cover portion 72 has a lower edge 90 positioned to extend to the bottom surface 88 of the chassis 16 , preferably as close as possible to the bottom surface 88 , when the transmission system cover 68 is in the first position. The side cover portion 72 can be molded with laterally projecting portions or recessed portions to closely correspond to the contours of the belt transmission system 40 . Holes (not shown) through the side cover portion 72 are optional. These configurations having holes or projecting portions may be selected in some models of snowmobiles because there is not enough clearance between a flat side cover portion 72 and for example, a nut 94 which affixes the drive pulley 62 to the engine output shaft.
[0032] When the snowmobile 10 is running without moving, or especially when it is moving across the ground, the engagement of the belt 66 with the pulleys 62 , 64 produces a substantial amount of noise. In conventional snowmobiles, the noise and its reflections off the side of the bottom pan of the snowmobiles can exit through the air vents in the hood.
[0033] In order to provide a noise insulation result, the side cover portion 72 is preferably profiled to cover the opening defined between the upper cover portion 70 and the bottom surface 88 of the chassis 16 , and between the vertical panel 86 of the chassis 16 and a section of the engine cradle portion 20 which is disposed forwardly of the drive pulley 62 and immediately supports the bracket 78 . Preferably, the inner side of the transmission cover 68 includes a noise absorption structure as shown in FIG. 5. For example, a layer of foam material 96 can be attached to the inner side of the side cover portion 72 . Optionally, a similar foam layer also can be applied to the inner surface of the upper cover portion 70 . Thus, the noise is kept within the space defined by the engine 24 , the upper and side cover portions 72 , 64 , and the chassis 16 , and is partially absorbed by the foam layer 96 .
[0034] The upper cover portion 70 of the illustrated embodiment is made of aluminium, but can be formed of other materials which can adequately bear the impact forces exerted thereupon by the thrown pieces of a broken belt. The plastic side cover portion 72 can be attached to the outer side edge 74 of the upper cover portion 70 by any well known and suitable fastening means. In this particular embodiment, a plurality of bolts 92 are used to bolt the side cover portion 72 together with the upper cover portion 70 . Alternatively, the transmission system cover 68 can be made as a single unit, such as an integral cover made from a blank of sheet metal in a pressing process.
[0035] The entire transmission system cover 68 is disposed within the external shell of fairings 54 of FIG. 1, and is accessable and pivotally openable when a corresponding side panel of the external shell is opened. When the corresponding side panel of the external shell is opened, the transmission system cover 68 can not only be pivotally opened, but can also be completely removed from the chassis 16 by removing the clips 80 and the pin 74 .
[0036] Modifications and improvements to the above-described embodiment of the present invention may become apparent to those skilled in the art. The foregoing description is intended to be exemplary rather than limiting. The scope of the present invention is therefore intended to be limited solely by the scope of the appended claims. | A belt transmission system of a snowmobile includes a cover which has an upper cover portion and a side cover portion. The cover is pivotally mounted to the chassis of the snowmobile so that it can not only be conveniently installed or removed, but can also be pivotally opened to allow for access to the belt transmission system. The cover effectively prevents injury when the hood and side panel of fairings of the snowmobile are open. The cover further includes noise absorption material attached thereto. Thus, noise reduction is improved by better confining the noise produced by engagement of the belt with the pulleys within an inner space, and by partially absorbing the noise energy. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional of U.S. patent application Ser. No. 13/061,802, which is a U.S. National Phase Application based on International Application No. PCT/US2012/056222, filed Sep. 8, 2009, which claims the benefit of, and priority to, U.S. Provisional Patent Application Ser. No. 61/095,541, filed on Sep. 9, 2008. The disclosure of all applications are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the preparation of modified polymers by chemically incorporating a compositional modifier into a polymer chain to produce the modified polymer. More particularly, the invention relates to the preparation of condensation type copolyesters by joining short length polyester or polyester oligomers with a modifier which contains hydroxyl acids blocks.
BACKGROUND OF THE INVENTION
[0003] Condensation polymers such as thermoplastic polyesters, polycarbonates, and polyamides have many desirable physical and chemical attributes that make them useful for a wide variety of molded, fiber, and film applications. However, for specific applications, these polymers also exhibit limitations that should be minimized or eliminated. To overcome these limitations, polymers are frequently made containing one or more additives or comonomers depending upon the desired end use of the polymer. One of the most common thermoplastic polyester polymers is polyethylene terephthalate (PET).
[0004] PET polymer is used extensively in the packaging industry, especially in the production of bottles for carbonated and non-carbonated beverages. In the carbonated beverage industry, concerns include the rate of carbon dioxide escape from the container, taste deterioration of the contents due to degradation by light, and extraction of additives added either during melt polymerization or subsequent melt processing that is required to fabricate the container. To overcome these problems, PET resins are often modified by incorporating unique comonomers into the polymer backbone thus producing a wide variety of PET copolyesters. For example, 2,6-naphthalenedicarboxylate (2,6-NDC) is coplymerized with ethylene glycol (EG) and terephthalic acid (TPA), propylene glycol is coplymerized with ethylene glycol (EG) and terephthalic acid (TPA) (U.S. Pat. No. 6,313,235), and isophthalic acid (IPA) is coplymerized with ethylene glycol (EG) and terephthalic acid (TPA) (U.S. Pat. Nos. 7,297,721, 6,489,434, and 6,913,806).
[0005] Condensation polymers may be degraded by hydrolysis with catalyst of acid, or base. The rate of depolymerization depends upon the structure of the polymers. Poly(hydroxyl acids), such as poly glycolic acid or poly lactic acid or copolymers of glycolic acid and lactic acid are easily hydrolyzed at mild conditions, even at pH 7 and room temperature in several months. Therefore, poly(hydroxyl acids) have wide applications based on their degradability, such as in medical devices and drug delivery system. On the other hand, polyethylene terephthalate (PET) hydrolyzes very slowly at mild conditions. To decompose such kind of polyester will require high temperature and high pressure through reaction with methanol, ethylene glycol or ammonia/glycol, which all involves organic solvents. PET and its derivatives have also wide applications based on their non-degradability and mechanical strength, such as fibers, packaging bottles and films.
[0006] Although there are many attempts to modify condensation polymers for extension of their application as described above, no attempts have been reported to incorporate degradable blocks of polyester into non-degradable condensation polyester in which the degradable blocks are uniformly distributed in the polymer chains.
SUMMARY OF THE INVENTION
[0007] In one aspect, the present invention provides a polymer comprising non-degradable blocks and degradable blocks. In some embodiments, the polymer has a structure of Formulae (Ia) or (Ib):
[0000]
[0000] wherein t, m, p, q, r are integers other than zero, n is integers includes zero, R, R 1 , R 2 , R 3 , R 4 , R″ are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol. In some embodiments, the R, R 1 , R 2 , R 3 , R 4 , R″ are independently C 1 -C 10 alkyls.
[0008] In some embodiments, the degradable blocks has a structure according to Formula (III)
[0000]
[0009] wherein t, m, n are integers other than zero, X is Cl, Br, I, NH 2 —, HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls) or other polymer chains and R, R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0010] In some embodiments, the degradable blocks has a structure according to Formula (IV):
[0000]
[0000] wherein t, m, n are integers, R, R 1 , R 2 , arealkyls (CH 3 , C 2 H 5 ), R″ is any substitute groups, and R′ is H or alkyls.
[0011] In another aspect, the present invention provides a degradable segment according to Formula (III):
[0000]
[0012] wherein t, m, n are integers other than zero, X is Cl, Br, I, NH 2 —, HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls) or other polymer chains and and R, R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol. In some embodiments the degradable segment is made according to Scheme Ia:
[0000]
[0013] In another aspect, the present invention provides a degradable segment according to Formula (IV):
[0000]
[0014] wherein t, m, n are integers, R, R 1 , R 2 are alkyls (CH 3 , C 2 H 5 ), R″ is any substitute groups, and R′ is H or alkyls. In some embodiments the degradable segment is made according to Scheme Ib:
[0000]
[0015] In another aspect, the present invention provides a method of making a polymer comprising degradable blocks and non-degradable blocks, said method comprises the steps of: (a) synthesizing degradable hydroxyl acids blocks; (b) polymerizing non degradable polymer monomer or pre polymer with degradable hydroxyl acids blocks to form said polymers in a solution polymerization process or melting polymerization process.
[0016] In another aspect, the present invention provides a method of making a polymer comprising degradable blocks and non-degradable blocks, said method comprises the steps of: (a) synthesizing degradable hydroxyl acids blocks; (b) synthesizing non-degradable polymers; and (c) joining said non-degradable blocks with and said degradable polymers in a solution polymerization process or melting polymerization process.
[0017] In some embodiments of the method provided herein, the polymer has the structure according to Formulae (Ia) or (Ib):
[0000]
[0018] wherein t, m, n, p, q are integers other than zero, R, R 1 , R 2 , R 3 , R 4 , R″ are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0019] In some embodiments of the method provided herein the degradable blocks have the structure according to Formula (II):
[0000]
[0000] wherein t, m are integers; X is Cl, Br, I, NH 2 —, or HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls) and R is H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol, or Formula (III):
[0000]
[0000] wherein t, m, n are integers other than zero, X is Cl, Br, I, NH 2 —, HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls), and R, R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0020] In some embodiments of the method provided herein, the degradable blocks are diol. In some embodiments, the non-degradable blocks are esters. In some embodiments, the degradable blocks have the structure according to Formula (IV):
[0000]
[0000] wherein t, m, n are integers, X is Cl, Br, I, NH 2 —, HO—, R is alkyls (CH 3 , C 2 H 5 . . . ), R″ is any substitute groups, and R′ is H or alkyls.
[0021] In some embodiments of the method provided herein, the step (a) is carried out according to Scheme (Ia):
[0000]
[0022] In some embodiments of the method provided herein, the step (a) is carried out according to Scheme (II):
[0000]
[0023] In some embodiments of the method provided herein, the step (c) is carried out according to Scheme (IV):
[0000]
[0024] In some embodiments of the method provided herein, the degradable and non-degradable blocks comprise carbonyl chloride ends and said carbonyl chloride are converted into carboxylic acid before said step (c).
DETAILED DESCRIPTION OF THE INVENTION
I. Definitions and Abbreviations
[0025] Unless defined otherwise, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Generally, the nomenclature used herein and the laboratory procedures in cell culture, molecular genetics, organic chemistry and nucleic acid chemistry and hybridization are those well known and commonly employed in the art. Standard techniques are used for nucleic acid and peptide synthesis. The techniques and procedures are generally performed according to conventional methods in the art and various general references, which are provided throughout this document. The nomenclature used herein and the laboratory procedures in analytical chemistry, and organic synthetic described below are those well known and commonly employed in the art. Standard techniques, or modifications thereof, are used for chemical syntheses and chemical analyses.
[0026] The term “alkyl,” by itself or as part of another substituent, means, unless otherwise stated, a straight or branched chain, or cyclic hydrocarbon radical, or combination thereof, which may be fully saturated, mono- or polyunsaturated and can include di- and multivalent radicals, having the number of carbon atoms designated (i.e. C 1 -C 10 means one to ten carbons). Examples of saturated hydrocarbon radicals include, but are not limited to, groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, isobutyl, sec-butyl, cyclohexyl, (cyclohexyl)methyl, cyclopropylmethyl, homologs and isomers of, for example, n-pentyl, n-hexyl, n-heptyl, n-octyl, and the like. An unsaturated alkyl group is one having one or more double bonds or triple bonds. Examples of unsaturated alkyl groups include, but are not limited to, vinyl, 2-propenyl, crotyl, 2-isopentenyl, 2-(butadienyl), 2,4-pentadienyl, 3-(1,4-pentadienyl), ethynyl, 1- and 3-propynyl, 3-butynyl, and the higher homologs and isomers. The term “alkyl,” unless otherwise noted, is also meant to include those derivatives of alkyl defined in more detail below, such as “heteroalkyl.” Alkyl groups, which are limited to hydrocarbon groups, are termed “homoalkyl”.
[0027] The term “alkylene” by itself or as part of another substituent means a divalent radical derived from an alkane, as exemplified, but not limited, by —CH 2 CH 2 CH 2 CH 2 —, and further includes those groups described below as “heteroalkylene.” Typically, an alkyl (or alkylene) group will have from 1 to 24 carbon atoms, with those groups having 10 or fewer carbon atoms being preferred in the present invention. A “lower alkyl” or “lower alkylene” is a shorter chain alkyl or alkylene group, generally having eight or fewer carbon atoms.
[0028] The terms “alkoxy,” “alkylamino” and “alkylthio” (or thioalkoxy) are used in their conventional sense, and refer to those alkyl groups attached to the remainder of the molecule via an oxygen atom, an amino group, or a sulfur atom, respectively.
[0029] The term “heteroalkyl,” by itself or in combination with another term, means, unless otherwise stated, a stable straight or branched chain, or cyclic hydrocarbon radical, or combinations thereof, consisting of the stated number of carbon atoms and at least one heteroatom selected from the group consisting of O, N, Si and S, and wherein the nitrogen and sulfur atoms may optionally be oxidized and the nitrogen heteroatom may optionally be quaternized. The heteroatom(s) O, N and S and Si may be placed at any interior position of the heteroalkyl group or at the position at which the alkyl group is attached to the remainder of the molecule. Examples include, but are not limited to, —CH 2 —CH 2 —O—CH 3 , —CH 2 —CH 2 —NH—CH 3 , —CH 2 —CH 2 —N(CH 3 )—CH 3 , —CH 2 —S—CH 2 —CH 3 , —CH 2 —CH 2 , —S(O)—CH 3 , —CH 2 —CH 2 —S(O) 2 —CH 3 , —CH═CH—O—CH 3 , —Si(CH 3 ) 3 , —CH 2 —CH═N—OCH 3 , and —CH═CH—N(CH 3 )—CH 3 . Up to two heteroatoms may be consecutive, such as, for example, —CH 2 —NH—OCH 3 and —CH 2 —O—Si(CH 3 ) 3 . Similarly, the term “heteroalkylene” by itself or as part of another substituent means a divalent radical derived from heteroalkyl, as exemplified, but not limited by, —CH 2 —CH 2 —S—CH 2 —CH 2 — and —CH 2 —S—CH 2 —CH 2 —NH—CH 2 —. For heteroalkylene groups, heteroatoms can also occupy either or both of the chain termini (e.g., alkyleneoxy, alkylenedioxy, alkyleneamino, alkylenediamino, and the like). Still further, for alkylene and heteroalkylene linking groups, no orientation of the linking group is implied by the direction in which the formula of the linking group is written. For example, the formula —C(O) 2 R′— represents both —C(O) 2 R′— and —R′C(O) 2 —.
[0030] In general, an “acyl substituent” is also selected from the group set forth above. As used herein, the term “acyl substituent” refers to groups attached to, and fulfilling the valence of a carbonyl carbon that is either directly or indirectly attached to the polycyclic nucleus of the compounds of the present invention.
[0031] The terms “cycloalkyl” and “heterocycloalkyl”, by themselves or in combination with other terms, represent, unless otherwise stated, cyclic versions of “alkyl” and “heteroalkyl”, respectively. Additionally, for heterocycloalkyl, a heteroatom can occupy the position at which the heterocycle is attached to the remainder of the molecule. Examples of cycloalkyl include, but are not limited to, cyclopentyl, cyclohexyl, 1-cyclohexenyl, 3-cyclohexenyl, cycloheptyl, and the like. Examples of heterocycloalkyl include, but are not limited to, 1-(1,2,5,6-tetrahydropyridyl), 1-piperidinyl, 2-piperidinyl, 3-piperidinyl, 4-morpholinyl, 3-morpholinyl, tetrahydrofuran-2-yl, tetrahydrofuran-3-yl, tetrahydrothien-2-yl, tetrahydrothien-3-yl, 1-piperazinyl, 2-piperazinyl, and the like.
[0032] The terms “halo” or “halogen,” by themselves or as part of another substituent, mean, unless otherwise stated, a fluorine, chlorine, bromine, or iodine atom. Additionally, terms such as “haloalkyl,” are meant to include monohaloalkyl and polyhaloalkyl. For example, the term “halo(C 1 -C 4 )alkyl” is mean to include, but not be limited to, trifluoromethyl, 2,2,2-trifluoroethyl, 4-chlorobutyl, 3-bromopropyl, and the like.
[0033] The term “aryl” means, unless otherwise stated, a polyunsaturated, aromatic, hydrocarbon substituent, which can be a single ring or multiple rings (preferably from 1 to 3 rings), which are fused together or linked covalently. The term “heteroaryl” refers to aryl groups (or rings) that contain from one to four heteroatoms selected from N, O, and S, wherein the nitrogen and sulfur atoms are optionally oxidized, and the nitrogen atom(s) are optionally quaternized. A heteroaryl group can be attached to the remainder of the molecule through a heteroatom. Non-limiting examples of aryl and heteroaryl groups include phenyl, 1-naphthyl, 2-naphthyl, 4-biphenyl, 1-pyrrolyl, 2-pyrrolyl, 3-pyrrolyl, 3-pyrazolyl, 2-imidazolyl, 4-imidazolyl, pyrazinyl, 2-oxazolyl, 4-oxazolyl, 2-phenyl-4-oxazolyl, 5-oxazolyl, 3-isoxazolyl, 4-isoxazolyl, 5-isoxazolyl, 2-thiazolyl, 4-thiazolyl, 5-thiazolyl, 2-furyl, 3-furyl, 2-thienyl, 3-thienyl, 2-pyridyl, 3-pyridyl, 4-pyridyl, 2-pyrimidyl, 4-pyrimidyl, 5-benzothiazolyl, purinyl, 2-benzimidazolyl, 5-indolyl, 1-isoquinolyl, 5-isoquinolyl, 2-quinoxalinyl, 5-quinoxalinyl, 3-quinolyl, and 6-quinolyl. Substituents for each of the above noted aryl and heteroaryl ring systems are selected from the group of acceptable substituents described below.
[0034] For brevity, the term “aryl” when used in combination with other terms (e.g., aryloxy, arylthioxy, arylalkyl) includes both aryl and heteroaryl rings as defined above. Thus, the term “arylalkyl” is meant to include those radicals in which an aryl group is attached to an alkyl group (e.g., benzyl, phenethyl, pyridylmethyl and the like) including those alkyl groups in which a carbon atom (e.g., a methylene group) has been replaced by, for example, an oxygen atom (e.g., phenoxymethyl, 2-pyridyloxymethyl, 3-(1-naphthyloxy)propyl, and the like).
[0035] Each of the above terms (e.g., “alkyl,” “heteroalkyl,” “aryl” and “heteroaryl”) include both substituted and unsubstituted forms of the indicated radical. Preferred substituents for each type of radical are provided below.
[0036] Substituents for the alkyl, and heteroalkyl radicals (including those groups often referred to as alkylene, alkenyl, heteroalkylene, heteroalkenyl, alkynyl, cycloalkyl, heterocycloalkyl, cycloalkenyl, and heterocycloalkenyl) are generally referred to as “alkyl substituents” and “heteroakyl substituents,” respectively, and they can be one or more of a variety of groups selected from, but not limited to: —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R′″, —NR″C(O) 2 R′, —NR—C(NR′R″R′″)═NR″″, —NR—C(NR′R″)═NR′″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN and —NO 2 in a number ranging from zero to (2 m′+1), where m′ is the total number of carbon atoms in such radical. R′, R″, R′″ and R″″ each preferably independently refer to hydrogen, substituted or unsubstituted heteroalkyl, substituted or unsubstituted aryl, e.g., aryl substituted with 1-3 halogens, substituted or unsubstituted alkyl, alkoxy or thioalkoxy groups, or arylalkyl groups. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″ and R″″ groups when more than one of these groups is present. When R′ and R″ are attached to the same nitrogen atom, they can be combined with the nitrogen atom to form a 5-, 6-, or 7-membered ring. For example, —NR′R″ is meant to include, but not be limited to, 1-pyrrolidinyl and 4-morpholinyl. From the above discussion of substituents, one of skill in the art will understand that the term “alkyl” is meant to include groups including carbon atoms bound to groups other than hydrogen groups, such as haloalkyl (e.g., —CF 3 and —CH 2 CF 3 ) and acyl (e.g., —C(O)CH 3 , —C(O)CF 3 , —C(O)CH 2 OCH 3 , and the like).
[0037] Similar to the substituents described for the alkyl radical, the aryl substituents and heteroaryl substituents are generally referred to as “aryl substituents” and “heteroaryl substituents,” respectively and are varied and selected from, for example: halogen, —OR′, ═O, ═NR′, ═N—OR′, —NR′R″, —SR′, -halogen, —SiR′R″R′″, —OC(O)R′, —C(O)R′, —CO 2 R′, —CONR′R″, —OC(O)NR′R″, —NR″C(O)R′, —NR′—C(O)NR″R′″, —NR″ C(O) 2 R′, —NR—C(NR′R″)═NR′″, —S(O)R′, —S(O) 2 R′, —S(O) 2 NR′R″, —NRSO 2 R′, —CN and —NO 2 , —R′, —N 3 , —CH(Ph) 2 , fluoro(C 1 -C 4 )alkoxy, and fluoro(C 1 -C 4 )alkyl, in a number ranging from zero to the total number of open valences on the aromatic ring system; and where R′, R″, R′″ and R″″ are preferably independently selected from hydrogen, (C 1 -C 8 )alkyl and heteroalkyl, unsubstituted aryl and heteroaryl, (unsubstituted aryl)-(C 1 -C 4 )alkyl, and (unsubstituted aryl)oxy-(C 1 -C 4 )alkyl. When a compound of the invention includes more than one R group, for example, each of the R groups is independently selected as are each R′, R″, R′″ and R″″ groups when more than one of these groups is present.
[0038] Two of the aryl substituents on adjacent atoms of the aryl or heteroaryl ring may optionally be replaced with a substituent of the formula -T-C(O)—(CRR′) q —U—, wherein T and U are independently —NR—, —O—, —CRR′— or a single bond, and q is an integer of from 0 to 3. Alternatively, two of the substituents on adjacent atoms of the aryl or heteroaryl ring may optionally be replaced with a substituent of the formula -A-(CH 2 ) r —B—, wherein A and B are independently —CRR′—, —O—, —NR—, —S—, —S(O)—, —S(O) 2 —, —S(O) 2 NR′— or a single bond, and r is an integer of from 1 to 4. One of the single bonds of the new ring so formed may optionally be replaced with a double bond. Alternatively, two of the substituents on adjacent atoms of the aryl or heteroaryl ring may optionally be replaced with a substituent of the formula —(CRR′) s —X—(CR″R′″) d —, where s and d are independently integers of from 0 to 3, and X is —O—, —NR′—, —S—, —S(O)—, —S(O) 2 —, or —S(O) 2 NR′—. The substituents R, R′, R″ and R′″ are preferably independently selected from hydrogen or substituted or unsubstituted (C 1 -C 6 ) akyl.
[0039] As used herein, the term “heteroatom” includes oxygen (O), nitrogen (N), sulfur (S), phosphorus (P) and silicon (Si).
II. The Compositions
[0040] In one aspect, the present invention provides condensation polymers comprising degradable blocks of short chain length of poly hydroxyl acids as joints of non-degradable polymer chains. In general, such polymers retains the mechanical strength of non-degradable blocks (the major blocks of the polymer) but are easily degraded at their degradable blocks (the location of joints) and therefore the long chain polymers will be degraded back to non-degradable short chains.
[0041] In some embodiments, the present invention provides degradable blocks or degradable segments having the structure according to Formula (III):
[0000]
[0000] wherein t, m, n are integers; X is Cl, Br, I, NH 2 —, HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls) or other polymer chains, and R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol. In some embodiments, X is removed when incorporated into polymers.
[0042] In some embodiments, the present invention provides degradable blocks or degradable segments having the structure according to Formula (IV):
[0000]
[0000] wherein t, m, n are integers; R, R 1 , R 2 are alkyls (CH 3 , C 2 H 5 . . . ); R′ is H or alkyls (CH 3 , C 2 H 5 . . . ); R″ is any substitute groups; and R′ is H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0043] In some embodiments, the non-degradable blocks are polyester (exclude the polyhydroxyl acids, which are degradable), with functional groups to react with degradable short chains. By “non-degradable” herein is meant that the rate of hydrolysis is much slower then that of polyhydroxy acids, rather than absolutely no degradation.
[0044] In one aspect, the present invention provides non-degradable polymers with degradable blocks. These polymers comprise of both degradable blocks and non-degradable blocks such as Formulae (Ia) and (IIb):
[0000]
[0000] wherein t, m, n, p, q are integers; R, R 1 , R 2 , R 3 , R 4 , R″ are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0045] In some embodiments, R, R 1 , R 2 , R″ are independently C 1 to C 10 alkyls.
[0046] In some embodiments, the degradable blocks are short chain poly hydroxyacids with functional groups at both ends to react with non degradable-blocks.
[0047] In some embodiments, the polymers comprise degradable blocks according to Formulae (IIIa):
[0000]
[0000] wherein t, m, n are integers; and R, R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0048] In some embodiments, the polymers comprise degradable blocks according to Formulae (IV):
[0000]
[0000] wherein t, m, n are integers; R, R 1 , R 2 , are alkyls (CH 3 , C 2 H 5 ); R″ is any substitute groups; and R′ is H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0049] The ratio between the non-degradable blocks and the degradable blocks in the polymers can vary. In some embodiments, the polymers comprises non-degradable blocks as major components (from 50% to 100% weight percentage) and degradable blocks as minor components (from 0% to 50% weight percentage).
III. Method of Making
[0050] In another aspect, the present invention provides methods of manufacturing polymers.
[0051] The method of manufacturing polymers with degradable blocks in present invention comprises three major modules: (a) synthesis of degradable hydroxyl acids blocks, (b) synthesis of non-degradable polymers, and (c) joining both degradable blocks and non degradable polymers together.
(a). Synthesis of Degradable Hydroxyl Acids Blocks
[0052] In one aspect, the present invention provides methods of synthesizing degradable hydroxyl acids blocks, such as the process in Scheme Ia or Ib:
[0000]
[0000]
[0053] In some embodiments, a poly hydroxyl acids oligomer according to Formula (II) is first synthesized according to Huang's methods (U.S. Application No. 61/054,218) and/or Hermes and Huang's method (U.S. Pat. No. 5,349,047), both are herein incorporated by reference in their entirety. Formula (II):
[0000]
[0000] wherein t, m are integers; X is Cl, Br, I, NH 2 —, or HO—, R′OCO—C 6 H 4 —COO— (where R′ is H, CH 3 , C 2 H 5 or any other alkyls), and R is H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0054] In some embodiments, R is C 1 to C 10 alkyls.
[0055] The poly hydroxyl acids oligomer then reacts with ethylene glycol (EG) to form a new oligomer with both ends of halide, hydroxy or amine (Formula (III)) (Scheme I) or with terephthalic acid (TPA) to form a new oligomer with both ends of carboxylic acids or carboxylate esters (Formula (IV)) (Scheme II).
[0000]
[0056] The poly hydroxyl acids oligomer halide then reacts with ethylene glycol (EG) to form a new oligomer with end of hydroxy or which then reacts with terephthalic acid (TPA) to form a new oligomer with both ends of carboxylic acids or carboxylate esters (Formula (IV)) (Scheme IIa).
[0000]
[0057] The reaction of oligomer with diol or dicarboxylic acid involved here is esterification reaction which can be accomplished by react carbonyl chloride of polyhydroxyl acid oligomers (Formula (V)) with ethylene glycol or directly react the carboxylic acid group of oligomer to ethylene glycol with acid catalysts of ion exchange resin. In the case of oligomer reacting to terephthalic acid (TPA), it can be accomplished by reacting TPA with halocarboxylic acid oligomer and amines such as triethylamine or ethyldiisopropylamine.
[0058] In some embodiments, the polyhydroxyl acid oligomers have the structure according to Formula (V):
[0000]
[0000] wherein t, m are integers; X is Cl, Br, I, NH 2 —, or HO—; and R is substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0059] In some embodiment, glycol contained degradable blocks (Formula (III)) is reacted with TPA or terephthalate according to the Scheme III to form the blocks with carboxylic acid or carboxylate at both ends (Formula (IIIb)
[0000]
[0000] wherein t, m, n are integers; R′ is H, CH 3 , C 2 H 5 or any alkyls, R, R 1 , R 2 are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0000]
(b). Synthesis of Non-Degradable Polymers
[0060] The non-degradable blocks, such as polyester (exclude the polyhydroxyl acids, which are degradable), polycarbonate or polyamide are synthesized according to methods known in the art. In general, the non-degradable blocks have functional hydroxyl group at the ends of polymer chains (generally with very small amount of carboxylic acid as the end group), which are reactive with degradable short chains.
[0061] To control the molecular weight or degree of polymerization of non-degradable polymer blocks, the time and pressure of traditional melting process can be adjusted. The alternative way is to react terephthaloyl chloride with diol in various ratio for two different monomers to control the degree of polymerization (DP) and the end group (hydroxyl ended or carbonyl chloride ended).
[0062] In some embodiment, the non-degradable blocks have the structure according to Formula (VI):
[0000]
[0000] wherein n is an integer other than zero, R 1 , R 2 and R″ are members independently selected in each structural units from H, substituted or unsubstituted alkyl, substituted or unsubstituted heteroalkyl, substituted or unsubstituted cycloalkyl, substituted or unsubstituted heterocycloalkyl, substituted or unsubstituted aryl and substituted or unsubstituted heteroaryl, substituted or unsubstituted alkoxy, ester, nitro, amine, amide, or thiol.
[0063] In some embodiment, the end group of the non-degradable blocks need to be modified into carboxylic acid, if the blocks will be joined with Formula (III). Scheme IV shows the reaction of the modification:
[0000]
[0064] The solvent used in this reaction is 1,1,2,2-tetrachloroethane or any other suitable organic solvent which can dissolve the non-degradable blocks at reflux temperature or below.
[0065] In case of carbonyl chloride ended blocks, direct hydrolysis converts carbonyl chloride into carboxylic acid.
(c). Joining Both Degradable Blocks and Non-Degradable Polymers
[0066] In another aspect, the present invention provides methods for joining non-degradable polymers with degradable blocks together to obtain high molecular weight polymers.
[0067] In conventional polyester manufacturing, copolyesters are typically produced by two different routes: ester exchange plus polycondensation (the DMT process) or direct esterification plus polycondensation (the direct esterification process). Either of these routes comprises two stages: In the first stage a polymer ester is formed by polymerization the monomers at about 180° C. to 230° C. The second stage, referred as post polymerization reaction, is carried out at a higher temperature (280° C.) or other process to obtain higher molecular weight polyester.
[0068] Instead of move on to second stage, the present invention utilizes the degradable blocks to join the polyesters produced in the first stage directly.
[0069] In some embodiments, when non-degradable blocks are ended with hydroxyl group from the melting reaction process, carboxylic acid or carboxylate ended degradable blocks (formula IIIA, formula IV) can be added into the reactor of melting process directly at beginning or middle of the reaction. To ensure the degradable blocks are uniformly distributed in the overall polymer chains, the non-degradable blocks are generally synthesized first with commercial melting process of polycondensation (e.g. 2˜4 hours at 275° C. under vacuum and then the degradable blocks is added and the reaction continues at 275° C. for another 2˜4 hours under vacuum.) Scheme V shows one of example reaction in this process when the byproduct H 2 O is removed under vacuum. Similar ester exchange reactions can be carried out in the melting polymerization by removal of alcohols under vacuum.
[0000]
[0070] If the distribution of degradable blocks in the final polymer chains is not a concern, the degradable blocks generally can be added to monomers of non-degradable polymer at the beginning to form degradable blocks contained polymer through mature industrial PET manufacture process, such as those shown in Scheme VI. The distribution of degradable blocks in polymers obtained with such approach will be random but will still degradable at their degradable blocks when they are exposed to proper environments such as basic solution.
[0000]
[0071] In some embodiments, the joint degradable segment is not ended with carboxylic acid and therefore we need to convert the end groups of non-degradable blocks as described herein.
[0072] The joining reactions here again are esterification process. Although there are many possible processes to esterification, a very convenient method is to follow the reactions between α-halocarboxylate and carboxylic acid as disclosed in Huang's method (U.S. Patent Application No. 61/054,218), the disclosure of which is incorporated by reference in its entirety. In order to obtain high molecular weight polymer, the stoichiometry between two reactants, the degradable blocks and short chain non-degradable polymers with carboxylic acid as end group here, must be controlled very well.
[0073] Generally, it is difficulty to calculate the stoichiometry of short chain non-degradable polymers because of the length diversity of polymer chain. However, due to the acidic end groups in short chain polymers, through titration of the content of acid groups in the polymer solution, we can finger out the acid equivalents per gram and therefore know exactly how much degradable halo blocks we need to form longer co-polymer.
IV. Applications
[0074] The polymers provided herein can find use in a variety of applications, such as packaging bottles for beverages, food packing films, shopping bags and other containers.
[0075] It is understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated by reference for all purposes.
EXAMPLES
Example 1
Synthesis of Ethylene Di-Bromoacetylate
[0076] To a solution of bromoacetyl chloride (TCI, 95 gram, 0.6 mole) in 100 ml dry ethyl acetate was added dropewisely anhydrous ethylene glycol (Sigma-Aldrich, 12.41 gram, 0.2 mole). The solution was stirred at 70° C. under N 2 protection for 16 hours and then washed with 200 ml DI water and 200 ml brine. The solvent was removed in vacuum after drying with anhydrous MgSO 4 . The crude product was vacuum pumper for 24 hours and then vacuum distilled. ˜100° C. /3 mm Hg fraction was collected. 35 gram product was obtained, yield 58%. 1 HNMR (CDCl 3 , 400 Mz) δ 4.365 (S, 4H); δ 3.830 (S, 4H).
Example 2
Synthesis of Ethylene Di-Bromoacetylate(BrGEGBr)
[0077] To a 250 ml round bottom flask were placed bromoacetic acid (Sigma-Aldrich, 69.5 g, 0.5 mole), ethylene glycol (Sigma-Aldrich, 15.44 g, 0.25 mole), Dowex C-211, H + form cation ion exchange resin (4 g) and benzene (100 ml). The mixture was refluxed with Dean Stark Trap for 16 hours, record water trapped. When there was no more water come out, the solution was cool down to room temperature and the resin was filtrated out. Water was measured (8.5 ml). The solvent benzene was removed in vacuum. The product was vacuum distilled at about 3 mm Hg, ˜100 C/3 mm Hg fraction was collected (40 g), yield 53%. 1 HNMR (CDCl 3 , 400 Mz) δ 4.365 (S, 4H); δ 3.830 (S, 4H).
Example 3
Synthesis of Bromoacetylate Glycolic Acid (BrGG Acid)
[0078] To a 250 ml round bottom flask were placed bromoacetic acid (Sigma-Aldrich, 69.5 g, 0.5 mole), glycolic acid (Sigma-Aldrich, 37.52 g, 0.5 mole), Dowex C-211, H + form cation ion exchange resin (4 g) and benzene (100 ml). The mixture was refluxed with Dean Stark Trap for 13 hours, record water trapped. When there was no more water come out, the solution is cool down to room temperature and the resin is filtrated out. Water was measured (11 ml). The solvent benzene was removed in vacuum. The product was vacuum distilled at about 3 mm Hg, 105˜108° C. /3 mm Hg fraction was collected (12.9 g), yield 13.1% (the major product were poly glycolic acid oligomers). 1 HNMR (CDCl 3 , 400 Mz) δ 4.850 (S, 2H); δ 3.950 (S, 2H).
Example 4
Synthesis of Ethylene Bromoacetylate Glycolate (BrGGEGGBr)
[0079] To a 250 ml round bottom flask were placed BrGG acid (from Example III, 29.55 g, 0.15 mole), ethylene glycol (Sigma-Aldrich, 7.45 g, 0.12 mole), Dowex C-211, H + form cation ion exchange resin (4 g) and benzene (100 ml). The mixture was refluxed with Dean Stark Trap for 16 hours, record water trapped. When there was no more water come out, the solution was cool down to room temperature and the resin was filtrated out. Water was measured (4.3 ml). The filtrate solution is washed with Sat. NaHCO 3 aq solution (100 ml) to remove excess BrGG. The solvent benzene was removed in vacuum after dried with Mg504.
Example 5
Synthesis of PET Oligomer
[0080] To a 250 ml two neck round bottom flask equipped with condenser are placed terephthalic acid chloride (64.015 g, 98%, 0.309 mole) and 150 ml toluene, ethylene glycol (18.658 g, 99.8%, 0.3 mole) in 50 ml toluene is dropwisely added at 80° C. (oil bath 100° C.). After completion of addition, the mixture is refluxed under N 2 for 16 hours. The solvent is removed in vacuum and the residues are heated to 120° C. under vacuum for 3 hours. The residues are stirred with H 2 O (400 ml) for 3 hours, check pH value shows acidic. The solid product is filtrated and dried at 120° C. overnight.
Example 6
[0081] Synthesis of PET oligomer. To a 250 ml stainless steel bomb are placed Bis(2-hydroxyethyl) terephthalate (BHET, Sigma-Aldrich, 30 g, 0.118 mole), 350 ppm Sb203 (Alfa Aesar) and a magnetic stirring bar. The system is purged with N2/Vaccuum three times and then typically heated to 275° C. in 30 min. The System is kept at 275 C under vacuum (3 mm Hg) for a time period from 2˜5 hours. The bomb is then opened and dry ice is added into the bomb to cool down the melt to room temperature quickly. The bulk solid is roughly grinded into small pieces and the viscosity is measured in phenol/1,1,2,2-tetrachloroethane (60/40 weight ratio) according to SPI's (The Society of Plastic Industry) standard PET measurement procedure. The Table 1 summarized the IV (intrinsic viscosity) for various reaction times.
[0000]
Time of Reaction (min)
IV
120
0.08
150
0.12
180
0.18
240
0.43
Example 7
[0082] Conversion the end group of PET oligomers into carboxylic acid. PET oligomers (IV=0.12, 20 gram from Example 6) is placed in round bottom flask with 1,1,2,2-tetrachloroethane (Alfa Aesar, 100 ml) and Terephthaloyl chloride (sigma-Aldrich, 10 g). The solution is refluxed for 16 hours with stirring and then is cooled down to room temperature and diluted with 200 ml ethyl ether. The solid product is collected and dried after filtration, grinded and placed into DI water (400 ml) and 150 ml acetonitrile. The mixture is stirred for 5 hours and then pH is adjusted to 7˜8 with HCl and stirred for 1 more hour. The white solid is collected and dried at 120° C. for >3 hours after filtration.
Example 8
[0083] Synthesis of PET polymers with GEG blocks. To a solution of PET oligomer from Example V (11.088 g, 0.01 mole) and Et3N (2.0238 g, 0.02 mole) in 90 ml anhydrous acetonitrile is added dropwisely a solution of BrGEGBr (3.0394 g, 0.01 mole) in 10 ml anhydrous acetoniltrile. The mixture is stirred at room temperature for 48 hours. The solution is poured into 500 ml DI water, stirred at room temperature for two hours, filtrated and dried at 110° C. overnight. 11.69 g product is obtained. Yield 93.5%.
Example 9
[0084] Synthesis of PET polymers with GGEGG blocks. To a solution of PET oligomer from Example 5 (11.088 g, 0.01 mole) and Et3N (2.0238 g, 0.02 mole) in 90 ml anhydrous acetonitrile is added dropwisely a solution of BrGGEGGBr (4.200 g, 0.01 mole) in 10 ml anhydrous acetoniltrile. The mixture is stirred at room temperature for 48 hours. The solution is poured into 500 ml DI water, stirred at room temperature for two hours, filtrated and dried at 110° C. overnight.
Example 10
[0085] Synthesis of PET polymers with degradable blocks. PET oligomers (IV=0.18, 20 gram from Example 6) and degradable blocks (repeat unit molar ration 10:1) are placed in the stainless steel bomb with a magnetic stirring bar and N2/vacuum purged three times. The system is placed in a 275° C. oil bath for 3 hours with stirring under vacuum. The bomb is then opened and added with dry ice to cool down the melt to room temperature quickly. The bulk solid is roughly grinded into small pieces and the viscosity is measured in phenol/1,1,2,2-tetrachloroethane (60/40 weight ratio) according to SPI's (The Society of Plastic Industry) standard PET measurement procedure. The Table 2 summarized the IV (intrinsic viscosity) for various reaction times.
Example 11
[0086] Synthesis of MeGTGMe (Formula (IV)). To a solution of TPA (Sigma-Aldrich, 33.9 g, 98%, 0.2 mole) and Et3N (40.4 g, 56 ml, 0.4 mole) in 300 ml anhydrous acetonitrile is added dropwisely a solution of methyl bromoacetate (Sigma-Aldrich, 62.44 g, 98%, 0.4 mole) in anhydrous acetonitrile (30 ml). The mixture is stirred at room temperature for 24 hours. The solution is then filtrated to remove the solid Et3N salt. The solvent in filtrate is removed in vacuum and the residues are washed (stirring in) with 1% HCl (500 ml), NaHCO3 sat aq solution (1000 ml) and washed with DI water. The white solid product (48.8 g) is collected after filtration and drying in oven (120° C.) overnight. Mp=107˜109° C. Yield 78%.
Example 12
[0087] Modification of degradable blocks (MeTGEGTMe). To a solution of mono-Methyl terephthalate (36.03 g, 0.2 mole) and BrGEGBr (30.4 g, 0.1 mole) in 150 ml anhydrous acetonitrile is added dropwisely triethylamine (20.24 g, 0.2 mole) in a period of one hour at room temperature. The solution was stirred for 20 hours and the white precipitate is filtered out and stirred with 1% HCl (150 ml), NaHCO 3 saturated aqueous solution (150 ml) for two hours respectively. The crude product was collected through filtration and dried at 120° C. overnight. The crude product was recrystallized in hot acetonitrile and 37.7 gram final product was collected, Mp167° C., yield 76%.
Example 13
Synthesis of PET with Modified Degradable Blocks
[0088] To a 150 ml round flask was charged with MeTGEGTMe (14.83 g, 0.03 mole), BHET (7.63 g, 0.03 mole) and Sb 2 O 3 (0.03 gram). The mixture was heated to 200° C. under vacuum (20 mmHg) with stirring. The melt was kept at 200° C. for 7 hours and then poured into ice-water.
Example 14
[0089] Synthesis of ethylene glycol capped methyl glycolate. To a solution of ethylene glycol (18.62 g, 0.3 mole), ground NaOH (12 g, 0.3 mole) in anhydrous acetonitrile was added dropwisely methyl chloroacetate (32.56 g, 0.3 mole) at 0° C. in a period of 1 hour. The solution was stirred at 0° C. for another 7 hours and the solvent acetonitrile was removed in vacuum.
Example 15
[0090] Synthesis of MeGETEGMe. To a 250 ml round bottom flask were placed terephthalic acid (16.6 g, 0.10 mole), ethylene glycol capped methyl glycolate (26.83 g, 0.2 mole), Dowex C-211, H + form cation ion exchange resin (4 g) and benzene (100 ml). The mixture was refluxed with Dean Stark Trap for 16 hours, record water trapped. When there was no more water come out, the solution was cool down to room temperature and the resin was filtrated out. Water was measured (3.6 ml). The solvent benzene was removed in vacuum. The product was dissolved in ethyl acetate and washed with 1% HCl, saturated NaHCO 3 aqueous solution and saturated NaCl aqueous solution. The solvent was remove in vacuum and the solid crud product was collected.
Example 16
[0091] Polymerization of MeGETEGMe with BHET. Mixture of MeGETEGMe and BHET (1:1 molar ratio) and Sb 2 O 3 was melting polymerized according to previous examples. At the end of polymerization the polymer melt is poured into the ice-water for quick cooling process. | The present invention relates to the preparation of modified polymers by incorporating a compositional modifier into a polymer to produce the modified polymer. More particularly, the invention relates the preparation of condensation type copolyesters or copolyamides by joint short length polyester or polyester oligomers or short length polyamide or polyamide oligomers with a modifier which contains hydroxyl acids blocks. | 2 |
This is a continuation of application Ser. No. 532,841 filed Sept. 16, 1983, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to apparatus for use in giving athletes instruction and more particularly an apparatus including a mirror which permits an athlete to study his body movements for improving his performance.
Many devices exist in the prior art directed to the problem of teaching athletes proper body movements for various sports. These devices include apparatus which require the strapping of the athletes limbs to various moving elements of the apparatus which provides an artificial character to the instruction and forces rather than guides the athlete through the proper motions.
One prior art device is described in U.S. Pat. No. 3,140,550 to Wayfield. The Wayfield patent describes an apparatus which enables the swimmer to be guided through the various stages of instructions and to learn the various movements of the body and how to coordinate them. The apparatus comprises a cabinet adapted to receive the body of a swimmer and dimensioned to provide unobstructed use of the arms and legs in executing swimming strokes. The cabinet includes a plurality of fluid expelling nozzles appropriately located for releasing fluid under pressure in a timed relation to indicate to the swimmer appropriate coordination of the parts of the body in executing swimming strokes.
A swimming instruction device is also disclosed by U.S. Pat. No. 2,875,528 to Garrett describing an apparatus on which a swimmer is supported at the correct level in the water under conditions in which both the swimmer and instructor may observe the arm and leg actions of the swimmer. The apparatus comprises a tank filled with water having a post appropriately located therein for supporting a swimmer at a desired level within the tank and leaving the arms and legs of the swimmer free to move. A series of windows and a system of mirrors are provided so that the instructor and swimmer, respectively, may observe the arm and leg movements in executing swimming strokes.
Owens, Jr., U.S. Pat. No. 4,083,559 describes an apparatus for training players in baseball and other sports. The apparatus employs a mirror which permits the player to view all his body movements while projecting the ball toward the mirror as a target. The apparatus comprises a shock resistent mirror which may be variously mounted for angular adjustment to permit the player a full body view of his image. The mirror is suspended from a crossbar and may be positioned in an appropriate manner independently of a netting or like web surrounding the mirror.
Robertson, U.S. Pat. No. 2,494,000 describes a method and apparatus for teaching manual skills to golfers. Robertson provides a means for comparing the golfers body movements to follow as closely as possible the body movements of an expert performing the same stroke. This is accomplished by projecting the image of an expert performing a skill on a screen and superimposing on the continuously moving image of the expert the continuously moving image of the golfer performing the same skill as he endeavors to match his movements in time and position with those of the expert.
SUMMARY OF THE INVENTION
The apparatus of the invention comprises a mirror assembly including two sheets of shatter resistent acrylic plastic having reflective characteristics. The acrylic plastic sheets are held together by a peripheral channel-like framewok engaging the exposed edges of the sheet members. The framework includes means for suspending the mirror assembly from a wall or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantaes and objects of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a perspective partially broken away view of a swimming pool showing use of one embodiment of the invention;
FIG. 2 is a front view showing the apparatus of the invention connected in series;
FIG. 3 is a sectional partially broken away view of the apparatus of the invention taken along line 3--3 of FIG. 2;
FIG. 4 is a front partially broken away view showing the edge locking apparatus means for the apparatus;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4;
FIG. 6 is a perspective view of an alternate embodiment of the invention used for golfing instruction;
FIG. 7 is another alternate embodiment of the invention used for bowling instruction;
FIG. 8 is another alternate embodiment of the invention used for bowling instruction; and
FIG. 9 is another alternate embodiment of the invention used for tennis instruction.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIGS. 2 and 3, the instructional apparatus of the invention is generally identified by the reference number 10. The mirror assembly 10 comprises a pair of acylic plastic sheets 12 and 14. The sheets 12 and 14 are stacked or positioned adjacent to each other so that they are in facing contact. The sheets 12 and 14 are held together by a frame 16 enclosing the edges thereof. The frame 16 has a channel like configuration formed by spaced and parallel leg members 18 extending upwardly from a base member 20 defining a channel cavity to receive the edges of the sheets 12 and 14. The frame 16 is fabricated of a plexiglass material and frictionally engages the surface of the sheets 12 and 14 along the edges thereof.
An interconnecting flange assembly extends along the frame 16. The interconnecting assembly comprises a leg member 22 perpendicular to the exposed surface of the base member 20 and a flange member 23 spaced and parallel to the base member 20. The interconnecting flange member is an integral part of the frame 16. The flange assembly enables connecting a series of mirror assemblies 10 as shown in FIG. 2. The assemblies 10 are connected together by sliding the flange member 23 of one assembly 10 into the channel defined by the flange member 23 and base member 20 on the frame 16 of the other or adjacent assembly 10 as shown in FIG. 3. The flange member 23 includes a plurality of beads 25 on the exposed surface thereof. The beads 25 are slightly yieldable for gripping the walls of the channel when the assemblies 10 are interconnected as shown in FIG. 3.
The frame 16 includes oppositely facing locking channels 28 defined by pairs of L-shaped legs 29. A plurality of lock members 27 are received within the channels 28 at each corner of the assemblies 10. The locking members 27 are fastened in the channels 28 by set screws 31 as best shwon in FIG. 4. Locking the frame 16 in this manner provides excellent rigidity for the assemblies 10.
The sheets 12 and 14 are resistent to shock and are fabricated of acrylic material. One sheet acrylic material is mirrored and the other sheet is clear. Acrylic plastic is extremely resistent to breakage, yet it is lightweight. A four by eight foot sheet of acrylic plastic weighs approximately twenty-four pounds. Thus, the apparatus of the invention comprising two acrylic sheets weights approximately fifty pounds including the frame 16.
Due to its lightweight construction, the mirror assembly 10 of the invention is portable and easily positioned for use without requiring special mounting equipment. For example, the mirror assembly 10 may be hung on a wall suspended from a rope or wire having the ends thereof extending through channel 28 in the fashion of a picture or the like. Alternatively, the mirror assembly 10 may be suspended from adjustable hooks or the like.
Referring now to FIG. 1, the mirror assembly 10 of the invention is shown used in swimming instruction. A plurality of mirror assemblies of the invention are shown located at various points about a swimming pool to assit the swimmer in developing proper swimming strokes. A series of mirror assemblies are located at various locations in the pool. The mirror assemblies are joined by the interlocking flange assemblies in the manner shown in FIG. 4. The interlocking flange assemblies are provided with oppositely facing channels for receiving the edges of adjoining mirror assemblies.
In FIG. 1, the various uses of the apparatus of the invention in a swimming pool are disclosed. The mirror assemblies are strategically located about the pool so that a swimmer may observe his body movements while performing various swimming strokes. For example, the mirror assemblies located at the bottom of the pool are ideally suited for observing horizontal motions of butterfly, breast stroke and free style strokes. The series of mirror assemblies located along the side of the pool are ideally suited for observing vertical motions of butterfly, breast stroke, and free style strokes. Likewise, a mirror assembly located near the back of the diving board permits the diver to check his poise and form on back take-offs from the diving board. The horizontal mirror assembly at one end of the pool permits a swimmer to watch his swimming motion from the front while performing butterfly, breast stroke and free style strokes. The end mounted or vertical mirror assembly permits a swimmer to observe his back stroke motions, particularly, hand entry into the water.
An alternate embodiment of the apparatus of the invention is shown in FIG. 6. In this embodiment, the apparatus 30 is used to assist a golfer in developing a proper swing. The apparatus 30 comprises a horizontal mirror assembly 32 and an oblique mirror assembly 34 extending outwardly from the mirror assembly 32 at a 45° angle. The golfer stands on the mirror assembly 32 and watches his swing from below in the mirror assembly 32 and from in front in the mirror assembly 34 while keeping his eye on the ball.
In FIGS. 7 and 8, an alternate embodiment of the invention for use in bowling instruction is shown. In this embodiment, the apparatus 50 is mounted on legs 52 above the bowling lane several feet from the scratch line. The mirror assembly 50 is approximately two feet in height so as not to obscure the bowlers view of the pins. The bowler is able to observe his approach, back swing and release of the bowling ball in the mirror assembly 50. Alternatively, the mirror assembly 50 may be horizontally mounted in the bowling lane as shown in FIG. 7.
In FIG. 9, an embodiment of the invention used for tennis instruction is shown. In this embodiment, the mirror assembly 60 is positioned so that a tennis player hits the ball against the surface of the mirror assembly. The mirror assembly 60 may be mounted to a fence or next to the tennis net on suitable supports. The tennis player hits the ball against the mirror assembly 60 and observes his approach, swing and follow through.
In summary, the present invention discloses a mirror assembly and frame which may be conveniently used in various sports for athletic instruction by permitting athletes to study their body movements and thereby improve their performance.
While the foregiong is directed to the preferred embodiment of the invention, other and further embodiments of the invention may be devised without departing from the basic concept thereof, the scope thereof is determined by the claims which follow. | Apparatus for training athletes comprising a mirror assembly which permits the athlete to view all his body movements. The apparatus comprises a shock resistance mirror assembly including a sheet of clear acrylic material and a sheet of mirrored acrylic material in facing contact which may be variously mounted to permit an athlete a full body view of his image. Two or more mirror assemblies may be joined end to end. | 0 |
BACKGROUND OF THE TECHNOLOGY
[0001] A known spur gear transmission of EP-A-686788 has a single-piece housing. The latter forms, between a drive-output-side housing wall and a partition, a drive-output-side chamber which contains the drive output shaft with the drive output gearwheel. In order that the drive output gearwheel can be mounted in the drive-output-side chamber, its side wall has to have an assembly opening. This is achieved in that the drive-input-side housing cover is connected to the transmission housing by means of a parting joint which runs at an incline and extends above the drive-output-side chamber. The cover is connected to the transmission housing by fastening screws which run in an axially parallel manner, that is to say not perpendicularly to the parting joint. The housing also forms a drive-input-side chamber into which the motor pinion projects through the cover. Said motor pinion meshes with an intermediate gearwheel which is arranged on an intermediate shaft in the drive-input-side chamber. The intermediate shaft supports an intermediate pinion which drives the drive output gearwheel. Said intermediate shaft is mounted at both sides of the intermediate pinion, specifically in the drive-output-side wall and in the partition. The drive-input-side, exposed end of the intermediate shaft projects into a corresponding bore of the cover in order to centre the latter. This bore is not designed as a bearing.
[0002] Said known arrangement has not been proven. Firstly, the assembly is very difficult because the fastening screws exert forces on the cover, which forces have a force component running parallel to the parting joint, which force component seeks to move the cover relative to the housing. However, a movement of said type absolutely must be avoided because it leads to friction contact of the shaft with the centering bore in the cover. This can not only result in damage to the shaft, but can also lead to overloading of the intermediate shaft bearing. It is not obvious how this problem could be solved. In particular, the inclined parting joint cannot easily be replaced with the otherwise customary parting joint which runs perpendicularly to the axial direction because then the assembly of the drive output gearwheel would not be possible. A further disadvantage of the known construction consists in that the inclination of the parting joint requires precise adjustment of the cover about an axis perpendicular to the inclined parting joint, since an imprecise positioning of the cover with respect to this axis would lead to an angular error in the toothing of the input drive pinion with the intermediate gearwheel of the first stage. It is barely practically possible to obtain said precise adjustment. Finally, the known transmission has the disadvantage that the stiffness of the housing is impaired by the inclined profile of the parting joint which extends into the drive-output-side chamber.
[0003] Given that the drive output shaft can be mounted with the drive output gearwheel and the associated bearings in the housing which is designed without an undercut, the creation of a lateral assembly opening by an inclined cover joint is unnecessary. The disadvantages explained above can thus be avoided. The assembly is very simple because after inserting the shafts and wheels it is necessary merely to put on the cover. As a result of the third bearing, which is provided in the cover, of the intermediate shaft, the cover is automatically centered. In contrast, the triple bearing arrangement leads to favourable force conditions at the intermediate shaft and its bearings, thereby permitting smaller dimensioning of said bearings and therefore a reduction of the spatial requirement. There are also no additional assembly steps required for axially fixing the shaft, because said axial fixing can be effected by means of the two bearings at the ends of the shaft.
[0004] Although a triple bearing arrangement of a transmission shaft is known (“SEW Eurodrive” brochure, FIG. 5.3), this relates to a transmission having a multi-part housing which has an assembly opening not only at the drive input side but also at the drive output side of a housing central part and contains a partition. The triple bearing arrangement of the intermediate shaft of said transmission is situated in bearing bores which are formed by the housing central part. This entails cumbersome assembly, because the intermediate shaft and its bearings must be mounted from both sides of the housing central part. In addition, the multi-part design of the housing has the disadvantages, in relation to single-part housings having only one assembly opening, of reduced stiffness or, for the same stiffness, increased weight and increased costs. It is not possible to gather any indications from said prior art of how to facilitate assembly and avoid centering errors in the transmission specified at the beginning.
SUMMARY
[0005] In one disclosed embodiment, the known disadvantage of a triple bearing arrangement of a shaft on account of its static indeterminacy does not apply, because the cover, as a result of the centering action caused by the shaft, is fixed in precisely that position in which the third bearing, which is arranged in the cover, is aligned with the two other bearings. Angular errors in the toothing of the first stage also cannot occur, because the cover joint is perpendicular to the axis direction. A further advantage of the invention is that the central bearing of the three shaft bearings is considerably relieved of load and can therefore be of smaller dimensions. As a result, there is a gain in space in the region of said bearing arrangement, which gain in space can be utilized for the arrangement of the drive output shaft or its bearing arrangement. While, in the case of the first-mentioned known construction, the intermediate gearwheel must be arranged as close as possible to the bearing, which is provided in the partition, of the intermediate shaft in order to limit the bending loading of the shaft, the invention opens up the possibility of arranging said gearwheel remote from the central intermediate shaft bearing. This results in a greater degree of design freedom. For example, this creates the possibility of arranging the drive-input-side drive output shaft bearing and the central intermediate shaft bearing so as to be offset with respect to one another in the axis direction, wherein the central intermediate shaft bearing can be arranged further remote from the drive input than the drive output shaft bearing. Another result of said design freedom is in housings which can be used selectively for two-stage or three-stage transmissions. In the two-stage case, the intermediate gearwheel is to be arranged close to the cover, while in the three-stage case, said intermediate gearwheel is to be mounted remote from the cover, because the position close to the cover is taken up by the further gearwheel. This different positioning of the intermediate gearwheel is possible on account of the invention despite the reduced dimensioning of the intermediate shaft and its bearings, because these are arranged at both sides of the intermediate gearwheel.
[0006] The transmission in one embodiment is very easy to assemble, because, for correct assembly of the cover, it is necessary merely to mount the intermediate shaft in its drive-output-side and central bearings and subsequently to place and screw the cover in the position which is predefined in this way. It is particularly easy to assemble when the remaining structure of the housing is also easy to assemble. This applies in particular to a construction in which not only the intermediate shaft but also the drive output shaft with the associated wheels and bearings can be pre-assembled and inserted as a finished unit into the housing. This is the case in a transmission whose drive-output-side chamber is delimited only by two faces, the first of which, for holding the drive output shaft, opens without an undercut in the direction of the drive output side, while the other, for the assembly of the intermediate shaft, opens without an undercut in the direction of the drive input side.
[0007] In another embodiment, the drive output shaft unit, like the intermediate shaft unit, can be mounted from the drive input side by virtue of the drive-output-side chamber, for the assembly of the drive output shaft, opening without an undercut in the direction of the drive input side.
[0008] The lack of undercut is restricted by the addition that said lack of undercut should be present at least in the unprocessed state of the cast or pressed part. This is intended to prevent this feature from being evaded by means of a turning process which is carried out only during the machining stage and has no effect on the ease of assembly. In the finished state, it is sufficient if the diameter of the holding bore in the case of the drive-input-side bearing of the drive output shaft is at least so large that the drive output gearwheel and the drive-output-side drive output shaft bearing can fit through. In the case of the intermediate shaft, it is correspondingly sufficient if the holding bore in the case of the assembly-side bearing has a diameter which is so large that the intermediate pinion and the drive-output-side bearing of the intermediate shaft can fit through. It is not important whether the holding bore possibly also has a turned portion between said positions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a longitudinal section of a first exemplary embodiment with a flange-mounted motor,
[0010] FIG. 2 shows a perspective view of the empty housing from the drive output side,
[0011] FIG. 3 shows a corresponding view of the cover from the drive output side,
[0012] FIG. 4 shows a longitudinal section through a second exemplary embodiment as per line IV-IV of FIG. 7 ,
[0013] FIGS. 5 and 6 show perspective views of the empty housing of the associated cover,
[0014] FIG. 7 shows a view of the open housing from the drive input side, with the intermediate shaft,
[0015] FIG. 8 is a simplified illustration corresponding to FIG. 7 , without the intermediate shaft,
[0016] FIG. 9 shows a section as per line IX-IX of FIG. 4 ,
[0017] FIG. 10 shows a detail from FIG. 8 , and
[0018] FIGS. 11 to 14 show successive stages of the assembly of the intermediate shaft.
DETAILED DESCRIPTION
[0019] The transmission housing 1 , which in FIG. 1 is hatched from bottom left to top right, of the first exemplary embodiment has a foot 2 and a drive-input-side opening which is closed off by a cover 3 on which, in the example illustrated, a motor 26 is flange-mounted, with an input drive pinion 7 projecting into the transmission housing.
[0020] The housing 1 forms a drive-output-side chamber 5 which holds the drive output shaft 16 with the drive output gearwheel 6 and the associated bearings, specifically a drive-input-side bearing 8 in a bearing bore 9 and a drive-output-side bearing 10 in a bearing bore 11 . The chamber 5 having the bearing bores 9 and 11 is not undercut as viewed from the drive input side. The drive output shaft 16 , the gearwheel 6 and the rolling bearings 8 , 10 can therefore be inserted as a pre-assembled unit from the drive input side. The drive output shaft unit is held axially in the chamber 5 at the drive input side by means of a projection 19 of the cover 3 and at the drive output side by a circlip or a housing collar (not shown).
[0021] That part of the drive-output-side chamber 5 which holds the drive output shaft 16 is enclosed by a wall 28 which is aligned substantially axially parallel and which extends cylindrically over more than 180° at least in the region of the bearing bores 9 and 11 . Said wall 28 is connected to the foot 2 , partially by means of ribs and partially by means of a transverse wall 4 .
[0022] Situated on the drive input side of the housing is a drive-input-side chamber 12 which is enclosed by walls 29 and the cover 3 and in which are situated one or more transmission stages. Shown is an example in which the input drive pinion 7 acts on an intermediate gearwheel 13 which is supported by an intermediate shaft 14 . Said intermediate shaft 14 supports, at its other end, an intermediate pinion 15 which meshes with the drive output gearwheel 6 . The drive-output-side chamber 5 has, for holding the intermediate shaft 14 , a lateral convexity 5 a which is surrounded by walls 23 which run substantially axially parallel and is delimited at the drive output side by a wall 24 . The cylindrical inner face 20 , which extends over more than 180° in circumference, of said lateral convexity 5 a forms the bearing bore for two rolling bearings of the intermediate shaft. Of said rolling bearings, the rolling bearing 22 is arranged at the drive-output-side end of the intermediate shaft 14 of the chamber convexity 5 a , and the rolling bearing 25 is arranged approximately at the centre of the shaft and at the drive-input-side end of the chamber convexity 5 a . This permits support of the intermediate shaft directly at both sides of the highly-loaded intermediate pinion 15 . This limits the bending moment which is to be absorbed by the intermediate shaft and permits favourable dimensioning.
[0023] A third bearing 17 for the drive-input-side end of the intermediate shaft is situated in a bearing bore 18 of the cover 3 . In this way, the intermediate shaft 14 is additionally supported on the free side of the intermediate gearwheel 13 . The central bearing is correspondingly relieved of load and can therefore be of space-saving dimensions. In addition, this creates the possibility of arranging the intermediate gearwheel at a relatively great distance from the central bearing 25 , which has the advantage that said central bearing 25 of the intermediate shaft and the drive-input-side bearing 8 of the drive output shaft 16 can be arranged axially offset with respect to one another. This makes it possible to place the central bearing 25 of the intermediate shaft—as already discussed above—directly adjacent to the intermediate pinion 15 .
[0024] The disadvantages of the statically indeterminate arrangement, because of which the triple bearing arrangement of a shaft is normally avoided, are evaded in that the bearing of the shaft in the cover is utilized to centre said cover. This ensures that said third bearing is mounted precisely aligned with the two other bearings. In order that there is no resulting undesired double fit of said bearing in relation to the engagement of the cover projection 19 into the bearing bore 9 , said engagement is provided with a correspondingly great degree of play. Like the drive output shaft 16 , the intermediate shaft 14 as an assembled unit with the intermediate gearwheel 13 and all bearings 17 , 22 , 25 can be mounted as a pre-assembled unit from the drive input side of the transmission. The assembly complexity is correspondingly low. At the same time, the advantage is obtained that the entire transmission housing with the exception of the drive-input-side cover 3 is of single-piece design and is correspondingly stiff.
[0025] In the second exemplary embodiment, the housing 30 forms a drive-input-side chamber 32 , whose opening is closed off by the cover 31 , and a drive-output-side chamber 33 . The two chambers 32 , 33 are separated from one another by a partition 34 . A drive input unit 35 is flange-mounted on the cover 31 , the input drive pinion 36 of which drive input unit 35 projects into the drive-input-side chamber 32 . The drive input unit can be formed by a drive motor or an intermediate housing which forms a special bearing for the shaft of the pinion 36 which is mounted in a floating manner. Alternatively, said shaft can also be mounted on the other side of the pinion 36 by means of a bearing (not illustrated) in the bearing bore 37 of the partition 34 .
[0026] In the two-stage arrangement illustrated, the input drive pinion 36 acts on an intermediate gearwheel 40 which is seated on an intermediate shaft 41 which forms an intermediate pinion 42 . Said intermediate shaft 41 is mounted at three points, specifically by means of a bearing 43 in a bearing bore 44 of the cover 31 , by means of a bearing 45 in a bearing bore 46 of the partition 34 , and a bearing 47 in a bearing bore 48 in the drive-output-side wall 38 of the drive-output-side chamber 33 . The intermediate shaft 41 is fixed in its longitudinal direction in the housing by means of shoulders which delimit the bearing bores 44 and 48 .
[0027] The intermediate pinion 42 acts on a drive output gearwheel 50 on the drive output shaft 51 which is mounted by means of a bearing 52 in a bearing bore 53 of the partition 34 and by means of a bearing 54 in a bearing bore 55 at the drive-output-side end of the housing. The drive output shaft 51 with the associated parts is secured in the housing by means of a circlip 56 before the bearing 54 .
[0028] As can be seen in FIGS. 5 and 7 , the partition 34 can be reinforced by means of ribs 68 and contain apertures 69 which have been omitted in some other illustrations for the sake of simplicity.
[0029] The faces which form the drive-input-side chamber 32 adjoin, without an undercut, the opening which is closed off by the cover 31 . Said faces can therefore be shaped without a lost core in a pressure die casting process. That region of the drive-output-side chamber 33 in which the drive output shaft 51 is situated and which, in FIG. 9 , appears to be delimited by the face 57 adjoins, without an undercut, the drive-output-side opening of said face 57 , which opening is formed by the bearing bore 55 and the bore faces, which are if appropriate situated at the drive output side of said bearing bore 55 , for holding a sealing cover 58 , and which opening can therefore likewise be formed without a core.
[0030] The drive-output-side chamber 33 has, for holding the intermediate shaft 41 , a widening 60 which is delimited at the drive output side by the wall 38 and therefore cannot be formed from the same side as the region associated with the drive output shaft 51 . In order to be able to be formed without a core from the opposite side, the surface 61 of said widening 60 adjoins, without an undercut, a corresponding assembly opening 62 in the partition 34 .
[0031] The widening 60 of the drive-output-side chamber 33 is larger than would be required for holding the intermediate shaft 41 . Said widening 60 is specifically large enough to allow the drive-output-side bearing 47 in addition to the already-mounted drive output gearwheel 50 to pass through during assembly. Said widening 60 is expediently partially delimited by a cylindrical face 61 whose central axis 64 is offset with respect to the provided axis 65 of the intermediate shaft in the direction away from the drive output shaft 51 ( FIGS. 8 and 11 ).
[0032] The assembly opening 62 forms a widening of the bearing bore 46 which is provided in the partition 34 for the intermediate shaft bearing 45 . The widening results in a cutout in the peripheral face of the bearing bore 46 , in which cutout the bearing 45 is not supported. Since the width of said cutout is however smaller than the diameter of the bearing bore, the peripheral face of the bearing bore 46 extends over more than 180°, specifically over the angle α at both sides of the radius 63 which is aligned towards the drive output shaft. Said angle is so large that the resultant 64 of the forces arising from the toothing, which resultant is offset by approximately 110° with respect to said radius 63 in the case of conventional toothings, is situated within the region supported by the bearing bore 46 .
[0033] The assembly opening 62 and the widening 60 of the drive-output-side chamber 33 are large enough for the intermediate shaft 41 with the pre-assembled drive-output-side bearing 47 as per FIGS. 12 and 13 to be pushed in past the drive output gearwheel 50 . This makes it possible to insert the intermediate shaft 41 with the intermediate gearwheel 40 and all the associated bearings 43 , 45 , 47 as a pre-assembled unit into the housing.
[0034] Said process is shown in various stages in FIGS. 11 to 14 . In FIG. 11 , it is possible to see, below the bearing bore 46 in the partition 34 , the assembly opening 62 which is adjoined without an undercut by the widening 60 of the drive-output-side chamber. Firstly, said pre-assembled unit, approximately in the position of the axis 64 , is pushed in the direction of the arrow in FIG. 12 until the drive-output-side bearing 47 reaches the wall 38 which contains the bearing bore 48 of said bearing 47 . The unit is then pushed transversely in the direction of the arrow in FIG. 13 in order to reach the provided axial position 65 . Here, the pinion 42 and the drive output gearwheel come into engagement with one another. Finally, the pre-assembled unit of the intermediate shaft 41 is pushed forwards as per FIG. 14 in the direction of the arrow until the bearings 47 and 45 have found their intended position in the bearing bores 48 and 46 (see FIG. 4 ). In order that the transverse movement out of the position of FIG. 13 into that of FIG. 14 is possible, the free axial spacing between the drive output gearwheel 50 and the wall 38 which forms the drive-output-side bearing bore 48 must correspond at least to the width of the drive-output-side bearing 47 .
[0035] The assembly opening which is provided in the partition for the pre-assembled intermediate shaft could also be formed by the bearing bore 46 alone without the widening 62 if the bearing bore is large enough. If, however, the bearing 45 can be of small design on account of the widening 62 and on account of the additional bearing-mounting of the intermediate shaft by means of the drive-output-side bearing 47 , this has the important advantage that the intermediate shaft bearing 45 in the partition 34 can be accommodated in approximately the same plane as the bearing 52 of the drive output shaft. It is thus possible with little expenditure to reduce the installation length and the weight of the transmission. It is also thereby possible to further increase the housing stiffness, which is already increased according to the invention by means of the absence of additional assembly openings. The low cost expenditure is obtained by means of the compact design, the capability for cost-effective production of the housing in a pressure die casting process, the capability for pre-assembly of all shafts, gearwheels and bearings, and the possible dispensation with centering means on the housing cover, which is explained further below.
[0036] The second exemplary embodiment shows a two-stage transmission. Said transmission can however also be of three-stage design. In this case, an additional shaft is arranged in the drive-input-side chamber, for which additional shaft the partition 34 and the cover 31 contain further bearing bores 70 , 71 . Said additional shaft supports an additional gearwheel on which the input drive pinion acts and which is situated in the plane in which the intermediate gearwheel 40 is illustrated in the drawing. Said intermediate gearwheel 40 is moved to the left in the drawing on the intermediate shaft 41 in order to be able to interact with the pinion of the additional shaft.
[0037] With regard to the desired reduction in expenditure, the triple bearing arrangement of the intermediate shaft, which is generally avoided on account of static overdeterminacy, is worth noting. In the present case, said triple bearing arrangement has on the one hand the advantage that it permits the above-described favourable dimensioning of the intermediate shaft bearing which is arranged in the partition, so that said intermediate shaft bearing can be arranged in a plane with a bearing of the drive output shaft. Said triple bearing arrangement has on the other hand the advantage that the described alternative positions for the intermediate gearwheel can be provided for two-stage and three-stage transmission, because said intermediate gearwheel is mounted at both sides. Finally, said triple bearing arrangement has the advantage of the cover centering at the bearing 44 , which is arranged in the cover, of the intermediate shaft 41 . Said cover centering is sufficient in the case of a two-stage design of the transmission. For the case of the three-stage design, the housing and the cover can be provided with additional pairs of interacting centering faces 72 , 73 . Said centering faces 72 , 73 are arranged so as to effect a complementary centring centering action with regard to the rotational position of the cover about the axis of the intermediate shaft bearing 43 . For this purpose, it is necessary for the centering face pairs to have a face component which encloses an angle of less than 90° with a radius 74 , 75 which proceeds from the axis of the intermediate shaft. | Two-stage or three-stage spur gear transmission having a single-piece housing which has a drive-input-side cover opening and a closing cover which closes off said cover opening, having a drive output shaft which supports a drive output gearwheel between two bearings, and having an intermediate shaft which supports an intermediate gearwheel, which is driven directly or indirectly by an input drive pinion, and an intermediate pinion, which meshes with the drive output gearwheel, and is mounted by means of two intermediate shaft bearings which are adjacent to the intermediate pinion. The two intermediate shaft bearings which are adjacent to the intermediate pinion are arranged in a drive-output-side chamber, which is preferably not undercut in the direction of the assembly opening, of the housing. A third intermediate shaft bearing is arranged in a bearing bore of the cover. Said cover is centered on said third intermediate shaft bearing along a parting joint which runs perpendicular to the axis direction. | 8 |
This invention relates to armored cables. More specifically, this invention relates to armored optical fiber cables.
BACKGROUND OF THE INVENTION
Conventional electromechanical cables for oil well logging include insulated metal conductors for the transmission of electrical signals. Such cables have signal transmission bandwidths that are limited to about 100 KHz over lengths that correspond to typical depths of oil wells, 12,000 to 20,000 feet. Much of the information that is obtainable with modern logging tools is not retrievable from down the well bore due to the restricted signal bandwidth that is characteristic of state-of-the-art conventional logging cables. Consequently, a need exists to provide oil well logging cables that have substantially higher signal transmission bandwidths. Optical fibers can provide signal transmission bandwidths one to three orders of magnitude higher than the insulated wires that are used in conventional well logging cables.
Glass optical fibers have two properties which make it difficult to successfully incorporate them into strain cables. These properties are static fatigue degradation and microbending loss.
Silica glass fibers have small cracks (microcracks) on their surface. The depth of these microcracks can increase through a stress-accelerated chemical reaction between the silica glass and moisture, called static fatigue. The tensile strength of the glass fiber decreases substantially as the microcracks increase in depth. Glass is an elastic material with a high Young's modulus. Strain in a glass optical fiber generates tensile stress and results in static fatigue. Thus, glass optical fibers are not suitable for use under high strain (>0.5%) in the presence of moisture over extended periods of time.
Optical fibers transmit light signals by the principle of total internal reflection. This principal depends upon the light rays being totally reflected back into the core region each time they impinge upon the core to cladding interface of the optical fiber. Total internal reflection can only occur when the angle of incidence between the rays and the core to cladding interface is below a certain critical value. Bending of an optical fiber causes some of the light which is propagating in the fiber core to impinge upon the core to cladding interface at angles of incidence greater than the minimum value and to be refracted out of the optical core and lost. The amount of the light that is lost becomes greater as the effective diameter of the bend becomes smaller. When the bending of the optical fiber is caused by deflection due to local lateral forces, the resulting decrease in signal strength is called microbending loss. When an optical fiber is deflected by a local inhomogeneity, such as a lamp in its coating layers, the effective diameter of the bend depends upon the local strain the fiber is under. Generally, the fiber will bend to a smaller effective diameter as the strain level it is under increases. Consequently, higher strain levels result in higher levels of microbending loss.
A necessary condition for accurate logging of a well bore is an accurate knowledge of the position of the logging tool within the well bore. The position of the tool is defined by the actual length of logging cable that is suspended in the well bore. The actual length of suspended cable can be determined from a knowledge of the amount of unstressed cable length that has been lowered into the well plus a knowledge of the elongation versus tension characteristics of the cable and the tension along the suspended cable length. The amount of unstressed cable length that has been lowered into the well bore can be precisely measured. The tension profile along the suspended length of cable can be accurately calculated. Therefore, the actual length of cable suspended in the well can be accurately determined if the elongation versus tension characteristics of the cable are accurately known and are repeatable.
Conventional electromechanical cables for well logging can be constructed to withstand harsh high temperature environments and to accept high levels of axial strain while still remaining functional. More specifically, for example, each conductor element in a conventional logging cable comprises a bundle of copper wires. The copper wires yield inelastically at low strain. When the cable is alternately stretched and relaxed, the copper does not fully return to its original state and eventually the copper wires become brittle, due to strain hardening, and break. However, even this serious condition does not necessarily render the cable inoperable because a break in one or more wires with adjacent nonbroken wires permits the current to be passed to the neighboring wires and thus the conductor still appears whole and the cable remains functional. Thus, conventional logging cables can withstand considerable inelastic and elastic strain and still remain functional.
Well logging cables are generally constructed with two layers of external steel armor wires. The armor wires are preformed and applied in helices of opposing handedness to prevent the cable from unwinding when supporting a free hanging load. Inside the armored jacket can be seven insulated copper conductors laid six around one in helices generally of opposite handedness to those of the steel wires in the inner armor layer. However, there is no definite relationship between the helices of the copper conductors and those of the inner armor wires since they are added in separate fabrication steps and usually with a bedding layer of a pliant material therebetween. A result of this conventional cabling geometry is that the interface between the inner armor wires and the underlying insulated conductors consists of a multiplicity of cross-over points separated by the pliant bedding material.
When a conventional well logging cable is tensioned at elevated temperatures, it will elongate by an amount which is not acurately predictable. This is because the elongation consists of two parts, one that is linear and one that is highly nonlinear and inelastic. The inelastic part occurs because the armor wires inelastically deform the underlying compliant bedding and the wire insulation, due to very high local stresses at the crossover points, and take on a smaller pitch diameter. The inelastic part of the cable elongation is not very predictable or repeatable and consequently the position of the logging probe will not be accurately known.
In order to prevent inelastic strain from occurring in use, conventional logging cables are given a hot prestretch during fabrication. When properly conducted, the hot prestretch operation will result in a cable that exhibits a linear and elastic elongation in response to tension. The hot prestretching operation imparts a permanent (inelastic) strain of between 3/4 to 11/2 percent to conventional seven-conductor logging cables. Hot prestretching of a conventionally designed armored cable containing one or more optical fibers within its core would leave the glass optical fibers under a permanent elongation of 3/4 to 11/2 percent. Optical fibers in cables subjected to these high permanent strain levels would soon fail from static fatigue and/or exhibit intolerably high microbending losses. It is apparent that conventional prestretching technology cannot be applied to armored optical fiber cables. Thus, it would be highly desirable to have an armored fiber optic cable which overcomes these and other difficulties and permits the expansion of optical fiber communications technology into areas of harsh environments.
SUMMARY OF THE INVENTION
I have invented a cable and method of fabrication which minimizes the inelastic part of the cable elongation by minimizing the deformability of the core. The central bundle of the cable comprises at least two inner layers, including the inner armor, which are stranded in a "unilay" configuration of a given handedness around a central element. A "unilay" configuration is defined as a cable bundle wherein the element is in continuous contact with, and in the same orientation with respect to its nearest neighbors. The central bundle contains at least one optical fiber. The cross-sections of the central bundle are identical at every point along the cable, except for a rotation about the central axis. The unilay construction distributes the transverse forces continuously along the touching components instead of concentrating the forces at crossover points as in contrahelically formed layers of cable elements or layers of unidirectionally cabled elements that have different lay lengths. The lay length of the cable is long, on the order of about 3.5 inches for a cable with an outside diameter of about 0.5 inch. The lay length should be increased in direct proportion as the diameter of the cable increases. "Lay length" is defined as the distance along the cable or helical axis traversed by one complete helical revolution of the element. The cable has at least one outer armor layer which is contrahelically wound around the central bundle. The outer armor layer is of opposite handedness to the central bundle and substantially balances the torque of the inner armor when the cable is under tension. The elements of the layers are hard and resistant to deformation. This means that any conductor elements contained in the cable are single metal conductors and not multifilament conductors.
The layers in the central bundle are fabricated in a single operation with the same lay length and with the same handedness. The outer armored layer of opposite handedness is applied directly over the central bundle.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates a cross-sectional view of an armored optical fiber cable.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be more clearly illustrated by referring to FIG. 1. FIG. 1 illustrates an armored optical cable 10 of my invention. The armored optical cable 10 will be described with respect to specific embodiments such as overall size, dimensions and materials used to fabricate a well logging cable which comes within the scope of the invention. However, the invention is not intended to be limited solely to the specific dimensions or materials used in the description nor to only well-logging applications. The described cable is useful in any application which requires minimum cable deformations under load.
The armored optical cable 10 has a central core 12. The central core 12 has an outer diameter of about 0.120 inches ±1%. The central core comprises one or a plurality of optical fibers 14. The optical fibers 14 can be single-mode or multimode fibers, or mixtures thereof. The optical fibers are surrounded by a cushioning material such as an elastomeric cushioning material, for example, silicon elastomers and the like. If the central core comprises a plurality of optical fibers, the optical fibers should preferably be stranded together with the same helical handedness as the elements 22 and the inner armor wires 24 of the central bundle 30. For example, the three fibers illustrated have a right-handed lay sense and about a 3.5 inch lay length (1.2° lay angle). In the illustrated embodiment, the three-fiber assembly is embedded in and surrounded with a compliant, resilient material 16 such as silicone RTV. The coated fibers are further coated with a hard, stiff jacket 18 of a material such as a fiberglass-epoxy matrix. The jacket 18 has an outer diameter of about 0.094 inches ±2%. A suitable glass-epoxy jacket material is fabricated under the name of Stratoglas®, a product of the Air Logistics Corporation of Pasadena, Calif.
Surrounding the hard, stiff jacket 18 is an outer jacket 20 of material such as polyvinylidene (Kynar®, a product of the Pennwalt Company), perfluoroalkoxy (PFA Teflon®, a product of the DuPont Corporation), polyetheretherketone, (PEEK®, a product of ICI), or similar material. The outer jacket 20 should be of a sufficient thickness so that the central core 12 has the appropriate outer diameter of about 0.120 inches ±1%.
Alternatively, the cable 10 would have a central core 12 of a gas pressure tight type cable of the appropriate diameter illustrated in U.S. Pat. No. 4,312,565, incorporated herein by reference. Another alternative is to have a central metal tube of the appropriate diameter with one or more optical fibers therein.
In the preferred embodiment, the space for the central core 12 is formed by at least six elements 22, such as conductor strands, layed around the central core 12 with a right-handed lay sense and a 3.5 inch lay length (9.8° lay angle). To obtain a larger diameter for the central core 12, more conductor strands, e.g., eight, as illustrated, are used to fabricate the space for the central core 12. The conductor strands 22 should be fabricated from material which minimizes deformation and is capable of interlocking with the inner armor 24. Suitable conductor strands are solid copper-plated steel wire having a diameter of about 0.0403 ±1%. The conductor strands should have a minimum conductivity of 60% minimum of International Annealed Cooper Standard (IACS) with a yield strain of about 0.9% minimum at 0.2% offset. A material meeting these requirements is Copperweld®. The solid copper-plated steel wire is coated with an insulator such as Kynar® to an outer diameter of about 0.071 inches. The central core 12 and the conductor strands 22 should have a combined outer diameter of about 0.262 inches.
An alternative embodiment is to fabricate the cable with a solid central core 12 having about 0.120 inches O.D. ±1% with a conductivity of 30% minimum of IACS, and a yield strain of about 0.9% minimum at 0.2% offset. In this embodiment, the elements 22 contain several central optical fibers surrounded with a suitable protective jacket. A suitable element 22 has a central optical fiber with about a 125 micron diameter with the silicon RTV coating it to a thickness of about 325 microns O.D. and with a Hytrel®, a product of Du Pont, coating to an O.D. of about 500 microns ±5%. A suitable glass optical fiber meeting these requirements can be purchased from ITT Corporation. A glass-epoxy matrix is applied over this optical fiber to an O.D. of about 0.040 inches ±2% and Kynar® or other suitable coating is applied over the glass-epoxy matrix to an O.D. of about 0.071 inches ±1%. Assuming eight elements 22, up to three of the elements would be the optical fibers and the other elements are conductor strands such as Copperweld®. Preferably, the optical fibers are integrated among the eight elements.
At least twice the number of inner armor wires 24 surround the conductor strands 22. In this preferred embodiment, sixteen inner armor wires 24 should be of a drawn, galvanized, improved plow steel rope wires (AISI) or other suitable material with a diameter of about 0.0575 inches ±1%, minimum tensile strength of about 244 KPSI minimum torsions (8") of about 39, a coating adherence as evidenced by a 3D mandrel wrap test. The inner armor wires 24 are layed as part of the central bundle 30 with a right-handed lay sense and a 3.5 inch lay length (15.5° lay angle). The central bundle 30 has an outside diameter of about 0.368 inches. It is important that the sixteen inner armor wires 24 be electro-galvanized with bright and smooth finishes such as a minimum zinc coating of about 0.2 oz./ft. 2 . The inner armor wires 24 lie adjacent to the insulated conductors and hence must provide a smooth interface for transferring compressive loads to the insulated wires.
A suitable protective material 26 for the intended environment of the cable 10 is applied during the fabrication of the central bundle 30 out to the inner armor 24. Suitable materials for a well logging cable are nitrile rubber based filling compounds and the like. The inner armor wires 24 are wound around the conductor strands 22 as illustrated to provide room for eight intersticial elements 28. The eight intersticial elements 28 are optional and can be either a corrosion inhibitor lubricant 26, such as TMS 5878 Compound, a product of Quaker Chemical Company, or wires or insulated conductors or jacketed optical fibers. The intersticial elements 28 are layed with the same lay sense as conductor strands 22 and inner armor wires 24. The intersticial elements 28 are cabled with a right-handed lay sense and a 3.5 inch lay length (12.5° lay angle). The intersticial elements 28 must have a maximum outside diameter of about 0.028 inches minimum zinc coating of about 0.1 oz./ft 2 , minimum tensile strength of about 251 KPSI, minimum torsions (8") of about 83, and a coating adherence as evidenced by 2D mandrel wrap test. If the intersticial elements 28 are used to control the placement of the inner armor wires 24, then the elements 28 should preferably be solid, bright, galvanized wires. It is important that any intersticial elements 28 have a rounded and smooth external surface since they lie adjacent to the insulated conductor strands and must provide a smooth surface for transferring compressive loads to the insulated strands.
A unique feature of the armored optical cable 10 is the fact that the elements of the central bundle 30 are fabricated with the same lay length and handedness so that they nestle together and do not crossover each other. Another unique feature is the fact that the conductor strands 22 and the inner armor wires 24 are assembled in the same operation so that the elements 22 and 24 rest on each other and not in the grooves formed between the conductor strands 22. This construction gives the cable greater flexibility and reduces friction between the conductor strands 22 and the inner armor wires 24. These features provide for minimal deformation of the interface between the elements and hence minimal inelastic elongation of the cable.
Surrounding the inner armor wires 24 and forming the outside diameter of the cable 10 is at least one layer of outer armor wires. Illustrated in the preferred embodiment are twenty-four strands of outer armor wires 32. The outer armor wires 32 should be fabricated from galvanized, improved plow steel rope wires (AISI) or other suitable materials having about a 0.049 diameter ±1%, minimum zinc coating of about 0.4 oz./ft. 2 , test per ASTM A-90, minimum tensile strength of about 246 KPSI, test per ASTM E-8, minimum torsions (8") of about 47, test per FED SPEC RR-W-410, and an adherence coating meeting ASTM A-641 using a 3D mandrel. The wires 32 are preferably preformed and layed with a lay sense opposite that of elements 22 and 24. The outer armor must be wound in opposite handedness to the inner armor and of sufficient compressive strength such that the inner armor and the outer armor are substantially torque balanced. For this example, the lay handedness of the outer armor wires 32 should be a left-handed lay sense and a 3.5 inch lay length (20.5° lay angle). As the outer armor wires 32 are being applied, the central bundle 30 is coated with a corrosion-resistant and lubricating material 34 such as TMS5878, and the like. The overall dimensions of the optical cable 10 will be about 0.469 inches.
The preferred armored optical cable 10 described herein is fabricated in one in-line operation. The central bundle 30 is formed from one bay of planetary bobbins and the outer armor wires 32 are applied directly over the central bundle 30 from a tandem bay of planetary bobbins. The outer armor wires 32 are applied in an opposite handedness such that the torques exerted by said inner and outer armor wires are substantially balanced. A suitable method of balancing the contrahelically wound outer armor wires 32 and the inner armor wires 24 is disclosed in U.S. Pat. No. 4,317,000, completely incorporated herein by reference. The machines which fabricate the cable of my invention are known in the art as planetary cabling machines. A suitable source for the fabrication of the cable is Blake Wire and Cable Company of Torrence, Calif. Of course, the cable can also be fabricated by a tube winder cabling machine; however, the outer armor wires will have to be applied in a separate step.
Having described my invention with respect to a particularly preferred embodiment and some preferred alternatives, it should be understood that the invention is not intended to be limited solely to the description therein. Modifications which would be obvious are intended to be within the scope of the invention. For example, the cable is not limited to any specific diameter, number of optical fibers, and the like. A different environment or job application which required a larger load placed on the cable could require a larger diameter cable with larger and/or more conductor strands, inner armor wires, in direct proportion. Furthermore, it is necessary that the conductor strands and the inner armor are fabricated in one operation with the same handedness and the inner armor is set up so as not to lie in the grooves formed by the conductor strands. The outer armor must be wound in opposite handedness to the inner armor and of sufficient compressive strength such that the inner armor and the outer armor are substantially torque balanced. | An armored optical cable and process of manufacturing is described. The armored optical cable exhibits minimal inelastic elongation in response to tension at elevated temperatures and is capable of withstanding harsh ambient conditions. The armored optical cable is fabricated in a unitary operation with a central bundle of one handedness surrounded by at least one outer armor layer of opposite handedness substantially torque balanced to the handedness of the central bundle. | 3 |
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