description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application No. 61/413,575, which was filed Nov. 15, 2010.
TECHNICAL FIELD
[0002] This disclosure relates to composite bathing vessels.
BACKGROUND
[0003] Bathing vessels such as showers and bathtubs have surrounds that are subject to stresses. The walls may support grab bars and towel bars, and users may interact with the walls of the surrounds by stressing them.
[0004] Bathing vessels may be manufactured from a variety of different materials, such as plastic materials. Plastic bathing vessels, however, must meet certain minimum performance requirements. For instance, the American National Standards Institute (ANSI) sets forth minimum physical requirements and testing methods for plastic bathtub and shower units. A bathing vessel that meets the requirements is approved for use in homes, buildings or other structures as a plumbing fixture.
SUMMARY
[0005] According to an embodiment shown herein, a bathing vessel has a first and a second sandwiched wall, each wall having a first layer of polyurethane material, a second layer of polyurethane material attached to the first layer, a third layer of acrylonitrile butadiene styrene (ABS) material attached to the second layer, and a fourth layer of acrylic material attached to the third layer. A load element is disposed across and is integral with the first and second sandwiched walls. The load element distributes a load on one wall to an other wall and is visible to users of the bathing vessel. The load element is also a design element.
[0006] According to a further embodiment shown herein, a bathing vessel has a first and a second sandwiched wall, each wall having a first layer of polyurethane material, a second layer of polyurethane material attached to the first layer, and a third layer of acrylonitrile butadiene styrene (ABS) material attached to the second layer. A load element is disposed across and is integral with the first and second sandwiched walls. The load element distributes a load on one wall to an other wall and is visible to users of the bathing vessel. The load element is also a design element.
[0007] According to a further embodiment shown herein, a method for constructing a bathing vessel includes the steps of: choosing a layered material defining a first wall and a second wall, the layered material having a first layer of polyurethane material, a second layer of polyurethane material attached to the first layer, and a third layer of acrylonitrile butadiene styrene (ABS) material attached to the second layer; determining a load to be distributed across the first wall and the second wall; forming a load element that is integral with and in the first and second walls that is visible to users, and crosses the first wall and the second wall to distribute the load across the first and the second wall; and, making the load element a design element.
[0008] According to a still further embodiment shown herein, a bathing vessel has a first and a second sandwiched wall and a load element that is integral with and disposed across said first and second sandwiched walls that distributes a load on one wall to the other wall and is visible to users of said bathing vessel wherein said load element is also a design element.
[0009] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a one piece bathing vessel.
[0011] FIG. 2 is a side view of bathing vessel of FIG. 1 .
[0012] FIG. 3 is a detailed view, taken along the lines 3 - 3 of FIG. 2 .
[0013] FIG. 4 is a detailed view, taken along the lines 4 - 4 of FIG. 2 .
[0014] FIG. 5 is side view of the material forming the bathing vessel of FIG. 1 .
[0015] FIG. 6 depicts a method of designing a bathing vessel.
DETAILED DESCRIPTION
[0016] Referring now to FIGS. 1-3 , a perspective view of a one-piece bathing vessel 10 , including tub 15 , a surround 13 , a skirt 15 in front of the tub 25 , a deck 20 circling a top of the tub, a right sidewall 30 extending upwardly from the deck 20 , a left surround wall 35 extending upwardly from the deck 20 and a back wall 40 extending upwardly from the deck 25 and attaching to and integral with the left surround wall 35 and the right surround wall 30 . A nailing flange 45 is disposed around the bathing vessel 10 and is used to attach the bathing vessel 10 to a stud wall 70 or an attachment plane 75 . A design/load element 50 extends from the left surround wall 35 across the back wall 40 and across to the right side surround wall 30 . The curved portion 60 of the design/load element 50 has a back 65 . Though a one-piece bathing vessel is shown herein, one of ordinary skill in the art will recognize from the teachings herein, that a one-piece surround made of a side wall(s) and a back wall may also be constructed as taught herein.
[0017] Referring to FIGS. 2 and 3 , details of the design/load element 50 are shown. But for the design element/load element 50 , and the nailing flange 45 , the back wall 40 and the right and left surround walls 30 , 35 are disposed a distance D 1 of 0.05 inches from a stud wall 70 or an attachment plane 75 . Some requirements, such as for ANSI, require the sidewalls 30 , 35 or back wall 40 not to deflect more than 0.25 inch. By keeping these walls less than 0.25 inch away from the stud wall 70 or attachment plane 75 , the distance these walls can deflect is less than 0.25 inch and the requirements are then met. Because of the flexibility of the walls 35 , 40 , 30 , given the material 57 , as will be discussed infra, uses, the D 1 should be less than or equal to 0.25 inches. The nailing flange 45 and the sidewalls and back walls 35 , 40 , 30 , each have a thickness D 2 of 0.070 inches.
[0018] The design/load element 50 has a ledge extending around the back wall 40 and the side walls 30 , 35 and the curved area 60 also extending around the back wall 40 and the side walls 30 , 35 . As seen in FIG. 4 , the design/load element 50 is defined from behind the bathing vessel 10 . The curved area 60 helps give the design load element a better aesthetic look and feel to a user. The ledge 55 has a width D 3 of 1.69 inches. By creating the ledge and the curved area in conjunction with a material 57 as will be discussed infra, stresses on the back wall 40 and the side walls 30 , 35 are absorbed into the design/load element 50 and distributed across the back wall 40 and the side walls 30 , 35 . As a result, less material 57 may be utilized to effect a cost benefit for the bathing vessel 10 . Though a particular design/load element 50 is disclosed herein, other design/load element 50 are contemplated herein. The ledge 55 and curved area 60 bisect a span of each of the walls to shorten the span of the wall area holding the loads 80 , 85 to facilitate increased rigidity while minimizing material requirements.
[0019] Referring to FIG. 5 , The bathing vessel 10 is made of a material that is flexible yet rigid so that point loads on the walls such as grab bar 80 or grab bar 85 which typically require extensive local reinforcement 90 (see FIG. 1 ), which may be a metallic panel that may attach to the studs 70 , do not require extensive local reinforcement of the back wall 40 or the side walls 30 , 35 because the point load is distributed through the design/load element 50 across the sidewalls 30 , 35 and the back wall 40 .
[0020] The material must be flexible and rigid to enable the load to be distributed across the back wall 40 , left side wall 35 and the right side wall 30 . FIG. 4 shows a cross-section through a portion of one of the walls 35 . The walls 35 are a multi-layer structure that generally includes a first layer of polyurethane material 130 a, a second layer of polyurethane material 130 b, a layer of acrylonitrile butadiene styrene (ABS) material 130 c, and a layer of acrylic material 130 d (collectively layers 130 a - d ), such as polymethylmethacrylate. As shown, the layer of acrylic material 130 d is a top layer and is exposed for view to a user within the bathing vessel 20 . The layers 130 b and 130 c are intermediate layers, and the layer 130 a is a bottommost layer that is generally obscured from view of a user within the bathing vessel 10 . Each of the layers 130 a - d is bonded to its respective neighboring layer or layers. In embodiments, the specific materials and order of the layers 130 a - d contributes to providing the bathing vessel with a desired degree of strength, such as to meet ANSI requirements.
[0021] In embodiments, the layer of acrylic material 130 d is arranged on the first layer of polyurethane material 130 a, the layer of acrylonitrile butadiene styrene (ABS) material 130 c is arranged between the layer of acrylic material 130 d and the first layer of polyurethane material 130 a, and the second layer of polyurethane material 130 b is arranged between the layer of ABS material 130 c and the first layer of polyurethane material 130 a. In some examples, additional layers may be arranged among the layers 130 a - d . In other examples, the walls 35 include only the layers 130 a - d and are free of other layers, materials, adhesives, or the like.
[0022] The thicknesses of the individual layers 130 a - d is not necessarily shown to scale and may vary, depending on the desired wall strength and location in the wall 35 , for example. In embodiments, the ratio of the thickness of the layer of acrylic material 130 d to the thickness of the layer of ABS material is no greater than 1, to facilitate meeting strength requirements.
[0023] In embodiments, the first layer of polyurethane material 130 a, the second layer of polyurethane material 130 b, or both, are foamed polyurethane materials. In some examples, the density of the first layer of polyurethane material 130 a is different than the density of the second layer of polyurethane material 130 b. For instance, the density of the first layer of polyurethane material 130 a is greater than the density of the second layer of polyurethane material 130 b, to facilitate achievement of a desired degree of strength of the walls 35 .
[0024] In a further example, the second layer of polyurethane material 130 b is a rigid layer and has a density of 1-10 pounds per cubic foot. The first layer of polyurethane material 130 a is an elastomeric layer and has a density of between about 25-65 pounds per cubic foot though in some examples approximately 55-65 pounds per cubic foot are used. In one example, the density is approximately 62 pounds per cubic foot.
[0025] Referring now to FIG. 6 , local requirements, such as ANSI standards, may require walls 30 , 35 , 40 , to withstand point or other loads that have heretofore required extensive local reinforcement. If designing or constructing a bathing vessel 10 herein, a designer may choose to use the material 57 herein (step 95 ). The designer would then design a load element such as ledge 55 , taking into account the following variables: finite element analysis or the like how stresses of point loads are distributed around walls 30 , 35 , 40 in view of a proposed design (step 110 ); minimizing material 57 required as the design evolves (step 115 ) and minimizing local reinforcement 90 required (step 105 ). The designer then provides and aesthetic (step 120 ), such as curved area 60 , to make the bathing vessel attractive to consumers. By understanding that the material helps distribute the point or other loads with the inclusion of a design/load element 50 , the designer may include a design/load element 50 that is both aesthetic and provides support for the loads across the walls 30 , 35 , 40 . After designing a design/load element 50 , the designer may then opt for smaller local reinforcement, or a thinner material 57 .
[0026] It is commonly believed and accepted that the load displacement of the surface of the walls 30 , 35 , 40 , of the bathing vessel 10 is a function of the rigidity of the immediate area. However, it has been determined that by using less rigid materials, a load can be distributed throughout the unit by use of a design element that ties the walls together. In other words, a wrap around shelf or other design feature that has continuity across the back wall surface in carrying through the corner radius and onto each sidewall, can distribute the load across the entire unit. By distributing the load across the entire unit, thinner material may be used, allowing weight in material savings.
[0027] Furthermore, the embodiments shown utilize design elements to shorten the span of the wall area to facilitate increased rigidity while minimizing material requirements. In addition, the wall design elements use a minimum distance from the stud plane (or installation alcove surface) at key loading points to minimize the maximum deflection of the walls of the bathing vessel.
[0028] Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
[0029] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims. | A bathing vessel has a first and a second sandwiched wall, each wall having a first layer of polyurethane material, a second layer of polyurethane material attached to the first layer, a third layer of acrylonitrile butadiene styrene (ABS) material attached to the second layer, and a fourth layer of acrylic material attached to the third layer. A load element is disposed across and is integral with the first and second sandwiched walls. The load element distributes a load on one wall to an other wall and is visible to users of the bathing vessel. The load element is also a design element. | 8 |
FIELD OF THE INVENTION
This invention relates to positive working photoresists. More particularly it pertains to photoresists containing resin, such as a polyimide precursor or a soluble polyimide, a photoactivatable acid generator, and a solubility enhancer, capable of promoting dissolution of the photoactivated portion of the resist, while it has no effect on the rest portion of the resist.
BACKGROUND OF THE INVENTION
Positive working photoresists are known in the art. They generally comprise film-forming polymeric resin binder containing a photoactive compound. The resin binders most frequently used are made from phenol-formaldehyde condensation products, such as Novolak for example. Positive resists are prepared using the novolak type resin by incorporating therein a photoactive compound, for instance, one of the group of the 4- or 5-substituted diazonaphthoquinone (1,2)-diazide sulfonic acid esters. The alkali soluble novolak resins, when mixed with a photoactive acid-generating compound, become insoluble in aqueous alkaline solutions. However, areas exposed to actinic radiation become soluble to these alkaline solutions, called developers, as acidic groups are generated.
Positive resists are most often used as masks to protect substrates from chemical etchants in the manufacture of semiconductors. In such manufacture, the photoresist is coated onto the surface of a semiconductor substrate, and then imaged and developed to remove areas subjected to actinic radiation. The resist image remaining on the surface of the substrate is usually employed as a protective mask to facilitate the selective etching of the exposed portions of the substrate thereby defining a circuit pattern.
Etching of the substrate may be conventionally carried out by chemical treatment, or by dry etching, e.g. reactive ion etching with chemically active gas ions, such as fluorocarbon species for example, formed by glow discharge. Additionally, modern techniques for processing semiconductors may call for plasma and sputter etching, ion beam implantation, and the like.
One of the problems associated with these techniques is that many resist materials cannot withstand the process severity and are eroded along with the substrate, or flow due to reaction with the gaseous ions and the rather high temperatures often encountered on the semiconductor substrate (typically above 200° C.) resulting in loss of pattern resolution. For example, many novolak type phenol formaldehyde resins begin to flow at temperatures around 120° C. and erode when struck by the gas stream generated during reactive ion etching.
When photoresist compositions are employed as dielectric layers, not only thermal stability is essential, but the resist must also maintain good dielectric and mechanical properties.
Over the years, polyamic acid resins produced by condensation of an aromatic dianhydride and an aromatic diamine have received widespread attention as polymeric binders for photoresist compositions because they are readily converted by heat to thermally stable polyimides with very balanced mechanical and dielectric properties. However, the use of polyamic acids has been restricted for the most part to negative working photoresist compositions because of their high solubility in alkaline solutions.
Several problems associated with the use of negative working polyimide photoresists for imageable dielectric layers could be overcome if positive working photoresists were used. In the first place, dielectric applications commonly require that holes be patterned in the existing coating. Hole patterning is most effectively accomplished through the use of a positive resist, in which the exposed areas are removed. In addition, a slight side slope is desired in order to achieve effective metal contacts. Positive resist naturally achieve the necessary sloping sidewalls because the top of the film receives a higher exposure than the bottom of the film, and is therefore slightly more soluble. A third advantage of positive resist over negative resist is due to the fact that the spec of dust on photomask is not so critical. Higher manufacture yield due to lower defects can be improved with positive working polyimide. Positive working resists are also distinguished, as compared to negative resist, by high resolution due to less image swelling, the ability to utilize aqueous developers, which is of importance ecologically and economically, and by the fact that the presence of oxygen has no effect on the exposure time.
Attempts have been made to prepare positive working polyamic acid based compositions using diazoquinone-(1,2)-diazide-sulfonic acid esters such as disclosed in U.S. Pat. No. 4,880,722, among others. Thus, attempts have been made in the past to render the polyamic acid resin insoluble in an alkaline developer by admixture with a orthonaphthoquinone diazide compound. It was believed that sufficient quantities of the diazide compound would render the unexposed areas of the photoresist composition completely insoluble in aqueous alkaline developing solution because of the hydrophobicity and insolubility of the diazides themselves before photolysis or photoimage development. By use of this different solubility, it was believed that sharp distinction between imagewise exposed and unexposed areas during development would occur and thus ensure that only exposed areas would be dissolved in the developer; while unexposed areas would remain insoluble and unaffected in the developer. However, such attempts have had only limited success in that polyamic acid based photoresist systems exhibit such high dissolution rate in conventional commercially available alkaline solutions such as tetramethyl ammonium hydroxide, that adequate control over the process to obtain high resolution can only be achieved with weak alkaline developers such as dilute (0.5%) diethylethanolamine, for example.
Attempts to decrease the dissolution rate of the polyamic acid photoresist precursor, by increasing the concentration of the photoactive compound in the photoresist, e.g. up to about 50% by weight, increase the optical density of the photoresist to such a high extent, that full penetration of the film thickness by a radiation source is unattainable for all practical purposes.
In U.S. Pat. No. 4,880,722 (Moreau, et al.), it is disclosed that the dissolution rate in alkaline developers of image-wise exposed photoresist systems based on diazoquinone sensitized polyamic acid is reduced to prepare relief images of fine line resolution by reducing the acidity of the polyamic acid prior to exposure. This reduction in acidity is achieved by pre-baking the coating to partially imidize the polyamic acid to a level of 20% imidization; or partial neutralization with basic organic reagents; or the use of blends of the polyamic acid with its ester derivatives or with copolymers of the acid and its ester. However, pre-baking to achieve partial imidization above 100° C., as for example at even 120° C., causes loss of photosensitivity due to degradation of the diazoquinone photosensitizers. Furthermore, acidity reduction through employment of basic organic reagents, therein disclosed, tends to promote corrosion of the conductors found in integrated circuits. Blends of polyamic acid with its ester derivatives tend to cause phase separation during pre-baking process.
In addition, resist formulations which contain polyamic acids and diazoquinone compounds have limited storage life, since diazoquinone compounds tend to decompose in the presence of acid.
U.S. Pat. No. 4,863,828 (Kawabe et al.) discloses a positive working photoresist composition, which comprises a light sensitive substance of 1,2-naphthoquinonediazide-4-and/or -5-sulfonate of 2,3,4,3',4',5'-hexahydroxybenzophenone and an alkali soluble novolak resin dissolved in ethyl lactate or methyl lactate. This reference also discloses that the composition may further contain a polyhydroxy compound for accelerating dissolution of the composition into a developer, in a preferable amount of 0.2 to 5% by weight based on the solid contents of the composition.
U.S. Pat. No. 4,738,915 (Komine et al.) discloses positive-working photoresist compositions comprising a novolac resin and an ester compound between 2,3,4-trihydroxybenzophenone and naphthoquinone-1,2-diazido-5-sulfonic acid. In addition, the composition contains a specified amount of 2,3,4-trihydroxybenzophenone in a specified amount relative to the ester compounds as part of the photosensitive component which may be a reaction product obtained by the esterification reaction for the synthesis of the ester compounds containing unesterified 2,3,4-trihydroxybenzophenone.
U.S. Pat. Nos. 4,626,492 and 4,650,745 (Eilbeck) disclose a composition and a method, respectively, pertaining to a positive resist which is claimed to demonstrate improved photospeed and rate of development. The resist composition contains a solvent and select proportions of a novolac resin, a naphthoquinone diazide sensitizer, a dye which absorbs light and an effective proportion of a trihydroxybenzophenone compound.
U.S. Pat. No. 4,009,033 (Bakos et al.) discloses a positive photoresist which is claimed to have increased sensitivity to light, and which is formed by the addition of an acidic compound to a 1,2-quinone-diazido-sulfonic acid ester sensitizer.
In contrast to the present invention, as it will be explained in detail hereinbelow, none of the above references discloses, suggest or implies the combination of an alkali insoluble resin of the polyimide or polyimide-precursor type with an acid generator and an additive compound, used to enhance solubility, in an amount of 25-50 parts (preferably 30-40 parts) of said compound per 100 parts of resin.
SUMMARY OF THE INVENTION
The instant invention is directed to a positive working photoresist. More particularly it pertains to a positive photoresist composition comprising:
(a) 100 parts by weight of a resin selected from the group consisting of a polyimide precursor and a polyimide, the resin being substantially insoluble in alkaline media at a pH between 7 and 10, but soluble at a level of at least 2% by weight in at least one solvent selected from the group consisting of dimethylsulfoxide, diethylsulfoxide, N,N-dimethylformamide, N,N-diethylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N-cyclohexyl-2-pyrrolidone, 1,3-dimethyl-2-imidozolidione, N-methyl-2-pyrrolidone, phenol, o-, m-, p-cresol, xylenol, halogenated phenol, catechol, hexamethylphosphoramide, g-butyrolactone, chloroform, tetrachloroethane and a mixture thereof;
(b) 25-50 parts by weight of an acid generator, the acid generator being activatable by actinic radiation;
(c) 25-50 parts by weight of a solubility enhancer, the solubility enhancer being substantially non-volatile under 110° C., and soluble in alkaline media at a pH greater than 7.5; and
(d) a common solvent to the resin, the acid generator and the solubility enhancer.
It is preferable that the solubility enhancer comprises a hydroxyl group, more preferable that it is selected from the group consisting of
4,4'-Biphenol
Bis(4-hydroxyphenyl)methane
Tris-(2-hydroxyethyl)isocyanurate
2,2',4,4'-Tetrahydroxybenzophenone
Quinalizarin (1,2,5,8-tetrahydroxyanthraquinone)
Bis(2-hydroxyphenyl)methane
2,3,4-Trihydroxybenzophenone
2,4,4'-Trihydroxybenzophenone
2',3',4'-Trihydroxyacetophenone
2,3,4-Trihydroxybenzaldehyde
Pyrogallol (1,2,3-trihydroxybenzene)
2',4',6'-Trihydroxy-3-(4-hydroxyphenyl) propiophenone
2,2'-Biphenol
Phenol Red
1,5-dihydroxyanthraquinone
2,6-dihydroxyanthraquinone
Tetrahydroxy-1,4-benzoquinone, and
HO--C6H4--R--C6H4--OH, where --R-- is ═C(CH3)2, or
═C(CF3)2or═SO2,
and even more preferable that it is selected from the group consisting of
2,2',4,4'-Tetrahydroxybenzophenone
Tris-(2-hydroxyethyl)isocyanurate
4,4'-Biphenol
It is further preferable that the solubility enhancer comprises a silanol, preferably selected from the group consisting of triphenylsilanol, diphenylsilanediol, 1,4-bis(hydroxydimethylsilyl)benzene, and 1,3-bis(4-hydroxybutyl)tetramethyldisiloxane. More preferably, the silanol comprises diphenylsilanediol.
Very desirable is a requirement that a 5 micrometer thick film of the photoresist composition on a silicon wafer, which film has been baked at 100° C. for 1/2 hour, dissolves in less than 5 minutes in a 2.4% by weight solution of tetramethylammonium hydroxide in water.
The solubility enhancer may also be a monomeric acid, preferably benzoic or sulfonic acid.
The resin is preferably an esterified polyamic acid.
The acid generator is preferably selected from the group consisting of the product of condensation of naphthoquinone-(1,2)diazide-(5)-sulfonic acid with 2,3,4-trihydroxybenzophenone, and the product of condensation of naphthoquinone-(1,2)diazide-(4)-sulfonic acid with 2,3,4-trihydroxybenzophenone.
The common solvent preferably comprises a solvent selected from the group consisting of dimethylsulfoxide, diethylsulfoxide, N,N-dimethylformamide, N,N-diethylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N-methyl-2-pyrrolidone, N-cyclohexyl-2-pyrrolidone, 1,3-dimethyl-2-imidozolidione, N-methyl-2-pyrrolidone, phenol, o-, m-, p-cresol, xylenol, halogenated phenol, catechol, hexamethylphosphoramide, g-butyrolactone, chloroform, tetrachloroethane and a mixture thereof.
The present invention also pertains to a positive photoresist composition comprising:
(a) 100 parts by weight of a base polymer, the base polymer being substantially insoluble in alkaline media at a pH between 7 and 10;
(b) 25-50 parts by weight of an acid generator, the acid generator being activatable by actinic radiation;
(c) 25-50 parts by weight of a silanol, the silanol being non-volatile under 110° C., and soluble in alkaline media at a pH greater than 7.5; and
(d) a common solvent to the base polymer, the acid generator and the silanol.
Preferably, the base polymer is selected from the group consisting of acrylic, methacrylic, polyester, polystyrene, polycarbonate, novolac resin, esterified epoxy, polyurethane, polyurea, and a mixture thereof. Depending on the particular base polymer, the common solvent in this case should be such that dissolves all components of the compositions. A person of ordinary skill in the art is capable of easily selecting an appropriate solvent.
It is also preferable that the silanol comprises diphenylsilanediol.
A very preferred positive photoresist composition comprises:
(a) 100 parts by weight of a polyamic ethyl ester prepared by condensation of diethyl pyromellitate diacyl chloride with 4,4'-oxydianiline;
(b) 30-40 parts by weight of an acid generator, the acid generator being a product of condensation of naphthoquinone-(1,2)diazide-(5)-sulfonic acid with 2,3,4-trihydroxybenzophenone;
(c) 30-40 parts by weight of diphenylsilanediol; and
(d) 350-450 parts by weight of a common solvent to the ethyl ester, the acid generator, and the diphenylsilanediol, the common solvent comprising N-methyl-2-pyrrolidone and N-cyclohexyl-2-pyrrolidone.
Further, the present invention pertains to a method of forming a positive photoresist pattern on a substrate comprising the steps of:
(i) applying on a substrate a positive photoresist composition comprising
(a) 100 parts by weight of a polyimide precursor, the precursor being substantially insoluble in alkaline media at a pH between 7 and 10, but soluble at a level of at least 2% in at least one solvent selected from the group consisting of dimethylsulfoxide, diethylsulfoxide, N,N-dimethylformamide, N,N-diethylformamide, N,N-dimethylacetamide, N,N-diethylacetamide, N-cyclohexyl-2-pyrrolidone, 1,3-dimethyl2-imidozolidione, N-methyl-2-pyrrolidone, phenol, o-, m-, p-cresol, xylenol, halogenated phenol, catechol, hexamethylphosphoramide, g-butyrolactone, chloroform, tetrachloroethane and a mixture thereof;
(c) 25-50 parts by weight of an acid generator, the acid generator being activatable by actinic radiation;
(c) 25-50 parts by weight of a solubility enhancer, the solubility enhancer being substantially non-volatile under 110° C., and soluble in alkaline media at a pH greater than 7.5; and
(d) a common solvent to the polyimide precursor, the acid generator and the solubility enhancer.
(ii) evaporating the majority of the common solvent to substantially dry the photoresist;
(iii) imagewise exposing the dried photoresist to actinic radiation, the radiation being capable of photoactivating the acid generator; and
(iv) removing the photoactivated portions of the photoresist with an alkaline developer.
Preferably, the method further comprises a step of subjecting the developed photoresist to an effective amount of heat and temperature in order to induce imidization of the resin.
DETAILED DESCRIPTION OF THE INVENTION
As indicated above, there is a strong need in the art for a system which provides good control and broad development latitude of photoresists without reducing their sensitivity and resolution characteristics.
This invention resolves the vexing problems encountered in the composition of positive working polyimide photoresists by judicially selecting the components, amounts, and relationship among these components.
According to the present invention, a resin or base polymer is used which is substantially insoluble in alkaline media at a pH between 7 and 10, but soluble at a level of at least 2% by weight in a polar solvent as discussed earlier in the summary of the invention.
In combination with the resin, an acid generator being activatable by actinic radiation is employed at a level 25-50, preferably 30-40, and even more preferably 33-37 parts by weight per 100 parts of resin or base polymer.
Further, the composition of the present invention also comprises a solubility enhancer, which is substantially non-volatile under 110° C., and soluble in alkaline media at a pH greater than 7.5. The solubility enhancer is also employed at a level 25-50, preferably 30-40, and even more preferably 33-37 parts by weight per 100 parts of resin or base polymer. Amounts smaller than 25 parts are ineffective, while larger than 50 parts produce undesirable results, such as partial dissolution of the unexposed portions of the resist, as well as degradation of its mechanical and/or electrical properties, and the like.
Finally, a common solvent to the resin, the acid generator and the solubility enhancer is used to provide a solution suitable for application on wafers or other electronic devices.
The resin or base polymer may have any structure which gives it the aforementioned solubility characteristics, as long as the molecular weight is high enough to provide good integrity and film forming capability. Examples are alkali-insoluble but solvent-soluble polyimides and other polyimide precursors, such as esterified polyamic acids to an adequate degree to attain the "alkali-insoluble" status. The insolubility in alkaline media is very important, because the unexposed regions of the resist remain insensitive to the alkaline developer. In contrast, formulations containing soluble polyamic acids yield unexposed regions which are very sensitive to the alkaline developers, and thus the development latitude becomes very narrow. This is because the dissolution rate of the exposed regions of the resist is competing against the dissolution rate of the unexposed regions, and the difference of the two rates determines the development latitude. In contrast, the development latitude of an insoluble resin is considerably higher.
Solvent-soluble polyimides are alkali-insoluble, as they do not contain any groups, such as for example carboxyl groups, which would tend to solubilize the resin in alkaline media. Examples of preferred polyimides are 6FDA/MPD, 6FDA/ODPA/ODA, and PXDA/MPD. (abbreviations are listed in the glossary below). When polyimides are used, the imaged patterns can be postbaked at relatively low temperature such as 200° C. to remove any residual solvent, while in the case of esterified polyamic acids or other types of polyimide precursors, usually higher temperatures have to be employed, of the order of 300°-450° C.
The esterified polyamic acids according to this invention are preferably esterified with lower molecular weight alcohols, such as for example methyl, ethyl, propyl, isopropyl, butyl, t-butyl, other isobutyl and the like. Other alcohols may, of course, be also be used, such as for example the unsaturated esters of glycol monoallyl ether or 2-hydroxyethyl methacrylate known from the German Patent 2,437,348. The lower molecular weight alcohols are preferred as leaving behind lower amounts of residues during imidization of the precursor. Preferred esterified polyamic acids are polyamic ethyl esters prepared by condensation of diethyl pyromellitate diacyl chloride with 4,4'-oxydianiline.
Use of polyimides or their precursors is highly preferable as compared to other polymers because they can withstand harsh processing conditions in the final imide form, as well as because the unexposed portions of the film may play the role of a dielectric or an insulator, and remain as an active component in the final circuit configuration.
Examples of dianhydrides, which may be involved in the structure of the precursors or polyimides of the present invention are:
2,2-bis(3,4-dicarboxyphenyl)hexafluoropropane dianhydride, pyromellitic anhydride, 1,4,5,8-naphthalenetetracarboxylic dianhydride, 2,3,6,7-naphthalenetetracarboxylic dianhydride, 3,3',4,4'-biphenyltetracarboxylic dianydride, 1,2,5,6-naphthalenetetracarboxylic dianhydride, 2,2'3,3'-biphenyltetracarboxylic dianhydride, 3,3',4,4'-benzophenonetetracarboxylic dianhydride, 2,2-bis(3,4-dicarboxyphenyl)propane dianhydride, bis(3,4-dicarboxyphenyl)sulfone dianhydride, 3,4,9,10-perylenetetracarboxylic dianhydride, 1,1-bis(2,3-dicarboxyphenyl)ethane dianhydride, 1,1-bis(3,4-dicarboxyphenyl)ethane dianhydride, bis(2,3-dicarboxyphenyl)methane dianhydride, bis(3,4-dicarboxyphenyl)methane dianhydride, oxydiphthalic dianhydride, 9-trifluoromethyl-9-phenyl-2,3,6,7-xanthenetetra-carboxylic dianhydride, 9,9-bis(trifluoromethyl)xanthenetetra-carboxylic dianhydride, 12,14-(R)2-12,14-(Rf)2-12H,14H-5,7-dioxa-2,3,9,10-pentacenetetracarboxylic acid dianhydride (wherein R is selected from the group consisting of aryl, substituted aryl, and perfluoroalkyl, and Rf is perfluoroalkyl), and mixtures thereof.
Examples of diamines, which may be involved in the structure of the precursors or polyimides of the present invention are:
bis(4-aminophenyl)ether, 4,4'-diamino-3,3'-dimethylbiphenyl, 4,4'-diamino-3,3'-dimethoxybiphenyl, 4,4'-bis(4-aminophenoxy)biphenyl, 4,4'-diaminodiphenylsulfone, 3,3'-diaminodiphenylsulfone, bis[4-(4-aminophenoxy)phenyl]sulfone, bis[4-(3-aminophenoxy)phenyl]sulfone, bis[4-(2-aminophenoxy)phenyl]sulfone, 1,4-bis(4-aminophenoxy)benzene, 4,4'-diamino-2,2'-dichloro-5,5'-dimethoxybiphenyl, 4,4'-diamino-2,2',5,5'-tetrachlorobiphenyl, 9,10-bis(4-aminophenyl)anthracene, o-tolidine sulfone, 1,3-bis(4-aminophenoxy)benzene, 1,3-bis(3-aminophenoxy)benzene, 1,4-bis(4-aminophenyl)benzene, [4-(4-aminophenoxy)phenyl]ether, bis(4-aminophenyl)methane, bis(4-amino-3-ethylphenyl)methane, bis(4-amino-3-methylphenyl)methane, bis(4-amino-3-chlorophenyl)methane, bis(4-aminophenyl)sulfide, bis(3-aminophenyl)ether, 3,4'-diaminodiphenyl ether, 4,4'-diaminooctafluorobiphenyl, 1,3-diaminobenzene, 2,2-bis[4-(4-aminophenoxy)phenyl]propane, 2,2-bis[4-(4-aminophenoxy)phenyl]hexafluoropropane, 2,2-bis(4-aminophenyl)propane, 2,2-bis(4-aminophenyl)hexafluoropropane, 2,2-bis(4-amino-3-hydroxyphenyl)propane, 2,2-bis(4-amino-3-hydroxyphenyl)hexafluoropropane, 9,9-bis(4-aminophenyl)-10-hydroanthracene, diaminoanthraquinones (e.g., 1,5-diamino-9,10-anthraquinone and 2,6-diaminoanthraquinone), 4,4'-diamino-3,3'-dichlorobiphenyl, 4,4'-diamino-3,3'-dihydroxybiphenyl, 4,4'-diaminobiphenyl, 9,9-bis(4-aminophenyl)fluorene, bis(3-amino-4-methylphenyl)sulfone, 2-(4-aminobiphenyl)-2-[3-(4-aminophenoxy)phenyl]propane, Bisaniline M, Bisaniline P, bis(4-amino-2,6-methylphenyl)methane, 2,4-diamino-1-isopropylbenzene, 1,4-diamino-2,5-dichlorobenzene, 1,4-diamino-2,6-dichlorobenzene, 1,4-diamino-2,5-dimethylbenzene, 1,4-diamino-2-chlorobenzene, 1,3-diamino-4-chlorobenzene, 1,4-diamino-5-chloro-2-methylbenzene, 6-aceto-2,4-diamino-1,3,5-triazine, 1,4-diamino-2,3,5,6-tetramethylbenzene, 1,3-diamino-2,4,6 -trimethylbenzene, bis(3-aminopropyl)tetramethyldisiloxane, 2,7-diaminofluorene, 2,5-diaminopyridine, 1,4-diaminobenzene, 1,2-bis(4-aminophenyl)ethane, 4,4'-diaminobenzanilide, 4-aminophenyl 4-aminobenzoate, 1,5-diaminonaphthalene, 2,4-diaminotoluene, 1,3-diamino-5-trifluoromethylbenzene, 1,3-bis(4-aminophenyl)hexafluoropropane, 1,4-bis(4-aminophenyl)octafluorobutane, 1,5-bis(4-aminophenyl)decafluoropentane, 1,7-bis(4-aminophenyl)tetradecafluoroheptane, 2,2-bis[4-(3-aminophenoxy)phenyl]hexafluoropropane, 2,2-bis[4-(2-aminophenoxy)phenyl]hexafluoropropane, 2,2-bis[4-(4-aminophenoxy)-3,5-dimethylphenyl]hexafluoropropane, 2,2-bis[4-(4-aminophenoxy)-3,5-bis(trifluoromethyl)phenyl]-hexafluoropropane, 1,4-bis(4-amino-2-trifluoromethylphenoxy)benzene, 4,4'-bis(4-amino-2-trifluoromethylphenoxy)biphenyl, 4,4'-bis(4-amino-3-trifluoromethylphenoxy)biphenyl, 4,4'-bis(4-amino-2-trifluoromethylphenoxy)diphenyl sulfone, 4,4'-bis(3-amino-3-trifluoromethylphenoxy)diphenyl sulfone, 2,2-bis[4-(4-amino-3-trifluoromethylphenoxy)phenyl]hexafluoro-propane, 4,4'-diamino-3,3',5,5'-tetramethylbiphenyl, 4,4'-diamino-2,2'-bis(trifluoromethyl)biphenyl, 4,4'-diamino-2,2'-dimethylbiphenyl, 4,4'-diamino-3,3'-dimethylhexafluorobiphenyl, 4,4'"-diaminoquaterphenyl, 1,3-diamino-5-tert-butylbenzene, 1,4-bis(3-aminophenoxy)benzene, bis[4-(3-aminophenyl)phenyl]ether, 4,4'-diamino-2,2'-dichlorobiphenyl, 3,3'-diamino-4,4'-dihydroxybiphenyl, and mixtures thereof.
Examples of photoactivatable acid generators according to the present invention are photoactive compounds (sometimes called light sensitizers), such as for example o-quinonediazide compounds particularly esters derived from polyhydric phenols, alkyl-polyhydroxyphenones, arylpolyhydroxyphenones, and the like which can contain up to six or more sites for esterification, as described in U.S. Pat. Nos. 3,046,118, 3,046,121, 3,106,465, 3,201,239, 3,666,473, as well as 4,837,121, Col. 5 line 55 to Col. 6 line 66. They include resorcinol 1,2-naphthoquinonediazide-4-sulfonic acid esters; pyrogallol 1,2-naphthoquinonediazide-5-sulfonic acid esters, 1,2-quinonediazidesulfonic acid esters of (poly)hydroxyphenyl alkyl ketones or (poly)hydroxyphenyl aryl ketones such as 2,4-dihydroxyphenyl propyl ketone 1,2-benzoquinonediazide-4-sulfonic acid esters, 2,4-dihydroxyphenyl hexyl ketone 1,2-naphthoquinone-diazide-4-sulfonic acid esters, 2,4-dihydroxybenzophenone 1,2-naphthoquinonediazide-5-sulfonic acid esters,2,3,4-trihydrophenyl hexyl ketone, 2-naphthoquinonediazide-4-sulfonic acid esters, 2,3,4-trihydroxy-benzophenone 1,2-naphthoquinonediazide-4-sulfonic acid esters, 2,3,4-trihydroxy benzophenone 1,2-naphthoquinonediazide-5-sulfonic acid esters. 2,4,6-trihydroxybenzophenone 1,2-naphthoquinonediazide-4-sulfonic acid esters, 2,4,6-trihydroxybenzophenone 1,2-naphthoquinone-diazide-5-sulfonic acid esters, 2,2',4,4'-tetrahydroxy-benzophenone 1,2-naphthoquinonediazide-5-sulfonic acid esters, 2,3,4,4'-tetrahydroxy-benzophenone 1,2-naphtho-quinonediazide-5-sulfonic acid esters, 2,3,4,4'-tetrahydroxy-benzophenone 1,2-naphthoquinone-diazide-4-sulfonic acid esters, 2,2',2,4', 6'-pentahydroxybenzophenone 1,3-naphthoquinonediazide-5-sulfonic acid esters and 2,3,3',4,4',5'-hexahydroxybenzophenone 1,2-naphthoquinonediazide-5-sulfonic acid esters; 1,2-quinonediazidesulfonic acid esters of bis[-(poly)hydroxyphenyl]alkanes such as bis(p-hydroxyphenyl)-methane 1,2-naphthoquinonediazide-4-sulfonic acid esters, bis(2,4-dihydroxyphenyl)methane 1,2-naphthoquinone-diazide-5-sulfonic acid esters, bis(2,3,4-trihydroxy-phenyl)methane 1,2-naphthoquinonediazide-5-sulfonic acid esters, 2,2-bis(p-hydroxyphenyl)-propane 1,2-naphthoquinone-diazide-4-sulfonic acid esters, 2,2-bis(2,4-dihydroxyphenyl)propane 1,2-naphthoquinone-diazide-5-sulfonic acid esters and 2,2-bis(2,3,4-tri-hydroxyphenyl)propane 1,2-naphthoquinonediazide-5-sulfonic acid esters, 2,2-bis(p-hydroxyphenyl)-propane 1,2-naphthoquinone-diazide-4-sulfonic acidesters, 2,2-bis(2,4-dihydroxyphenyl)propane 1,2-naphthoquinone-diazide-5-sulfonic acid esters and 2,2-bis(2,3,4-tri-hydroxyphenyl)propane 1,2-naphthoquinonediazide-5-sulfonic acid esters. Besides the 1,2-quinonediazide compounds exemplified above, there can also be used the 1,2-quinonediazide compounds described in J. Kosar, "Light-Sensitive Systems", 339-352 (1965), John Wiley & Sons (New York)or in S. DeForest, "Photoresist", 50, (1975), MacGraw-Hill, Inc. (New York). In addition, these materials may be used in combinations of two or more. Further, mixtures of substances formed when less than all esterification sites present on a particular polyhydric phenol, alkylpolyhydroxyphenone, aryl-polyhydroxyphenone and the like have combined with o-quinonediazides may be effectively utilized in positive acting photoresists.
Of all the 1,2-quinonediazide compounds mentioned above, 1,2-naphthoquinonediazide-5-sulfonic acid di-, tri-, tetra-, penta-, and hexa-esters of polyhydroxy compounds having at least 2 hydroxyl groups, i.e. about 2 to 6 hydroxyl groups, are most preferred.
Among these most preferred 1,2-naphthoquinone-5-diazide compounds are 2,3,4-trihydroxybenzophenone 1,2-naphtho-quinonediazide-5-sulfonic acid esters, 2,3,4,4'-tetrahydroxy-benzophenone 1,2-naphthoquinone-diazide-5-sulfonic acid esters, and 2,2',4,4'-tetrahydroxybenzophenone 1,2-naphthoquinonediazide-5-sulfonic acid esters. These 1,2-quinonediazide compounds may be used alone or in combination of two or more.
The solubility enhancer can be a compound which is soluble in alkaline media at some pH higher than 7.5, which obeys the already discussed requirements, and which is compatible with the composition. By being compatible it is meant that it is either soluble in the res of the solid components of the composition after a film has been formed, or at least it is not grossly phase-separated. If micro-phase separation occurs, the separated phase globules should be smaller than the resolution desired, preferably by a factor higher than 2, and more preferably by a factor higher than 5. Since for the solvents to evaporate, the composition in, a film form on the desired substrate is heated usually at a temperature of 100°-110° C., the solubility enhancer has to be non-volatile at this range, so that it will remain in the film to play its role during the development.
It has been found by the Applicant that the solubility enhancer does not solubilize the unexposed part of the resist, if used under the conditions and requirements of the instant invention, while it provides an outstanding solubilizing effect on the exposed portions. It was also unexpected to observe that the properties of the polyimide film suffer very little, and much less of what one would expect. Adjustment of the acid generator in the absence of the solubility enhancer, does not approach the quality of the films, definition, and resolution achieved by the combinations employed in this invention.
A class of highly preferred solubility enhancers includes silanols, preferably selected from the group consisting of triphenylsilanol, diphenylsilanediol, 1,4-bis(hydroxydimethylsilyl)benzene, and 1,3-bis(4-hydroxybutyl)tetramethyldisiloxane, with special preference to diphenylsilanediol. This is due to the fact that in addition to providing excellent solubility balance between the exposed and unexposed areas, they also provide films of considerably lower water absorption.
Another preferable class is the one encompassing non-volatile compounds containing phenolic hydroxyls. The phenolic hydroxyls have adequate acidity to serve as solubility enhancers effectively, with reduced corrosive nature, as compared to carboxylic hydroxyls.
Acids, salts and other soluble compounds containing aliphatic hydroxyl groups are also useful in the practice of the present invention as solubility enhancers.
Some examples of preferred solubility enhancers, as aforementioned are:
4,4'-Biphenol
Bis(4-hydroxyphenyl)methane
Tris-(2-hydroxyethyl)isocyanurate
2,2',4,4'-Tetrahydroxybenzophenone
Quinalizarin (1,2,5,8-tetrahydroxyanthraquinone)
Bis(2-hydroxyphenyl)methane
2,3,4-Trihydroxybenzophenone
2,4,4'-Trihydroxybenzophenone
2',3',4'-Trihydroxyacetophenone
2,3,4-Trihydroxybenzaldehyde
Pyrogallol (1,2,3-trihydroxybenzene)
2',4',6'-Trihydroxy-3-(4-hydroxyphenyl) propiophenone
2,2'-Biphenol
Phenol Red
1,5-dihydroxyanthraquinone
2,6-dihydroxyanthraquinone
Tetrahydroxy-1,4-benzoquinone, and
HO-C6H4-R-C6H4-OH, where -R- is ═C(CH3)2, or
═C(CF3)2, or═SO2,
with special preference to
2,2',4,4'-Tetrahydroxybenzophenone
Tris-(2-hydroxyethyl)isocyanurate, and
4,4'-Biphenol
Examples of preferred solvents in the practice of this invention, especially in the case of polyimides or their precursors, include, but are not limited to, polar organic solvents, such as sulfoxide type solvents including dimethylsulfoxide, diethylsulfoxide, and the like, formamide type solvents, such as N,N-dimethylformamide, N,N-diethylformamide; acetamide type solvents, including N,N-dimethylacetamide, N,N-diethylacetamide; pyrrolidone type solvents, including N-methyl-2-pyrrolidone, N-cyclohexyl-2-pyrrolidone, 1,3-dimethyl-2-imidazolidinone, N-vinyl-2-pyrrolidone; phenolic solvents, including phenol, o-, m-, and p-cresol, xylenol, halogenated phenol, catechol; hexamethylphosphoramide; and a number of lactones including g-butyrolactones. These solvents may be used alone or as a mixture. Partial use of aromatic hydrocarbons such as xylene and toluene, is also possible, and sometimes desirable.
Where different resins or base polymers are utilized, solvents such as ketones, ethers, alcohols, and the like are also additional examples.
In a different embodiment of this invention, silanols, such as for example diphenylsilanediol may be also used as solubility enhancers in a variety of base polymers, such as for example acrylics, methacrylics, polyesters, polystyrenes, polycarbonates, novolac resins, esterified epoxies, polyurethanes, polyureas, and mixtures thereof.
The method of forming a pattern with the positive photoresist of the present invention on a substrate comprises initially a step of applying the photoresist composition usually by spin coating, dipping, or spraying. The majority of the solvent is then evaporated away at baking temperatures ranging usually between 90° and 110° C. In sequence, the dried photoresist film is imagewise exposed to actinic radiation, which photoactivates the acid generator. Following this step, the photoactivated portions of the photoresist are removed with an alkaline developer, usually by spraying or dipping. Preferably, an additional step is performed, involving heat treatment of the developed film at a temperature usually between 200°-450° C. for removing the rest of the solvent and further or fully imidizing the remaining film, depending on whether the resin was already an imide or a precursor to an imide, respectively.
A good test to determine whether a photoresist made according to the present invention has good dissolution characteristics is to form a film of the photoresist composition on a silicon wafer, which after having been baked at 100° C. for 1/2 hour has a thickness of 5 micrometers. This film should dissolve in less than 5 minutes when dipped in a 2.4% by weight solution of tetramethylammonium hydroxide in water.
GLOSSARY
CHP: N-cyclohexyl-2-pyrrolidone
6FDA: 2,2'-bis(3,4-dicarboxyphenyl)hexafluoropropane
MPD: Metaphenylenediamine
NMP: N-methyl-2-pyrrolidone
ODA: 4,4'-oxydianiline
ODPA: Oxydiphthalicanhydride
PXDA: 9-phenyl-9'-trifluoromethylxanthene-2,3,6,7-dianhydride
TMAH: Tetramethylammonium Hydroxide
EXAMPLES
This invention will be further illustrated by reference to the following specific examples. All parts, percents, ratios and the like are by weight.
COMPARATIVE EXAMPLES 1 AND EXAMPLES 2-8
The resist solutions were prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. The materials used and their concentrations are set forth in the following table:
______________________________________ Solubility Resin.sup.1 Sensitizer.sup.2 Enhancer.sup.3 Solvent.sup.4Formulation (Grams) (Grams) Type (Grams) (Grams)______________________________________A 50 4.4 -- -- --B 50 4.4 AA 0.55 --C 50 4.4 AA 1.10 --D 50 4.4 AA 2.2 --E 50 4.4 BB 4.4 5.0F 50 4.4 BB 4.950 5.0______________________________________ .sup.1 Resin is a preimidized condensation product (22% solids by weight) of 4,4'-hexafluoroisopropylidenebis-phthalic anhydride and a mixture of 4,4'-oxydianiline (50%) and 4,4'-diaminodiphenyl sulfone (50%) in a solvent mixture composed of 80% Nmethyl-2-pyrrolidone and 20% aromatic hydrocarbon. .sup.2 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.3 Solubility enhancer: AA: Tris(2-hydroxyethyl)isocyanurate BB: 4,4'-Biphenol .sup.4 Solvent: Propylene glycol methyl ether
Each formulation was coated on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter by means of a spin coating process. The coated wafers were dried for 30 minutes at 90° C. in a convection oven to give a surface film having thickness of 2.5-4.5 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then immersion developed in an aqueous alkaline solution with conditions described in the following table. The wafers were rinse with deionized water and forced air dried. The results and process conditions are set forth in the following table:
______________________________________ Con-Ex- cen- Dev. Clearam- Formu- Devel- tration Time Dose.sup.2ple lation oper.sup.1 (%) (Min) (mJ/cm.sup.2) Image______________________________________1 A TMAH 5 4 240 No 25° C. develop- ment2 B MEAM 40 3 180 Clear 40° C.3 B MEAM 50 2 150 Clear 45° C.4 C MEAM 50 5 180 Clear 40° C.5 C MEAM 50 3 150 Clear 40° C.6 D TMAH 9.2 2 110 Clear 40° C.7 E TMAH 2.38 2 144 Clear 40° C.8 F TMAH 2.38 1.5 144 Clear 40° C.______________________________________ .sup.1 Developer: MEAM: Monoethanolamine .sup.2 Clear Dose is defined by the minimum UV energy to clear the complete film thickness
The results clearly show the marked improvement in development which is achieved when the select additive is present in the resist composition in accordance with the present invention.
COMPARATIVE EXAMPLES 9 AND EXAMPLES 10-11
The resist solutions were prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. The materials used and their concentrations are set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________G 3 10 -- 1.2 --H 3.4 14.94 1.66 1.36 0.34I 3.4 14.94 1.66 1.36 0.68______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: NCyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: Tris(2-hydroxyethyl)isocyanurate
Each formulation was coated on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter by means of a spin coating process. The coated wafers were dried for 60 minutes at 90° C. in a convection oven to give a surface film having thickness of 3.0-3.5 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then immersion developed in an aqueous alkaline solution with conditions described in the following table. The wafers were rinse with deionized water and forced air dried. The results and process conditions are set forth in the following table:
______________________________________ Con-Ex- cen- Dev. Clearam- Formu- Devel- tration Time Dose.sup.2ple lation oper.sup.1 (%) (Min) (mJ/cm.sup.2) Image______________________________________ 9 G TMAH 5 1 180 No 22° C. develop- ment10 H TMAH 5 2.5 216 Clear 40° C.11 I TMAH 5 2.0 216 Clear 40° C.______________________________________ .sup.1 Developer: TMAH: Tetramethylammonium hydroxide .sup.2 Clear Dose is defined by the minimum UV energy to clear the complete film thickness
The results clearly show the marked improvement in development which is achieved when the select additive is present in the resist composition in accordance with the present invention.
EXAMPLES 12-13
The resist solutions were prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. The materials used and their concentrations are set forth in the following table:
______________________________________For- Polyimide Sensi- Solubilitymula- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5tion (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________J 3.4 14.94 1.66 1.36 1.36K 3.4 14.94 1.66 1.02 0.68______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: NCyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: 4,4'-Biphenol
Each formulation was coated on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter by means of a spin coating process. The coated wafers were dried for 20 minutes at 60° C. in a convection oven to give a surface film having thickness of 4.0-4.3 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then immersion developed in an aqueous alkaline solution with conditions described in the following table. The wafers were rinse with deionized water and forced air dried. The results and process conditions are set forth in the following table:
______________________________________Ex- Concen- Dev. Clearam- Formu- Devel- tration Time Dose.sup.2ple lation oper.sup.1 (%) (Sec) (mJ/cm.sup.2) Image______________________________________12 J TMAH, 2.38 65 120 Clear 22° C.13 K TMAH, 2.38 75 96 Clear 22° C.______________________________________ .sup.1 Developer: TMAH: Tetramethylammonium hydroxide .sup.2 Clear Dose is defined by the minimum UV energy to clear the complete film thickness
EXAMPLE 14
A resist composition was prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. Formulation for this solution is set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________L 12 38.08 9.52 4.2 4.2______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: Ncyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: Diphenylsilanediol
The formulation was coated by means of a spin coating process on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter. The coated wafers were dried for 1 minute at 105° C. on a hotplate to give a surface film having thickness of 9.4 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 35 seconds was used. The wafers were then spray developed for 100 seconds in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 22° C. followed by rinse with deionized water and forced air dried to give a patterned photoresist layer.
EXAMPLE 15
A resist composition was prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. Formulation for this solution is set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________M 12 36.72 9.18 4.8 4.8______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: NCyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: Diphenylsilanediol
The formulation was coated by means of a spin coating process on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter. The coated wafers were dried for 1 minute at 100° C. on a hotplate to give a surface film having thickness of 7.2 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then spray developed for 70 seconds in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 22° C. followed by rinse with deionized water and forced air dried to give a patterned photoresist layer.
EXAMPLE 16
A resist composition was prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. Formulation for this solution is set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________M 3 9.52 2.38 1.05 1.05______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: 1Cyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: 2,2',4,4'-Tetrahydroxybenzophenone
The formulation was coated by means of a spin coating process on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter. The coated wafers were dried for 10 minutes at 90° C. in a convection oven to give a surface film having thickness of 7.6 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was an Oriel G-line contact printer. An exposure time of 90 seconds was used. The wafers were then spray developed for 115 seconds in a 2.38% by weight aqueous solution of tetramethylammonium hydroxide at 22° C. followed by rinse with deionized water and forced air dried to give a patterned photoresist layer.
EXAMPLE 17
A resist composition was prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. Formulation for this solution is set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________N 3 10.11 1.78 1.05 1.05______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: 1Cyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: Oxalic acid
The formulation was coated by means of a spin coating process on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter. The coated wafers were dried for 10 minutes at 100° C. in a convection oven to give a surface film having thickness of 10.3 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then immersion developed for 5 minutes in a 5% by weight aqueous solution of tetramethylammonium hydroxide at 22° C. followed by rinse with deionized water and forced air dried to give a patterned photoresist layer.
EXAMPLE 18
A resist composition was prepared by dissolving diazo sensitizer, polyimide resin and solubility enhancer in a solvent mixture. Formulation for this solution is set forth in the following table:
______________________________________ Sensi- SolubilityFormu- Resin.sup.1 NMP.sup.2 CHP.sup.3 tizer.sup.4 Enhancer.sup.5lation (Grams) (Grams) (Grams) (Grams) (Grams)______________________________________O 3 10.11 1.78 1.05 1.05______________________________________ .sup.1 Resin is a polyamic ethyl ester prepared by condensation of diethy pyromellitate diacyl chloride with 4,4'-oxydianiline. .sup.2 NMP: Nmethyl-2-pyrrolidone .sup.3 CHP: 1Cyclohexyl-2-pyrrolidinone .sup.4 Sensitizer: Triester formed by condensing naphthoquinone(1,2)diazide(5)-sulfonic acid with 2,3,4trihydroxybenzophenone. .sup.5 Solubility enhancer: Tetrabutylammonium hydrogen sulfate
The formulation was coated by means of a spin coating process on a silicone wafer which was treated with an aminopropyltriethoxysilane adhesion promoter. The coated wafers were dried for 10 minutes at 100° C. in a convection oven to give a surface film having thickness of 7.1 μm. The dried wafers were then contact exposed through an Opto-Line multidensity resolution mask. The exposure unit was a Karl Suss contact printer. An exposure time of 30 seconds was used. The wafers were then immersion developed for 5 minutes in a 5% by weight aqueous solution of tetramethylammonium hydroxide at 22° C. followed by rinse with deionized water and forced air dried to give a patterned photoresist layer. | A positive working photoresist composition based on a polyimide or polyimide precursor, a photoactivatable acid generator, and an additive compound, preferably an aromatic silanol, capable of promoting dissolution of the photoactivated portion of the resist, while it has no effect on the rest portion of the resist. Also, a method of patterning the photoresist composition. | 6 |
[0001] Portions of the present invention were made with support of the United States Government via a grant from the National Institutes of Health under grant numbers HD33531 and NS34568. The U.S. Government therefore may have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] Gene transfer is now widely recognized as a powerful tool for analysis of biological events and disease processes at both the cellular and molecular level. More recently, the application of gene therapy for the treatment of human diseases, either inherited (e.g., ADA deficiency) or acquired (e.g., cancer or infectious disease), has received considerable attention. With the advent of improved gene transfer techniques and the identification of an ever expanding library of “defective gen”-related diseases, gene therapy has rapidly evolved from a treatment theory to a practical reality.
[0003] Traditionally, gene therapy has been defined as a procedure in which an exogenous gene is introduced into the cells of a patient in order to correct an inborn genetic error. Although more than 4500 human diseases are currently classified as genetic, specific mutations in the human genome have been identified for relatively few of these diseases. Until recently, these rare genetic diseases represented the exclusive targets of gene therapy efforts. Accordingly, most of the NIH approved gene therapy protocols to date have been directed toward the introduction of a functional copy of a defective gene into the somatic cells of an individual having a known inborn genetic error. Only recently, have researchers and clinicians begun to appreciate that most human cancers, certain forms of cardiovascular disease, and many degenerative diseases also have important genetic components, and for the purposes of designing novel gene therapies, should be considered “genetic disorders.” Therefore, gene therapy has more recently been broadly defined as the correction of a disease phenotype through the introduction of new genetic information into the affected organism.
[0004] Two basic approaches to gene therapy have evolved: (1) ex vivo gene therapy and (2) in vivo gene therapy. In ex vivo gene therapy, cells are removed from a subject and cultured in vitro. A functional replacement gene is introduced into the cells (transfection) in vitro, the modified cells are expanded in culture, and then reimplanted in the subject. These genetically modified, reimplanted cells are reported to secrete detectable levels of the transfected gene product in situ. The development of improved retroviral gene transfer methods (transduction) has greatly facilitated the transfer into and subsequent expression of genetic material by somatic cells. Accordingly, retrovirus-mediated gene transfer has been used in clinical trials to mark autologous cells and as a way of treating genetic disease.
[0005] In in vivo gene therapy, target cells are not removed from the subject. Rather, the transferred gene is introduced into cells of the recipient organism in situ that is, within the recipient. In vivo gene therapy has been examined in several animal models. Several recent publications have reported the feasibility of direct gene transfer in situ into organs and tissues such as muscle, hematopoietic stem cells, the arterial wall, the nervous system, and lung. Direct injection of DNA into skeletal muscle, heart muscle and injection of DNA-lipid complexes into the vasculature also has been reported to yield a detectable expression level of the inserted gene product(s) in vivo.
[0006] Treatment of inherited genetic diseases of the brain remains an intractable problem. An example of such are the lysosomal storage diseases. Collectively, the incidence of lysosomal storage diseases (LSD) is 1 in 12,000 births world wide, and in 58% of cases, there is significant central nervous system (CNS) involvement (Meikle et al., JAMA 281:249-254, 1999). Proteins deficient in these disorders, when delivered intraveneously, do not cross the blood-brain barrier, or, when delivered directly to the brain, are not widely distributed. Injection of viral vectors expressing recombinant lysosomal proteins, a proportion of which is secreted, can result in significant spread of enzyme in murine cerebrum. However, methods to improve the distribution of enzyme following intraventricular injection of recombinant protein, or from transduced cells, are required for approaching therapies in the significantly larger brains of humans. Similar to lysosomal storage diseases, approaching global therapy for degenerative diseases due to polyglutamine repeat expansion or mutations in channels remains a significant problem. Thus, methods to improve the distribution of secreted proteins following transduction of tissues in vivo is required.
SUMMARY OF THE INVENTION
[0007] The present invention provides polynucleotides (DNA or RNA), vectors and polynucleotides encoding a lysosomal enzyme, a secreted protein, a nuclear protein, or a cytoplasmic protein operably linked to a nucleic acid sequence encoding a protein transduction domain (PTD). As used herein, the term “secreted protein” includes any secreted protein, whether naturally secreted or modified to contain a signal sequence so that it can be secreted. Proteins not normally secreted may be modified to contain a secretory signal so that the Tat-protein fusion is secreted out of the cell, where they may then be broadly distributed and contact cellular or intracellular receptors, such as hormone receptors. For example, the secreted protein could be β-glucuruonidase, pepstatin insensitive protease, palmitoyl protein thioesterase. When expressed from the vector the target protein of interest is synthesized in cells, secreted, distributed, and taken up by other cells without a cognate receptor. Soluble lysosomal enzymes are secreted upon overexpression, and can be distributed in vivo when modified to contain the Tat-motif or a similar PTD motif. The PTD can be Tat PTD, and in particular, can be Tat 47-57 . The Tat-PTD fusion protein could also be a cytoplasmic protein (such as a cytotoxic agent), a nuclear protein (such as a transcription factor), a growth factor (such as GDNF, BDNF, NGF, or NT3). For example, a nuclear protein could be engineered to be secreted, be taken up by a neighboring cell, and then target the nucleus of the uptaking cell. Alternatively, Tat-PTD could be fused to proteins with anti-neoplastic activity, such as inhibitors of neovascularization, cell migration, or cell proliferation. The fusion proteins may be produced using conventional recombinant DNA technology.
[0008] Nucleic acid is “operably linked” when it is placed into a functional relationship with another nucleic acid sequence. For example, DNA for a presequence or secretory leader is operably linked to DNA for a polypeptide if it is expressed as a preprotein that participates in the secretion of the polypeptide; a promoter or enhancer is operably linked to a coding sequence if it affects the transcription of the sequence; or a ribosome binding site is operably linked to a coding sequence if it is positioned so as to facilitate translation. Generally, “operably linked” means that the DNA sequences being linked are contiguous, and, in the case of a secretory leader, contiguous and in reading phase. However, enhancers do not have to be contiguous. Linking is accomplished by ligation at convenient restriction sites. If such sites do not exist, the synthetic oligonucleotide adaptors or linkers are used in accordance with conventional practice. Additionally, multiple copies of the nucleic acid encoding enzymes may be linked together in the expression vector. Such multiple nucleic acids may be separated by linkers. The vector may be an adenoviral vector, an adeno-associated virus (AAV) vector, a retrovirus, or a lentivirus vector based on human immunodeficiency virus or feline immunodeficiency virus. Examples of such AAVs are found in Davidson et al., PNAS (2000) 97:3428-3432. The AAV and lentiviruses could confer lasting expression while the adenovirus would provide transient expression.
[0009] The present invention also provides a mammalian cell containing the expression vector described above. The cell may be human, and may be from spleen, kidney, lung, heart, liver or brain. The cell type may be a stem or progenitor cell population.
[0010] The present invention provides a method of treating a genetic disease or cancer in a mammal by administering a polynucleotide, polypeptide, expression vector, or cell described above. The genetic disease or cancer may be a lysosomal storage disease (LSD) such as infantile or late infantile ceroid lipofuscinoses, Gaucher, Juvenile Batten, Fabry, MLD, Sanfilippo A, Late Infantile Batten, Hunter, Krabbe, Morquio, Pompe, Niemann-Pick C, Tay-Sachs, Hurler (MPS-I H), Sanfilippo B, Maroteaux-Lamy, Niemann-Pick A, Cystinosis, Hurler-Scheie (MPS-I H/S), Sly Syndrome (MPS VII), Scheie (MPS-I S), Infantile Batten, GM1 Gangliosidosis, Mucolipidosis type II/III, or Sandhoff disease. Alternatively, the genetic disease may be a neurodegenerative disease, such as Huntington's disease, ALS, hereditary spastic hemiplegia, primary lateral sclerosis, spinal muscular atrophy, Kennedy's disease, Alzheimer's disease, a polyglutamine repeat disease, or focal exposure such as Parkinson's disease.
[0011] In general, the invention relates to polynucleotides, polypeptides, vectors, and genetically engineered cells (modified ex vivo or in vivo), and the use of them. In particular, the invention relates to a method for gene or protein therapy that is capable of both localized and systemic delivery of a therapeutically effective dose of the therapeutic agent.
[0012] According to one aspect of the invention, a cell expression system for expressing a therapeutic agent in a mammalian recipient is provided. The expression system (also referred to herein as a “genetically modified cell”) comprises a cell and an expression vector for expressing the therapeutic agent. Expression vectors of the instant invention include, but are not limited to, viruses, plasmids, and other vehicles for delivering heterologous genetic material to cells. Accordingly, the term “expression vector” as used herein refers to a vehicle for delivering heterologous genetic material to a cell. In particular, the expression vector is a recombinant adenoviral, adeno-associated virus, or lentivirus or retrovirus vector.
[0013] The expression vector further includes a promoter for controlling transcription of the heterologous gene. The promoter may be an inducible promoter (described below). The expression system is suitable for administration to the mammalian recipient. The expression system may comprises a plurality of non-immortalized genetically modified cells, each cell containing at least one recombinant gene encoding at least one therapeutic agent.
[0014] The cell expression system can be formed ex vivo or in vivo. To form the expression system ex vivo, one or more isolated cells are transduced with a virus or transfected with a nucleic acid or plasmid in vitro. The transduced or transfected cells are thereafter expanded in culture and thereafter administered to the mammalian recipient for delivery of the therapeutic agent in situ. The genetically modified cell may be an autologous cell, i.e., the cell is isolated from the mammalian recipient. The genetically modified cell(s) are administered to the recipient by, for example, implanting the cell(s) or a graft (or capsule) including a plurality of the cells into a cell-compatible site of the recipient.
[0015] According to yet another aspect of the invention, a method for treating a mammalian recipient in vivo is provided. The method includes introducing an expression vector for expressing a heterologous gene product into a cell of the patient in situ. To form the expression system in vivo, an expression vector for expressing the therapeutic agent is introduced in vivo into target location of the mammalian recipient by, for example, intraperitoneal injection or injection directly into the brain.
[0016] According to yet another aspect of the invention, a method for treating a mammalian recipient in vivo is provided. The method includes introducing the recombinant PTD-fusion protein into the tissues of the patient in vivo. The therapeutic agent is introduced in vivo into target location of the mammalian recipient by, for example, a pump to provide continuous delivery into brain ventricles.
[0017] The expression vector for expressing the heterologous gene may include an inducible promoter for controlling transcription of the heterologous gene product. Accordingly, delivery of the therapeutic agent in situ is controlled by exposing the cell in situ to conditions, which induce transcription of the heterologous gene.
[0018] The mammalian recipient may have a condition that is amenable to gene replacement therapy. As used herein, “gene replacement therapy” refers to administration to the recipient of exogenous genetic material encoding a therapeutic agent and subsequent expression of the administered genetic material in situ. Thus, the phrase “condition amenable to gene replacement therapy” embraces conditions such as genetic diseases (i.e., a disease condition that is attributable to one or more gene defects), acquired pathologies (i.e., a pathological condition which is not attributable to an inborn defect), cancers and prophylactic processes (i.e., prevention of a disease or of an undesired medical condition). Accordingly, as used herein, the term “therapeutic agent” refers to any agent or material, which has a beneficial effect on the mammalian recipient. Thus, “therapeutic agent” embraces both therapeutic and prophylactic molecules having nucleic acid or protein components.
[0019] According to one embodiment, the mammalian recipient has a genetic disease and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the disease. In yet another embodiment, the mammalian recipient has an acquired pathology and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the pathology. According to another embodiment, the patient has a cancer and the exogenous genetic material comprises a heterologous gene encoding an anti-neoplastic agent. In yet another embodiment the patient has an undesired medical condition and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the condition.
[0020] According to yet another embodiment, a pharmaceutical composition is disclosed. The pharmaceutical composition comprises a plurality of the above-described genetically modified cells or polypeptides and a pharmaceutically acceptable carrier. The pharmaceutical composition may be for treating a condition amenable to gene replacement therapy and the exogenous genetic material comprises a heterologous gene encoding a therapeutic agent for treating the condition. The pharmaceutical composition may contain an amount of genetically modified cells or polypeptides sufficient to deliver a therapeutically effective dose of the therapeutic agent to the patient. Exemplary conditions amenable to gene replacement therapy are described below.
[0021] According to another aspect of the invention, a method for forming the above-described pharmaceutical composition is provided. The method includes introducing an expression vector for expressing a heterologous gene product into a cell to form a genetically modified cell and placing the genetically modified cell in a pharmaceutically acceptable carrier.
[0022] According to still another aspect of the invention, a cell graft is disclosed. The graft comprises a plurality of genetically modified cells attached to a support, which is suitable for implantation into the mammalian recipient. The support may be formed of a natural or synthetic material.
[0023] According to still another aspect of the invention, an encapsulated cell expression system is disclosed. The encapsulated expression system comprises a plurality of genetically modified cells contained within a capsule, which is suitable for implantation into the mammalian recipient. The capsule may be formed of a natural or synthetic material. The capsule containing the plurality of genetically modified cells may be implanted in the peritoneal cavity, the brain or ventricles in the brain, or into the specific disease site.
[0024] According to still another aspect of the invention, a protein delivery method is disclosed. The protein is purified from genetically modified cells and then placed into the mammalian recipient. The purified protein is placed into the brain, into the peritoneum, or into the specific disease site.
[0025] These and other aspects of the invention as well as various advantages and utilities will be more apparent with reference to the detailed description of the invention and to the accompanying Figures.
[0026] As used herein, the term “lysosomal enzyme,” a “secreted protein,” a “nuclear protein,” a “cytoplasmic protein,” or a “Tat protein transduction domain” include variants or biologically active or inactive fragments of these polypeptides. A “variant” of one of the polypeptides is a polypeptide that is not completely identical to a native protein. Such variant protein can be obtained by altering the amino acid sequence by insertion, deletion or substitution of one or more amino acid. The amino acid sequence of the protein is modified, for example by substitution, to create a polypeptide having substantially the same or improved qualities as compared to the native polypeptide. The substitution may be a conserved substitution. A “conserved substitution” is a substitution of an amino acid with another amino acid having a similar side chain. A conserved substitution would be a substitution with an amino acid that makes the smallest change possible in the charge of the amino acid or size of the side chain of the amino acid (alternatively, in the size, charge or kind of chemical group within the side chain) such that the overall peptide retains its spacial conformation but has altered biological activity. For example, common conserved changes might be Asp to Glu, Asn or Gln; His to Lys, Arg or Phe; Asn to Gln, Asp or Glu and Ser to Cys, Thr or Gly. Alanine is commonly used to substitute for other amino acids. The 20 essential amino acids can be grouped as follows: alanine, valine, leucine, isoleucine, proline, phenylalanine, tryptophan and methionine having nonpolar side chains; glycine, serine, threonine, cystine, tyrosine, asparagine and glutamine having uncharged polar side chains; aspartate and glutamate having acidic side chains; and lysine, arginine, and histidine having basic side chains. Stryer, L. Biochemistry (2d edition) W. H. Freeman and Co. San Francisco (1981), p. 14-15; Lehninger, A. Biochemistry (2d ed., 1975), p. 73-75.
[0027] The amino acid changes are achieved by changing the codons of the corresponding nucleic acid sequence. It is known that such polypeptides can be obtained based on substituting certain amino acids for other amino acids in the polypeptide structure in order to modify or improve biological activity. For example, through substitution of alternative amino acids, small conformational changes may be conferred upon a polypeptide which result in increased. Alternatively, amino acid substitutions in certain polypeptides may be used to provide residues, which may then be linked to other molecules to provide peptide-molecule conjugates which, retain sufficient properties of the starting polypeptide to be useful for other purposes.
[0028] One can use the hydropathic index of amino acids in conferring interactive biological function on a polypeptide, wherein it is found that certain amino acids may be substituted for other amino acids having similar hydropathic indices and still retain a similar biological activity. Alternatively, substitution of like amino acids may be made on the basis of hydrophilicity, particularly where the biological function desired in the polypeptide to be generated in intended for use in immunological embodiments. The greatest local average hydrophilicity of a “protein”, as governed by the hydrophilicity of its adjacent amino acids, correlates with its immunogenicity. U.S. Pat. No. 4,554,101. Accordingly, it is noted that substitutions can be made based on the hydrophilicity assigned to each amino acid.
[0029] In using either the hydrophilicity index or hydropathic index, which assigns values to each amino acid, it is preferred to conduct substitutions of amino acids where these values are ±2, with ±1 being particularly preferred, and those with in ±10.5 being the most preferred substitutions.
[0030] The variant protein has at least 50%, at least about 80%, or even at least about 90% but less than 100%, contiguous amino acid sequence homology or identity to the amino acid sequence of a corresponding native protein.
[0031] The amino acid sequence of the variant polypeptide corresponds essentially to the native polypeptide's amino acid sequence. As used herein “correspond essentially to” refers to a polypeptide sequence that will elicit a biological response substantially the same as the response generated by the native protein. Such a response may be at least 60% of the level generated by the native protein, and may even be at least 80% of the level generated by native protein.
[0032] A variant of the invention may include amino acid residues not present in the corresponding native protein or deletions relative to the corresponding native protein. A variant may also be a truncated “fragment” as compared to the corresponding native protein, i.e., only a portion of a full-length protein. Protein variants also include peptides having at least one D-amino acid.
[0033] The variant protein of the present invention may be expressed from an isolated DNA sequence encoding the variant protein. “Recombinant” is defined as a peptide or nucleic acid produced by the processes of genetic engineering. It should be noted that it is well-known in the art that, due to the redundancy in the genetic code, individual nucleotides can be readily exchanged in a codon, and still result in an identical amino acid sequence. The terms “protein,” “peptide” and “polypeptide” are used interchangeably herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] [0034]FIG. 1. β-glucuronidase-Tat expression vectors. (a) Cartoon depicting the orientation of the Tat motifs at the carboxy termini of β-glucuronidase. The β-glucuronidase sequences were cloned into the E1 region of Ad shuttle plasmids, and the shuttles recombined with Ad backbones expressing GFP in the E3 region. The resultant viruses expressed β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 in E1 and GFP in E3. Both trangenes are driven off the RSV promoter. (b-d), β-glucuronidase activity after incubation of A549 cells with the recombinant proteins β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 , respectively. Using the assay conditions described in the Examples below the background levels of β-glucuronidase staining is very low (inset, panel b). The uptake of both native and tat-modified β-glucuronidase (inset, panel d) was notably punctate. (e-g), β-glucuronidase activity after incubation of A549 cells with the recombinant proteins β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 in the presence of D-mannose-6-phosphate. Bars=50 μm.
[0035] [0035]FIG. 2. eGFP and β-glucuronidase activity in sections of murine liver after i.v. injection of vectors expressing native or Tat-modified β-glucuronidase. (a-c), photomicrographs showing representative levels of GFP expression in murine liver following injection of Adβgluc, AdβglucTat 47-57 or AdβglucTat 57-47 , respectively. (d-f), sections from mice transduced with Adβgluc, AdβglucTat 47-57 or AdβglucTat 57-47 , respectively, stained in situ for β-glucuronidase activity. Bar=200 μm.
[0036] [0036]FIG. 3. β-glucuronidase activity in non-hepatic tissues after i.v. injection of mice with vectors expressing native or Tat-modified β-glucuronidase. β-glucuronidase activity was detected in situ ten days after i.v. injection of Adβgluc (a,c,e,g,i) or Adβgluc-Tat 47-57 (b,d,f,h,j). Representative sections from spleen (a,b), kidney (c,d) lung (e,f), heart (g,h) and brain (i,j) are shown. Scale bar is 400 μm. (k), enzyme activity levels in tissue lysates.
[0037] [0037]FIG. 4. GFP and β-glucuruonidase distribution and activity in brain. Mice were injected with Adβgluc (a,c), Adβgluc-Tat 47-57 (b,d) or Adβgluc-Tat 57-47 into straita, and GFP and β-glucuronidase activity evaluated ten days later on full corona sections (a-e) or tissue lysates (f). Equivalent i.u. (and particles) were injected. Sections photomicrographed in c and d are within 60 μm from those shown in a and b, respectively. (e), the volume of brain positive for GFP and β-glucuronidase quantified using NIH Image. (f), enzyme activities for the contralateral (CL) and injected hemispheres (IL) were determined as described in Methods, and expressed as CL/(CL+IL)×100.
[0038] [0038]FIG. 5. Expression of β-glucuronidase or β-glucuronidase-Tat 47-57 from transduced ependyma. Mice were injected with Adβgluc (a,d), Adβgluc-Tat 47-57 (b,e) or Adβgluc-Tat 57-47 (c,f) and brains harvested ten days later for evaluation of GFP (a-c) or β-glucuronidase (d-f) expression. Sections photomicrographed in a-c are within 60 μm from those shown in d-f. The volume of brain (both hemispheres) positive for β-glucuronidase activity was determined using NIH image.
[0039] [0039]FIG. 6. Expression of β-glucuronidase and β-glucurondiase-Tat in the brainstem. Mice were injected with Adβgluc or Adβgluc-Tat 47-57 and animals sacrificed ten days later for evaluation of GFP or β-glucuronidase expression.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Collectively, the prevalence of lysosomal storage diseases is strikingly high. As an example, a 16 year retrospective study in Australia revealed a prevalence between 1 in 6,700 to 1 in 7700 live births (Meikle, et al., (1999) JAMA 281(3):249-254). In 58% of cases, there is significant CNS involvement. Early work in rodent models of the lysosomal storage diseases has shown tremendous promise in addressing the systemic manifestations of these disorders, either by enzyme replacement or bone marrow transplant to adult recipients. However these therapies did not ameliorate or substantially delay progressive neurodegeneration. In the β-glucuronidase deficient mouse, inhibition of cognitive decline required that treatment be initiated in the neonatal period systemically prior to blood-brain barrier (BBB) closure (O'Connor, et al., (1998) J. Clin. Invest. 101:1394-1400), or directly to brain (Frisella, et al., (2001) Mol. Ther. (In Press)).
[0041] Recent work showed that the 11 amino acid motif from HIV Tat known as the protein transduction domain (PTD) improved the biodistribution of recombinant reporter proteins following systemic delivery (Fawell, et al., (1994). Proc. Natl. Acad. Sci. U.S.A. 91:664-668), (Schwarze, et al., (1999) Science 285:1569-1572). When partially denatured, the protein was capable of crossing the blood brain barrier of adult mice (Schwarze, et al., (1999) Science 285:1569-1572). These findings suggest that gene therapy with vectors engineered to express Tat-modified recombinant lysosomal proteins from systemic sources in vivo could be used to improve their biodistribution.
[0042] To test this, fusion proteins of human β-glucuronidase and the 11 amino acid PTD from HIV Tat were engineered in recombinant adenovirus expression vectors (FIG. 1 a ). As peptides representative of the PTDs from Drosophila antenapedea can translocate across cell membranes in either orientation (Derossi, et al., (1996) J. Biol. Chem. 271(30):18188-18193) fusion proteins with the HIV Tat peptide in the 47-57 and 57-47 orientation were generated. We first examined the properties of the modified β-glucuronidase for mannose-6 phosphate (M6P) dependent and independent entry into cells. HeLa cells were infected with 20 infectious units (i.u.)/cell of recombinant vectors expressing unmodified β-glucuronidase (Adβgluc), β-glucuronidase-Tat 47-57 (Adβgluc-Tat 47-57 ) or β-glucuronidase-Tat 57-47 (Adβgluc-Tat 57-47 ). Three days later, supernatants were collected and β-glucuronidase activity quantified. The Tat modification to the COOH-terminus did not inhibit enzyme activity. Equivalent units of β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 were added to the media of A549 cells in the presence or absence of M6P (FIGS. 1 b - g ). While all recombinant proteins entered cells readily (FIGS. 1 b - d ), M6P dramatically inhibited the uptake of native β-glucuronidase (FIG. 1 e ) relative to β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 (FIGS. 1 f,g ) as assayed by an in situ activity stain (Ghodsi, et al., (1998) Hum. Gene Ther. 9:2331-2340). Quantitation of enzyme activity showed that M6P inhibited 100% of uptake of native β-glucuronidase. β-Glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 , were inhibited by 24 and 51%, respectively (FIG. 1 h ). Thus β-glucuronidase modified at the COOH terminus with the PTD of Tat allowed for both M6P dependent and independent entry. Similar results were found when the wild type and Tat-modified β-glucuronidase-containing supernatants were added to cultures of NIH 3T3 cells with or without M6P.
[0043] Earlier studies showed that uptake of Tat-modified proteins occurred by adsorptive endocytosis in cell lines and primary cell cultures (Fawell, et al., (1994) Proc. Natl. Acad. Sci. U.S.A. 91:664-668), (Mann, et al., (1991) EMBO J. 10(7): 1733-1739). Mann and Frankel also showed that entry of [ 125 I] Tat was temperature dependent (Mann, et al., (1991) EMBOJ 10(7):1733-1739). This is distinct from peptides representative of the PTD from antenopedia, which enters cells readily at 4 and 37° C. (Derossi, et al., (1996) J. Biol. Chem. 271(30):18188-18193). Equivalent units of β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 were added to cells and uptake at 4 and 37° C. measured and compared. In all cases, enzyme uptake at 4° C. was dramatically inhibited compared to that occurring at 37° C. These data, and the observation that histochemical staining for enzyme activity at time points early after enzyme addition was punctate (FIG. 1 d , inset), suggests that Tat-modified β-glucuronidase, like native β-glucuronidase, enters cells in part through endocytic mechanisms.
[0044] We next investigated Adβgluc, Adβgluc-Tat 47-57 and Adβgluc-Tat 57-47 in vivo. Viruses were injected into mice tail veins, which results in transduction of hepatocytes (Stein, et al., (1999) J. Virol. 73(4):3424-3429). The vectors used in this study also expressed GFP in the E3 region to permit detection of infected cells (GFP positive) relative to β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 activity. Sections of liver analyzed 10 days after i.v. vector injection show roughly equivalent levels of GFP expression for all viruses (FIGS. 2 a - c ), but varied distribution of β-glucuronidase activity (FIGS. 2 d - f ). β-Glucuronidase-Tat 47-57 and β-glucuronidase-Tats 57-47 activity were detected throughout the parenchyma of the liver as evidenced by in situ enzyme activity assay (FIGS. 2 e,f ). In contrast, transduction with Adβgluc resulted in focal staining (FIG. 2 d ).
[0045] Similar to native β-glucuronidase (Stein, et al., (1999) J. Virol. 73(4):3424-3429), we also noted spread of β-glucuronidase-Tat 47-57 and β-glucuronidase-Tat 57-47 to other tissues (FIG. 3). In some instances the penetration of the enzyme within specific organs or tissues was remarkably distinct from native β-glucuronidase. For example, in the spleen (FIGS. 3 a,b ), extensive β-glucuronidase activity was found in the marginal zone and to a limited extent in the red pulp after transduction with Adgluc. However, β-glucuronidase-Tat 47-57 fully penetrated the red pulp (FIG. 3 b ). β-glucuronidase-Tat 57-47 was comparable. Interestingly, β-glucuronidase-Tat 47-57 distribution was similar to sections from mice receiving i.p. injections of partially denatured, purified E. coli β-galactosidase-Tat fusion proteins (Schwarze, et al., (1999) Science 285:1569-1572).
[0046] We also noted increased levels of enzyme in kidney (FIGS. 3 c,d ), lung (FIGS. 3 e,f ) heart (FIGS. 3 g,h ), and skeletal muscle for β-glucuronidase-Tat 47-57 and β-glucuronidase-Tat 57-47 . Although the distribution of β-glucuronidase activity was widespread in kidney and lung in AdβglucTat 47-57 vs. Adβgluc treated mice, β-glucuronidase activity remained undetectable in both lung lavage fluid and urine.
[0047] In contrast to earlier studies with recombinant protein (Schwarze, et al., (1999) Science 285:1569-1572), we noted only a modest increase in enzyme staining in brain, all limited to the choroid plexus (FIGS. 3 i,j ). Quantitative enzyme assay of brain lysates indicated that there were no significant differences between the treatment groups (FIG. 3 k ). Together the data suggest that the 11 amino acid PTD from Tat may alter the biodistribution of native proteins expressed and secreted in vivo from transduced cells. However the addition of the Tat motif to β-glucuronidase, expressed from systemically transduced tissues of adult mice, does not significantly improve enzyme levels within brain. Possibilities for the discrepancies include differences in the type of protein delivered. Dowdy and colleagues achieved penetration of the blood brain barrier with denatured/partially renatured β-galactosidase. Fawell and colleagues used native β-galactosidase-Tat conjugates in their studies, and did not see penetration of the brain. Both studies delivered approximately 4×10 −9 mole of β-galactosidase by intraperitoneal injection, for an estimated serum concentration of 1 μM. In our studies, the Tat-modified β-glucuronidase reached an approximate serum concentration of 16 nM, and likely remained in native conformation.
[0048] It is not known if the partially-denatured, Tat-modified reporters described by Dowdy and colleagues can pass an intact blood brain barrier in larger animal models. It would also be important to know if the Tat-motifs could impart improved distribution of proteins when administered directly to, or expressed from, cells within the brain. To determine this, vectors expressing β-glucuronidase, β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 (2×10 7 i.u.) were injected into the right hemisphere, and animals sacrificed 10 days later. All vectors yielded nearly equivalent levels of GFP expression (FIGS. 4 a,b ). However, the addition of the Tat motif to β-glucuronidase resulted in significantly greater distribution of enzyme compared to the non-modified protein (FIGS. 4. c vs. d ). As a consequence, there was a 1.5-fold increase in the volume of brain positive for β-glucuronidase activity (FIG. 4 e ), and a notable increase in the levels of β-glucuronidase activity in the contralateral hemisphere (FIG. 4 f ).
[0049] Ventricular administration of secreted proteins for the MPS or other lysosomal storage diseases would be preferred over multiple parenchymal injections if adequate spread of enzyme into the parenchyma can occur. Injection of the recombinant vectors into the lateral ventricles of mice led to significant transduction of ependyma as evidenced by GFP fluorescence (FIGS. 5 a,c ) (Ghodsi, et al., (1999) Exp.Neurol. 160:109-116). As shown previously, β-glucuronidase expression from Adβgluc was obvious in areas immediately adjacent to the ependyma (FIG. 5 d ). However, the penetration of β-glucuronidase-Tat was remarkably enhanced, resulting in significant increases in the volume of brain positive for active enzyme (FIG. 5 g ). In animals receiving intraventricular injection of Adβgluc, 5% of the brain was β-glucuronidase positive. In contrast, expression of β-glucuronidase-Tat 47-57 or β-glucuronidase-Tat 57-47 was distributed in 22 and 30% of the brain, respectively. Increased distribution of expressed enzyme after intraventricular injection has important implications for enzyme-based therapy or for gene therapy using vectors with high affinity to the ependymal lining, such as recombinant adenoviruses (Ghodsi, et al, (1999) Exp. Neurol. 160:109-116) and adeno-associated virus type 4 (Davidson, et al, (2000) Proc. Natl. Acad. Sci. U.S.A. 97(7):3428-3432).
[0050] Prior to this work, PTDs had been applied as synthetic peptides or used to improve transfer of nuclear and cytoplasmic proteins. We show that the PTD from HIV Tat allowed for significant improvements in the distribution of a lysosomal protein expressed and secreted from cells after viral-mediated gene transfer to liver and brain. When ependyma lining the ventricles were transduced, there was a 5 to 7 fold increase in the volume of brain positive for β-glucuronidase activity. Thus PTDs could also dramatically improve the biodistribution of recombinant enzyme following intraventricular injection. Together, our data represent a significant improvement in the development of gene and protein therapies for inherited genetic diseases affecting the brain.
[0051] The present invention provides methods of treating a genetic disease or cancer in a mammal by administering a polynucleotide, polypeptide, expression vector, or cell. For the gene therapy methods, a person having ordinary skill in the art of molecular biology and gene therapy would be able to determine, without undue experimentation, the appropriate dosages and routes of administration of the polynucleotide, polypeptide, or expression vector used in the novel methods of the present invention.
[0052] The instant invention provides a cell expression system for expressing exogenous genetic material in a mammalian recipient. The expression system, also referred to as a “genetically modified cell”, comprises a cell and an expression vector for expressing the exogenous genetic material. The genetically modified cells are suitable for administration to a mammalian recipient, where they replace the endogenous cells of the recipient. Thus, the genetically modified cells may be non-immortalized and are non-tumorigenic.
[0053] According to one embodiment, the cells are transformed or otherwise genetically modified ex vivo. The cells are isolated from a mammal (for example, a human), transformed (i.e., transduced or transfected in vitro) with a vector for expressing a heterologous (e.g., recombinant) gene encoding the therapeutic agent, and then administered to a mammalian recipient for delivery of the therapeutic agent in situ. The mammalian recipient may be a human and the cells to be modified are autologous cells, i.e., the cells are isolated from the mammalian recipient.
[0054] According to another embodiment, the cells are transformed or otherwise genetically modified in vivo. The cells from the mammalian recipient are transformed (i.e., transduced or transfected) in vivo with a vector containing exogenous genetic material for expressing a heterologous (e.g., recombinant) gene encoding a therapeutic agent and the therapeutic agent is delivered in situ.
[0055] As used herein, “exogenous genetic material” refers to a nucleic acid or an oligonucleotide, either natural or synthetic, that is not naturally found in the cells; or if it is naturally found in the cells, it is not transcribed or expressed at biologically significant levels by the cells. Thus, “exogenous genetic material” includes, for example, a non-naturally occurring nucleic acid that can be transcribed into anti-sense RNA, as well as a “heterologous gene” (i.e., a gene encoding a protein which is not expressed or is expressed at biologically insignificant levels in a naturally-occurring cell of the same type).
[0056] In the certain embodiments, the mammalian recipient has a condition that is amenable to gene replacement therapy. As used herein, “gene replacement therapy” refers to administration to the recipient of exogenous genetic material encoding a therapeutic agent and subsequent expression of the administered genetic material in situ. Thus, the phrase “condition amenable to gene replacement therapy” embraces conditions such as genetic diseases (i.e., a disease condition that is attributable to one or more gene defects), acquired pathologies (i.e., a pathological condition which is not attributable to an inborn defect), cancers and prophylactic processes (i.e., prevention of a disease or of an undesired medical condition). Accordingly, as used herein, the term “therapeutic agent” refers to any agent or material, which has a beneficial effect on the mammalian recipient. Thus, “therapeutic agent” embraces both therapeutic and prophylactic molecules having nucleic acid (e.g., antisense RNA) and/or protein components.
[0057] A number of lysosomal storage diseases are known (for example Neimann-Pick disease, Sly syndrome, Gaucher Disease). Other examples of lysosomal storage diseases are provided in Table 1. Therapeutic agents effective against these diseases are also known, since it is the protein/enzyme known to be deficient in these disorders.
TABLE 1 List of putative target diseases for PTD-based therapies. Disease a Post-natal b % Gaucher 71 13.0 Juvenile Batten 39 7.2 Fabry 36 6.6 % LSDs with CNS involvement MLD 35 6.4 58.317757 Sanfihippo A 33 6.1 Late Infantile Batten 27 5.0 Hunter 26 4.8 Krabbe 21 3.9 Morquio 21 3.9 Pompe 21 3.9 Niemann-Pick C 20 3.7 Tay-Sachs 19 3.5 Hurler (MPS-I H) 18 3.3 Sanfihippo B 18 3.3 Maroteaux-Lamy 17 3.1 Niemann-Pick A 16 2.9 Cystinosis 15 2.8 Hurler-Scheie (MPS-I H/S) 10 1.8 Sly Syndrome (MPS VII) 0 0 Scheie (MPS-I S) 10 1.8 Infantile Batten 10 1.8 GM1 Gangliosidosis 10 1.8 Mucolipidosis type lI/III 10 1.8 Sandhoff 10 1.8 other 32 5.9
[0058] As used herein, “acquired pathology” refers to a disease or syndrome manifested by an abnormal physiological, biochemical, cellular, structural, or molecular biological state. Exemplary acquired pathologies, are provided in Table 2. Therapeutic agents effective against these diseases are also given.
TABLE II Potential Gene Therapies for Motor Neuron Diseases and other neurodegenerative diseases. Candidates for Neuronal or Candidates for Gene Downstream Progenitor Cell Disease Replacement 2 Effectors 3 Replacement 4 ALS No Yes Yes Hereditary Spastin, paraplegin Yes Yes spastic hemiplegia Primary lateral No Yes Yes sclerosis 5 Spinal Survival motor neuron Yes Yes muscular gene, neuronal atrophy apoptosis inhibiting factor Kennedy's Androgen-receptor Yes Yes disease element Alzheimer's Yes Yes disease Polyglutamine Yes Yes Repeat Diseases
[0059] Delivery of a therapeutic agent by a genetically modified cell is not limited to delivery to a particular location in the body in which the genetically modified cells would normally reside. Accordingly, the genetically modified cells of the invention are useful for delivering a therapeutic agent, such as a replacement protein, an anti-neoplastic agent, or a neuroprotective agent, to various parts or the appropriate part of the body.
[0060] Alternatively, the condition amenable to gene replacement therapy is a prophylactic process, i.e., a process for preventing disease or an undesired medical condition. Thus, the instant invention embraces a cell expression system for delivering a therapeutic agent that has a prophylactic function (i.e., a prophylactic agent) to the mammalian recipient.
[0061] In summary, the term “therapeutic agent” includes, but is not limited to, the agents listed in the Tables above, as well as their functional equivalents. As used herein, the term “functional equivalent” refers to a molecule (e.g., a peptide or protein) that has the same or an improved beneficial effect on the mammalian recipient as the therapeutic agent of which is it deemed a functional equivalent. As will be appreciated by one of ordinary skill in the art, a functionally equivalent proteins can be produced by recombinant techniques, e.g., by expressing a “functionally equivalent DNA”. As used herein, the term “functionally equivalent DNA” refers to a non-naturally occurring DNA, which encodes a therapeutic agent. For example, many, if not all, of the agents disclosed in Tables 1-3 have known amino acid sequences, which are encoded by naturally occurring nucleic acids. However, due to the degeneracy of the genetic code, more than one nucleic acid can encode the same therapeutic agent. Accordingly, the instant invention embraces therapeutic agents encoded by naturally-occurring DNAs, as well as by non-naturally-occurring DNAs, which encode the same protein as, encoded by the naturally-occurring DNA.
[0062] The above-disclosed therapeutic agents and conditions amenable to gene replacement therapy are merely illustrative and are not intended to limit the scope of the instant invention. The selection of a suitable therapeutic agent for treating a known condition is deemed to be within the scope of one of ordinary skill of the art without undue experimentation.
[0063] Methods for Introducing Genetic Material into Cells
[0064] The exogenous genetic material (e.g., a CDNA encoding one or more therapeutic proteins) is introduced into the cell ex vivo or in vivo by genetic transfer methods, such as transfection or transduction, to provide a genetically modified cell. Various expression vectors (i.e., vehicles for facilitating delivery of exogenous genetic material into a target cell) are known to one of ordinary skill in the art.
[0065] As used herein, “transfection of cells” refers to the acquisition by a cell of new genetic material by incorporation of added DNA. Thus, transfection refers to the insertion of nucleic acid into a cell using physical or chemical methods. Several transfection techniques are known to those of ordinary skill in the art including: calcium phosphate DNA co-precipitation (Methods in Molecular Biology, Vol. 7, Gene Transfer and Expression Protocols, Ed. E. J. Murray, Humana Press (1991)); DEAE-dextran (supra); electroporation (supra); cationic liposome-mediated transfection (supra); and tungsten particle-faciliated microparticle bombardment (Johnston, S. A., Nature 346:776-777 (1990)). Strontium phosphate DNA co-precipitation (Brash D. E. et al. Molec. Cell. Biol. 7:2031-2034 (1987) is another possible transfection method.
[0066] In contrast, “transduction of cells” refers to the process of transferring nucleic acid into a cell using a DNA or RNA virus. A RNA virus (i.e., a retrovirus) for transferring a nucleic acid into a cell is referred to herein as a transducing chimeric retrovirus. Exogenous genetic material contained within the retrovirus is incorporated into the genome of the transduced cell. A cell that has been transduced with a chimeric DNA virus (e.g., an adenovirus carrying a cDNA encoding a therapeutic agent), will not have the exogenous genetic material incorporated into its genome but will be capable of expressing the exogenous genetic material that is retained extrachromosomally within the cell.
[0067] Typically, the exogenous genetic material includes the heterologous gene (usually in the form of a cDNA comprising the exons coding for the therapeutic protein) together with a promoter to control transcription of the new gene. The promoter characteristically has a specific nucleotide sequence necessary to initiate transcription. Optionally, the exogenous genetic material further includes additional sequences (i.e., enhancers) required to obtain the desired gene transcription activity. For the purpose of this discussion an “enhancer” is simply any non-translated DNA sequence which works contiguous with the coding sequence (in cis) to change the basal transcription level dictated by the promoter. The exogenous genetic material may introduced into the cell genome immediately downstream from the promoter so that the promoter and coding sequence are operatively linked so as to permit transcription of the coding sequence. A retroviral expression vector may include an exogenous promoter element to control transcription of the inserted exogenous gene. Such exogenous promoters include both constitutive and inducible promoters.
[0068] Naturally-occurring constitutive promoters control the expression of essential cell functions. As a result, a gene under the control of a constitutive promoter is expressed under all conditions of cell growth. Exemplary constitutive promoters include the promoters for the following genes which encode certain constitutive or “housekeeping” functions: hypoxanthine phosphoribosyl transferase (HPRT), dihydrofolate reductase (DHFR) (Scharfmann et al., Proc. Natl. Acad. Sci. USA 88:4626-4630 (1991)), adenosine deaminase, phosphoglycerol kinase (PGK), pyruvate kinase, phosphoglycerol mutase, the -actin promoter (Lai et al., Proc. Natl. Acad. Sci. USA 86:10006-10010 (1989)), and other constitutive promoters known to those of skill in the art. In addition, many viral promoters function constitutively in eucaryotic cells. These include: the early and late promoters of SV40; the long terminal repeats (LTRs) of Moloney Leukemia Virus and other retroviruses; and the thymidine kinase promoter of Herpes Simplex Virus, among many others. Accordingly, any of the above-referenced constitutive promoters can be used to control transcription of a heterologous gene insert.
[0069] Genes that are under the control of inducible promoters are expressed only or to a greater degree, in the presence of an inducing agent, (e.g., transcription under control of the metallothionein promoter is greatly increased in presence of certain metal ions). Inducible promoters include responsive elements (REs) which stimulate transcription when their inducing factors are bound. For example, there are REs for serum factors, steroid hormones, retinoic acid and cyclic AMP. Promoters containing a particular RE can be chosen in order to obtain an inducible response and in some cases, the RE itself may be attached to a different promoter, thereby conferring inducibility to the recombinant gene. Thus, by selecting the appropriate promoter (constitutive versus inducible; strong versus weak), it is possible to control both the existence and level of expression of a therapeutic agent in the genetically modified cell. If the gene encoding the therapeutic agent is under the control of an inducible promoter, delivery of the therapeutic agent in situ is triggered by exposing the genetically modified cell in situ to conditions for permitting transcription of the therapeutic agent, e.g., by intraperitoneal injection of specific inducers of the inducible promoters which control transcription of the agent. For example, in situ expression by genetically modified cells of a therapeutic agent encoded by a gene under the control of the metallothionein promoter, is enhanced by contacting the genetically modified cells with a solution containing the appropriate (i.e., inducing) metal ions in situ.
[0070] Accordingly, the amount of therapeutic agent that is delivered in situ is regulated by controlling such factors as: (1) the nature of the promoter used to direct transcription of the inserted gene, (i.e., whether the promoter is constitutive or inducible, strong or weak); (2) the number of copies of the exogenous gene that are inserted into the cell; (3) the number of transduced/transfected cells that are administered (e.g., implanted) to the patient; (4) the size of the implant (e.g., graft or encapsulated expression system); (5) the number of implants; (6) the length of time the transduced/transfected cells or implants are left in place; and (7) the production rate of the therapeutic agent by the genetically modified cell. Selection and optimization of these factors for delivery of a therapeutically effective dose of a particular therapeutic agent is deemed to be within the scope of one of ordinary skill in the art without undue experimentation, taking into account the above-disclosed factors and the clinical profile of the patient.
[0071] In addition to at least one promoter and at least one heterologous nucleic acid encoding the therapeutic agent, the expression vector may include a selection gene, for example, a neomycin resistance gene, for facilitating selection of cells that have been transfected or transduced with the expression vector. Alternatively, the cells are transfected with two or more expression vectors, at least one vector containing the gene(s) encoding the therapeutic agent(s), the other vector containing a selection gene. The selection of a suitable promoter, enhancer, selection gene and/or signal sequence (described below) is deemed to be within the scope of one of ordinary skill in the art without undue experimentation.
[0072] The therapeutic agent can be targeted for delivery to an extracellular, intracellular or membrane location. If it is desirable for the gene product to be secreted from the cells, the expression vector is designed to include an appropriate secretion “signal” sequence for secreting the therapeutic gene product from the cell to the extracellular milieu. If it is desirable for the gene product to be retained within the cell, this secretion signal sequence is omitted. In a similar manner, the expression vector can be constructed to include “retention” signal sequences for anchoring the therapeutic agent within the cell plasma membrane. For example, all membrane proteins have hydrophobic transmembrane regions, which stop translocation of the protein in the membrane and do not allow the protein to be secreted. The construction of an expression vector including signal sequences for targeting a gene product to a particular location is deemed to be within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0073] The following discussion is directed to various utilities of the instant invention. For example, the instant invention has utility as an expression system suitable for detoxifying intra- and/or extracellular toxins in situ. By attaching or omitting the appropriate signal sequence to a gene encoding a therapeutic agent capable of detoxifying a toxin, the therapeutic agent can be targeted for delivery to the extracellular milieu, to the cell plasma membrane or to an intracellular location. In one embodiment, the exogenous genetic material containing a gene encoding an intracellular detoxifying therapeutic agent, further includes sequences encoding surface receptors for facilitating transport of extracellular toxins into the cell where they can be detoxified intracellularly by the therapeutic agent. Alternatively, the cells can be genetically modified to express the detoxifying therapeutic agent anchored within the cell plasma membrane such that the active portion extends into the extracellular milieu. The active portion of the membrane-bound therapeutic agent detoxifies toxins, which are present in the extracellular milieu.
[0074] In addition to the above-described therapeutic agents, some of which are targeted for intracellular retention, the instant invention also embraces agents intended for delivery to the extracellular milieu and/or agents intended to be anchored in the cell plasma membrane.
[0075] The selection and optimization of a particular expression vector for expressing a specific gene product in an isolated cell is accomplished by obtaining the gene, potentially with one or more appropriate control regions (e.g., promoter, insertion sequence); preparing a vector construct comprising the vector into which is inserted the gene; transfecting or transducing cultured cells in vitro with the vector construct; and determining whether the gene product is present in the cultured cells.
[0076] In one embodiment, vectors for cell gene therapy are viruses, such as replication-deficient viruses (described in detail below). Exemplary viral vectors are derived from: Harvey Sarcoma virus; ROUS Sarcoma virus, (MPSV); Moloney murine leukemia virus and DNA viruses (e.g., adenovirus) (Ternin, H., “Retrovirus vectors for gene transfer”, in Gene Transfer, Kucherlapati R, Ed., pp 149-187, Plenum, (1986)).
[0077] Replication-deficient retroviruses, including the recombinant lentivirus vectors, are neither capable of directing synthesis of virion proteins or making infectious particles. Accordingly, these genetically altered retroviral expression vectors have general utility for high-efficiency transduction of genes in cultured cells, and specific utility for use in the method of the present invention. The lentiviruses, with their ability to transduce nondividing cells, have general utility for transduction of hepatocytes, cells in cerebrum, cerebellum and spinal cord, and also muscle and other slowly or non-dividing cells. Such retroviruses further have utility for the efficient transduction of genes into cells in vivo. Retroviruses have been used extensively for transferring genetic material into cells. Standard protocols for producing replication-deficient retroviruses (including the steps of incorporation of exogenous genetic material into a plasmid, transfection of a packaging cell line with plasmid, production of recombinant retroviruses by the packaging cell line, collection of viral particles from tissue culture media, and infection of the target cells with the viral particles) are provided in Kriegler, M. Gene Transfer and Expression, A Laboratory Manual, W.H. Freeman Co, New York, (1990) and Murray, E. J., ed. Methods in Molecular Biology, Vol. 7, Humana Press Inc., Clifton, N.J., (1991).
[0078] The major advantage of using retroviruses, including lentiviruses, for gene therapy is that the viruses insert the gene encoding the therapeutic agent into the host cell genome, thereby permitting the exogenous genetic material to be passed on to the progeny of the cell when it divides. In addition, gene promoter sequences in the LTR region have been reported to enhance expression of an inserted coding sequence in a variety of cell types (see e.g., Hilberg et al., Proc. Natl. Acad. Sci. USA 84:5232-5236 (1987); Holland et al., Proc. Natl. Acad. Sci. USA 84:8662-8666 (1987); Valerio et al., Gene 84:419-427 (1989). The major disadvantages of using a retrovirus expression vector are (1) insertional mutagenesis, i.e., the insertion of the therapeutic gene into an undesirable position in the target cell genome which, for example, leads to unregulated cell growth and (2) the need for target cell proliferation in order for the therapeutic gene carried by the vector to be integrated into the target genome (Miller, D. G., et al., Mol. Cell. Biol. 10:4239-4242 (1990)). While proliferation of the target cell is readily achieved in vitro, proliferation of many potential target cells in vivo is very low.
[0079] Yet another viral candidate useful as an expression vector for transformation of cells is the adenovirus, a double-stranded DNA virus. The adenovirus is frequently responsible for respiratory tract infections in humans and thus appears to have an avidity for the epithelium of the respiratory tract (Straus, S., The Adenovirus, H. S. Ginsberg, Editor, Plenum Press, New York, P. 451-496 (1984)). Moreover, the adenovirus is infective in a wide range of cell types, including, for example, muscle and endothelial cells (Larrick, J. W. and Burck, K. L., Gene Therapy. Application of Molecular Biology, Elsevier Science Publishing Co., Inc., New York, p. 71-104 (1991)). The adenovirus also has been used as an expression vector in muscle cells in vivo (Quantin, B., et al., Proc. Natl. Acad. Sci. USA 89:2581-2584 (1992)).
[0080] Like the retrovirus, the adenovirus genome is adaptable for use as an expression vector for gene therapy, i.e., by removing the genetic information that controls production of the virus itself (Rosenfeld, M. A., et al., Science 252:431434 (1991)). Because the adenovirus functions in an extrachromosomal fashion, the recombinant adenovirus does not have the theoretical problem of insertional mutagenesis.
[0081] Finally, a third virus family adaptable for an expression vector for gene therapy are the recombinant adeno-associated viruses, specifically those based on AAV2, AAV4 and AAV5 (Davidson et al, PNAS, 2000).
[0082] Thus, as will be apparent to one of ordinary skill in the art, a variety of suitable viral expression vectors are available for transferring exogenous genetic material into cells. The selection of an appropriate expression vector to express a therapeutic agent for a particular condition amenable to gene replacement therapy and the optimization of the conditions for insertion of the selected expression vector into the cell, are within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0083] In an alternative embodiment, the expression vector is in the form of a plasmid, which is transferred into the target cells by one of a variety of methods: physical (e.g., microinjection (Capecchi, M. R., Cell 22:479-488 (1980)), electroporation (Andreason, G. L. and Evans, G. A. Biotechniques 6:650-660 (1988), scrape loading, microparticle bombardment (Johnston, S. A., Nature 346:776-777 (1990)) or by cellular uptake as a chemical complex (e.g., calcium or strontium co-precipitation, complexation with lipid, complexation with ligand) (Methods in Molecular Biology, Vol. 7, Gene Transfer and Expression Protocols, Ed. E. J. Murray, Humana Press (1991)). Several commercial products are available for cationic liposome complexation including Lipofectin™ (Gibco-BRL, Gaithersburg, Md.) (Felgner, P. L., et al., Proc. Natl. Acad. Sci. 84:7413-7417 (1987)) and Transfectam™ (ProMega, Madison, Wis.) (Behr, J. P., et al., Proc. Natl. Acad. Sci. USA 86:6982-6986 (1989); Loeffler, J. P., et al., J. Neurochem. 54:1812-1815 (1990)). However, the efficiency of transfection by these methods is highly dependent on the nature of the target cell and accordingly, the conditions for optimal transfection of nucleic acids into cells using the above-mentioned procedures must be optimized. Such optimization is within the scope of one of ordinary skill in the art without the need for undue experimentation.
[0084] The instant invention also provides various methods for making and using the above-described genetically-modified cells. In particular, the invention provides a method for genetically modifying cell(s) of a mammalian recipient ex vivo and administering the genetically modified cells to the mammalian recipient. In one embodiment for ex vivo gene therapy, the cells are autologous cells, i.e., cells isolated from the mammalian recipient. As used herein, the term “isolated” means a cell or a plurality of cells that have been removed from their naturally-occurring in vivo location. Methods for removing cells from a patient, as well as methods for maintaining the isolated cells in culture are known to those of ordinary skill in the art.
[0085] The instant invention also provides methods for genetically modifying cells of a mammalian recipient in vivo. According to one embodiment, the method comprises introducing an expression vector for expressing a heterologous gene product into cells of the mammalian recipient in situ by, for example, injecting the vector into the recipient.
[0086] In one embodiment, the preparation of genetically modified cells contains an amount of cells sufficient to deliver a therapeutically effective dose of the therapeutic agent to the recipient in situ. The determination of a therapeutically effective dose of a specific therapeutic agent for a known condition is within the scope of one of ordinary skill in the art without the need for undue experimentation. Thus, in determining the effective dose, one of ordinary skill would consider the condition of the patient, the severity of the condition, as well as the results of clinical studies of the specific therapeutic agent being administered.
[0087] If the genetically modified cells are not already present in a pharmaceutically acceptable carrier they are placed in such a carrier prior to administration to the recipient. Such pharmaceutically acceptable carriers include, for example, isotonic saline and other buffers as appropriate to the patient and therapy.
[0088] The genetically modified cells are administered by, for example, intraperitoneal injecting or implanting the cells or a graft or capsule containing the cells in a target cell-compatible site of the recipient. As used herein, “target cell-compatible site” refers to a structure, cavity or fluid of the recipient into which the genetically modified cell(s), cell graft, or encapsulated cell expression system can be implanted, without triggering adverse physiological consequences More than one recombinant gene can be introduced into each genetically modified cell on the same or different vectors, thereby allowing the expression of multiple therapeutic agents by a single cell.
[0089] The instant invention further embraces a cell graft. The graft comprises a plurality of the above-described genetically modified cells attached to a support that is suitable for implantation into a mammalian recipient. The support can be formed of a natural or synthetic material.
[0090] According to another aspect of the invention, an encapsulated cell expression system is provided. The encapsulated system includes a capsule suitable for implantation into a mammalian recipient and a plurality of the above-described genetically modified cells contained therein. The capsule can be formed of a synthetic or naturally-occurring material. The formulation of such capsules is known to one of ordinary skill in the art. In contrast to the cells which are directly implanted into the mammalian recipient (i.e., implanted in a manner such that the genetically modified cells are in direct physical contact with the cell-compatible site), the encapsulated cells remain isolated (i.e., not in direct physical contact with the site) following implantation. Thus, the encapsulated system is not limited to a capsule including genetically-modified non-immortalized cells, but may contain genetically modified immortalized cells.
[0091] The following provides examples of how the Tat-PTD alters the properties of a representative lysosomal protein, β-glucuronidase. Similar results would be expected for all soluble lysosomal proteins. Moreover, the data would also hold for other non-lysosomal proteins that or normally secreted, or to proteins modified to contain a signal sequence to allow for their secretion. The underlying theme is that the inclusion of a PTD onto those sequences will allow for altered and improved biodistribution for therapeutic purposes.
[0092] Therefore, the following examples are intended to illustrate but not limit the invention.
EXAMPLES
Example 1
Production of Recombinant Vectors
[0093] [0093] Primer 1 (5′-AAACTCGAGATGGCCCGGGGGTCGGCGGTTGCC-3′) (SEQ ID NO:1) and primer 2 (5′-TGCTCTAGATCATCTTCGTCGCTGTCTCCGCTTCTTCCTGCCATAACCGCC (SEQ ID NO:2) ACCG-CCAGTAAACGGGCTGTT T TCCAAACA-3′)
[0094] were used to create the β-glucuronidase-Tat 47-57 fusion protein. Primer 1 and primer 3
(5′TGCTCTAGATCAATAGCCCCTCTTC TTCCGTCT (SEQ ID NO:3) CTGTCGTCGTCTACCGCCACCGCCAGTAAACGGGCTGTTTTCCA AACA-3′)
[0095] were used to make the β-glucuronidase-Tat 57-47 fusion protein. PCR fragments were digested with XhoI and XbaI and the fragments cloned into similarly cut E1 shuttle plasmids (pPacRSVKpnA; described in (Anderson, et al., (2000) Gene Ther. 7(12):1034-1038)). The resultant plasmids were named pPacRSVβGluc-Tat PTD 47-57 or pPacRSV βGluc-Tat PTD 57-47 . Adenoviruses with β-glucuronidase, β-glucuronidase-Tat PTD 47-57 or β-glucuroniase-Tat PTD 57-47 in E1 and eGFP in E3 were produced by co-transfecting PacI linearized pPacRSVβGluc-Tat PTD 47-57 , pPacRSVβGluc-Tat PTD 57-47 or pPacRSVβgluc with PacI digested E3 modified Ad5 backbones containing a RSVGFP expression cassette in E3. For ease of discussion the recombinant viruses, Ad5βgluc-Tat 47-57 /E3GFP, Ad5βgluc-Tat 57-47 /E3GFP or Ad5βgluc/E3GFP are listed as Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc. Viruses were purified by CsCl gradient ultracentrifugation. Infectious units were determined by plaque assay and particle titers by OD 260 .
Example 2
In vitro Studies
[0096] HeLa cells were infected with Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or control Adβgluc at 20 infectious units (i.u.)/cell and supernatants harvested 72 h later. β-Glucuronidase activity was quantified using the previously described fluorometric assay. Briefly, aliquots were reacted in 10 mM 4-methylumbellifryl-β-D-glucuronidase (Sigma, St. Louis, Mo.) in 0.1 M sodium acetate (pH 4.8) for 1 h at 37° C. Reactions were stopped by addition of 2 ml of 320 mM glycine in 200 mM carbonate buffer, pH 10.0 (Glaser, et al, (1973) J. Lab. Clin. Med. 82:969-977). Fluorescence was measured at 415 nm after excitation at 360 nm (TD-700 Fluorometer; Turner Design, Sunnyvale, Calif.). β-Glucuronidase activity is expressed as nanomoles of 4-methylumbellferone released per hour (FLU) per mg protein. Purified β-glucuronidase (kindly provided by William Sly, Washington University, St. Louis Mo.) was used as standard. Protein concentrations were determined using the Bio-Rad DC protein assay (Bio-Rad Laboratories, Hercules, Calif.).
[0097] NIH 3T3 or A549 cells (500,000 cells plated the day before) were incubated with 5500 units of β-glucuronidase-Tat 47-57 , β-glucuronidase-Tat 57-47 or β-glucuronidase in the presence or absence of D-mannose-6-phosphate (10 mM) for 2 h at 37 or 4° C. After incubation cells were harvested and lysates prepared for fluorometric enzyme assay, or stained for β-glucuronidase activity in situ. For β-glucuronidase staining, cells were washed in PBS, fixed in 2% paraformaldehyde for 15 min, washed twice in PBS, twice with 0.05M sodium acetate, pH 4.5, for 5 min, and then incubated in 0.25 mM Napth-As-Bi-β-glucuronide (Sigma) in the same buffer for 40 min. Cells or tissues (below) were then stained for 30 min at 37° C. with 0.25 mM Napth-As-Bi-β-glucuronide in 0.05 M sodium acetate, pH 5.2, with 1/500 2% hexazotized pararosaniline (Sigma).
Example 3
In vivo Studies
[0098] β-Glucuronidase-deficient mice were obtained from the Jackson Laboratory (Bar Harbor, Me.) and from our own breeding colony. The genotype for the latter was confirmed by morphological and genetic analyses. The animals were between 8 and 10 weeks old and weighed 16-24 g. C57BL/6 wild-type mice were purchased from Harlan Sprague (Indianapolis, Ind.).
[0099] Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc were injected into the tail vein (2×10 9 i.u.) of β-glucuronidase deficient mice. Adβgluc-Tat 47-57 , Adβgluc-Tat 57-47 or Adβgluc (2×10 7 i.u. total) were injected into the right striatum or right lateral ventricle of C57BL/6 mice or β-glucuronidase deficient mice as described earlier (Stein, et al., (1999) J. Virol. 73(4):3424-3429). Animals were sacrificed 10 days after intravenous (n=3/group), striatal (n=5/group) or ventricular injection (n=5/group). Tissues were sonicated, placed in lysis solution (Sands, et al., (1994) J. Clin. Invest. 93:2324-2331) and centrifuged at 12000× g for 20 min. Aliquots were assayed using the fluorometric assay described above. For in situ enzyme assays, tissues were harvested, sectioned, and stained in situ for β-glucurondase activity as described above.
[0100] Coronal brain sections were photographed with Adobe Photoshop (Adobe system, Mountain View, Calif.), and the photos imported into NIH Image. Color thresh-holding was used, and the percentage of brain positive for activity calculated by dividing the area of staining by the total area (adjusted for ventricular size). In all cases a minimum of 2 mm (rostral to caudal) of cerebrum surrounding the injection site was scanned.
[0101] All publications, patents and patent applications are incorporated herein by reference. While in the foregoing specification this invention has been described in relation to certain embodiments, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein may be varied considerably without departing from the basic principles of the invention.
REFERENCES
[0102] 1. Meikle, P. J., Hopwood, J. J., Clague, A. E. and Carey, W. F. 1999. Prevalence of lysosomal storage disorders. JAMA 281(3):249-254.
[0103] 2. O'Connor, L. H., Erway, L. C., Vogler, C. A., Sly, W. S., Nicholes, A., Grubb, J., Holmberg, S. W., Levy, B. and Sands, M. S. 1998. Enzyme replacement therapy for murine mucopolysaccharidosis Type VII leads to improvements in behavior and auditory function. J. Clin. Invest. 101:1394-1400.
[0104] 3. Frisella, W. A., O'Connor, L. H., Vogler, C. A., Roberts, M., Walkley, S., Levy, B., Daly, T. M. and Sands, M. S. 2001. Intracranial injection of recombinant adeno-associated virus improves cognitive function in a murine model of mucopolysaccharidosis type VII. Mol. Ther . (In Press)
[0105] 4. Fawell, S., Seery, J., Daikh, Y., Moore, C., Chen, L. L., Pepinsky, B. and Barsoum, J. 1994. Tat-mediated delivery of heterologous proteins into cells. Proc. Natl. Acad. Sci. U.S.A. 91:664-668.
[0106] 5. Schwarze, S. R., Ho, A., Vocero-Akbani, A. and Dowdy, S. F. 1999. In vivo protein transduction: delivery of a biologically active protein into the mouse. Science 285:1569-1572.
[0107] 6. Derossi, D., Calvet, S., Trembleau, A., Brunissen, A., Chassaing, G. and Prochiantz, A. 1996. Cell internalization of the third helix of the antennapedia homeodomain is receptor-independent. J. Biol. Chem. 271(30):18188-18193.
[0108] 7. Ghodsi, A., Stein, C., Derksen, T., Yang, G., Anderson, R. D. and Davidson, B. L. 1998. Extensive β-glucuronidase activity in murine CNS after adenovirus mediated gene transfer to brain. Hum. Gene Ther. 9:2331-2340.
[0109] 8. Mann, D. A. and Frankel, A. D. 1991. Endocytosis and targeting of exogenous HIV-1 tat protein. EMBO J. 10(7):1733-1739.
[0110] 9. Stein, C. S., Ghodsi, A., Derksen, T. and Davidson, B. L. 1999. Systemic and central nervous system correction of lysosomal storage in mucopolysaccharidosis type VII mice. J. Virol. 73(4):3424-3429.
[0111] 10. Ghodsi, A., Stein, C., Derksen, T., Martins, I., Anderson, R. D. and Davidson, B. L. 1999. Systemic hyperosmolality improves β-glucuronidase distribution and pathology in murine MPS VII brain following intraventricular gene transfer. Exp.Neurol. 160:109-116.
[0112] 11. Davidson, B. L., Stein, C. S., Heth, J. A., Martins, I., Kotin, R. M., Derksen, T. A., Zabner, J., Ghodsi, A. and Chiorini, J. A. 2000. Recombinant AAV type 2, 4 and 5 vectors: transduction of varient cell types and regions in the mammalian CNS. Proc.Natl.Acad.Sci.U.S.A. 97(7):3428-3432.
[0113] 12. Anderson, R. D., Haskell, R. E., Xia, H., Roessler, B. J. and Davidson, B. L. 2000. A simple method for the rapid generation of recombinant adenovirus vectors. Gene Ther. 7(12):1034-1038.
[0114] 13. Glaser, J. H. and Sly, W. S. 1973. Beta-glucuronidase deficiency mucopolysaccharidosis: Methods for enzymatic diagnosis. J. Lab. Clin. Med. 82:969-977.
[0115] 14. Sands, M. S., Vogler, C., Kyle, J. W., Gribb, J. H., Levy, B., Galvin, N., Sly, W. S. and Birkenmeier, E. H. 1994. Enzyme replacement therapy for murine mucopolysaccharidosis type VII. J.Clin.Invest. 93:2324-2331.
1
3
1
33
DNA
Adenovirus
1
aaactcgaga tggcccgggg gtcggcggtt gcc 33
2
81
DNA
Adenovirus
2
tgctctagat catcttcgtc gctgtctccg cttcttcctg ccataaccgc caccgccagt 60
aaacgggctg ttttccaaac a 81
3
81
DNA
Adenovirus
3
tgctctagat caatagcccc tcttcttccg tctctgtcgt cgtctaccgc caccgccagt 60
aaacgggctg ttttccaaac a 81 | The present invention provides polynucleotides and expression vectors containing a sequence encoding a soluble lysosomal enzyme and a sequence encoding Tat protein transduction domain (PTD), and the corresponding polypeptides. The present demonstrates the utility of these protein fusions in altering the bioavailability of proteins for use in treating genetic diseases or acquired diseases. The invention further provides cell expression systems, and methods of treating a genetic disease or cancer in a mammal using the polynucleotides, polypeptides, or expression system of the present invention. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to, claims the earliest available effective filing date(s) from (e.g., claims earliest available priority dates for other than provisional patent applications; claims benefits under 35 USC §119(e) for provisional patent applications), and incorporates by reference in its entirety all subject matter of the following listed application(s) (the “Related Applications”) to the extent such subject matter is not inconsistent herewith; the present application also claims the earliest available effective filing date(s) from, and also incorporates by reference in its entirety all subject matter of any and all parent, grandparent, great-grandparent, etc. applications of the Related Application(s) to the extent such subject matter is not inconsistent herewith:
U.S. provisional patent application 61/860,844 entitled “A System and Method for Dating Textured Gelatin Silver Paper”, naming Paul Messier and Andrew Messier as inventors, filed 31 Jul. 2013.
BACKGROUND
1. Field of Use
These teachings relate generally to forensic photograph dating and more particularly to systems employing digital computers for determining the probabilistic date of a physical characteristic associated with a photograph. The teachings may also relate to any field where reflectance transformation imaging is employed, such as, for example, the fields of ballistics investigation or numismatics.
2. Description of Prior Art (Background)
A photographic print's date is elementary to the understanding of the work, its historical context and the photographer's artistic intent. It carries implications for its treatment, display and storage and can manifestly influence its market value. Recently, photographs have become the target of forgers, and as the market value of these works increase, so will forgery continue. The detection of forged photography is particularly difficult in the context of today's imaging technology as experts must be able to tell the difference between originals and reprints. For example, a forger in possession of photo-negatives would allow the forger to print an unlimited number of prints, which then can be passed off as original.
Texture is a defining attribute of photographic paper. Starting in the early 20th century, manufacturers manipulated texture to differentiate their products and to satisfy the aesthetic and functional requirements of photographers. Prior to WWII, when black and white silver gelatin paper was the dominant photographic medium, dozens of manufacturers worldwide produced a wide array of surfaces. From this period a book of specimen prints by the Belgian company Gevaert lists twenty five different surfaces comprising combinations of texture, reflectance, color and paper thickness (Gevaert Company of America c. 1935). Around the same time, a sample book from the Defender Company of Rochester N.Y. lists twenty seven surfaces (Defender Photo Supply Company c. 1935), Mimosa twenty six (Mimosa AG c. 1935) and Kodak twenty two (Eastman Kodak c. 1935). Each listed surface was proprietary to the different manufacturers and each was used across their multiple brands of paper with changes, additions, and deletions occurring over a span of many years.
Texture, a vital factor in the evaluation of paper surface, impacts the visibility of fine detail and thus provides insight into the artistic intent of the photographer and the envisioned purpose of a particular print. For example, prints intended for reproduction or documentary functions tend to be better suited on smooth-surface papers that render details with sharpness and clarity; on the other hand, more impressionistic or expressive subjects, especially those depicting large unmodulated masses of shadows or highlights, are best suited for papers with rough, broadly open textures (Eastman Kodak Company c. 1935).
A result of a careful and deliberate manufacturing process, texture applied to silver gelatin paper is designed to be distinct and distinguishable through processing and post-processing procedures. Given these texture attributes, an encyclopedic collection of surface textures can reveal vital clues about a photographic print of unknown origin. Likewise a method for classifying textures can provide a means to link prints to specific photographers or to other prints of known provenance.
Since the composition of photographic paper was frequently changed, fake photographs are likely to be printed on modern photographic paper or photographic paper not contemporaneous with the original photograph. Therefore, there is a need for a system to non-destructively date photographic paper.
Determining photographic paper surface texture, a critical feature in the manufacture, marketing and use of photographic paper, is one way to non-destructively date photographic paper. Using a raking light can reveal texture through a stark rendering of highlights and shadows. Though raking light photomicrographs effectively document surface features of photographic paper, the sheer number and diversity of textures used for historic papers prohibits efficient visual classification.
In addition, the raking light may be applied to a sample paper with different angles of incidence and different intensities, thereby rendering different highlights and shadows for the same photograph or sample. Therefore, a need exists for a method and apparatus for standardizing and classifying photograph textures revealed by a raking light.
BRIEF SUMMARY
The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.
The invention is directed towards a system for extracting texture features from a sample under investigation. The system includes a dome, wherein the dome comprises a plurality of LED rings disposed around an inner surface of the dome. The system also includes a LED controller for controlling the plurality of LEDs and the incident light impinging upon the sample situated within the dome. Also included is a CCD imager microscope and controller for capturing LED light reflected from the sample. The invention also includes a computer system for storing and analyzing the texture features from the sample. The computer system includes a processor for executing instructions; a display, operatively coupled to the processor; an input communications device; and a computer readable medium, operatively coupled to the processor. The computer readable medium contains a set of system instructions that, if executed by the processor, are operable to cause the computer system to construct a rules engine, the rules engine comprising texture identification rules and resources to classify the texture features.
The invention is also directed towards a system for extracting texture features from a sample under investigation. The system includes a plurality of light emitting diodes (LEDs) disposed semi-spherically around the sample, wherein the plurality of LEDs are arranged to form a plurality of LED rings and wherein each LED ring comprises a unique angle/distance pairing with respect to the sample.
In another embodiment the invention is directed towards a system for extracting texture features from a sample under investigation. The system includes a dome for enclosing the sample. The dome includes a plurality of light emitting diodes (LEDs) arranged to form a plurality of LED rings around the inner surface of the dome. The system also includes an LED controller for controlling the plurality of LEDs; a CCD imager microscope for capturing LED light reflected from the texture features inherent within the sample; and a charge coupled device (CCD) imager microscope controller for controlling the CCD imager microscope. In addition, the system includes a computer system for electronically storing and analyzing the texture features from the sample. The computer system includes a processor for executing instructions; a display, operatively coupled to the processor; and a computer readable medium, operatively coupled to the processor. The computer readable medium contains a set of system instructions that, if executed by the processor, are operable to cause the computer system to construct a rules engine, the rules engine comprising texture identification rules and resources to classify the texture features. The computer readable medium also contains a second set of system instructions that, if executed by the processor, are operable to cause the computer system to capture a plurality of texture datasets associated with the sample, wherein one of the plurality of texture datasets comprise a first set of texture features and a second one of the plurality of texture datasets comprise a second set of texture features. The datasets may be captured at the same time with different LED control settings and/or at different times with identical LED control settings.
BRIEF DESCRIPTION OF THE DRAWINGS
The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a pictorial illustration of a system configuration of an embodiment of the present invention;
FIG. 2 is a pictorial illustration of an alternate state of the system configuration of the present invention shown in FIG. 1 ;
FIG. 3 is a pictorial illustration of a third alternate state of the system configuration of the present invention shown in FIG. 1 ; and
FIG. 4 is a block diagram of computer architecture for implementing the system configurations shown in FIG. 1 - FIG. 3 .
DETAILED DESCRIPTION
The following brief definition of terms shall apply throughout the application:
The term “comprising” means including but not limited to, and should be interpreted in the manner it is typically used in the patent context;
The phrases “in one embodiment,” “according to one embodiment,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present invention, and may be included in more than one embodiment of the present invention (importantly, such phrases do not necessarily refer to the same embodiment);
If the specification describes something as “exemplary” or an “example,” it should be understood that refers to a non-exclusive example; and
If the specification states a component or feature “may,” “can,” “could,” “should,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” or “might” (or other such language) be included or have a characteristic, that particular component or feature is not required to be included or to have the characteristic.
Referring to FIG. 1 there is shown a pictorial illustration of a system configuration of an embodiment of the present invention 10 for applying a raking light 17 A to a sample 11 under investigation and subsequently imaging the reflected raking light 17 B with a microscope and CCD imager 13 . The raking light 17 A is emitted from one or more LEDs 18 arranged around the perimeter of dome 14 . It will be understood that each of the LEDs may comprise a unique angle A and/or distance D from sample 11 .
FIG. 1 shows a single LED 16 - 1 illuminated within an array of a plurality of light emitting diodes (LEDs) 18 mounted to lighting array dome or semi-sphere 14 . It will be appreciated that any number of LEDs may be used, such as for example 48 LEDs. It will also be appreciated that the LEDs may emit any suitable color or spectrum. The lighting array dome 14 includes the plurality of LEDs coupled to the LED controller 16 through a printed circuit board (PCB). The LED controller 16 provides an inter-face to address each LED 18 and controls: illumination intensity of each LED, on/off sequence of each LED with respect to the other LEDs, and exposure or energized state time of each LED. It will be appreciated that each LED comprises a static angle and distance to a reference point, e.g., a test sample, and each LED comprises dynamic illumination intensity, exposure time, gain, and sequencing. It will also be appreciated the LEDs may be arranged geometrically such as, for example, in LED rows around the inside of the lighting array dome 14 . And, each row may comprise a unique angle/distance pair with respect to sample 11 .
Also shown is CCD controller 12 to control key CCD functions including image capture, white balance, image output (file creation) and gain (light sensitivity of the sensor).
Still referring to FIG. 1 , an image 15 of the illuminated sample 11 is shown. As shown, the raking light 17 A illuminates the sample 11 from, in this example, an oblique angle, thus highlighting certain features of the sample 11 under investigation.
The dot in the graphical user interface (GUI) corresponds with the LEDs illuminated in the dome. For example, dot 16 - 1 c corresponds to LED 16 - 1 . Each of the LEDs, can be preset for desired illuminating while examining the impact of the illumination using a preview image to determine light intensity and other camera related exposure options. Once set, the LEDs are energized in a predetermined sequence with the corresponding raking images automatically captured and save by CCD imager 13 and CCD controller 12 . It will be understood that any suitable number of LEDs may be energized. It will also be appreciated that all LED and CCD settings may be captured to precisely repeat the LED illumination.
Referring also to FIG. 2 for comparison this illustration shows a different position of an illuminated LED and the corresponding dot 16 - 2 c in the controller 16 window. Of note is the effect of the different angle of raking light illumination 24 A on the sample 11 .
Still referring to FIG. 2 , an image 22 of the illuminated sample 11 is shown. As shown, the raking light 24 A illuminates the sample 11 from, in this example, a perpendicular angle, thus highlighting certain features of the sample 11 under investigation that are not readily apparent from a raking light of a different intensity or incident angle (compare item 22 with FIG. 1 , item 15 ).
Referring also to FIG. 3 for yet another comparison, this illustration shows a different position of an illuminated LED 16 - 3 and the corresponding dot 16 - 3 c in the controller 16 window. Of note is the effect of the different angle of illumination on the sample 11 shown in image 32 (compare with FIG. 2 , item and with FIG. 1 , item 15 ).
Still referring to FIG. 3 , an image 32 of the illuminated sample 11 is shown. The raking light from LED 16 - 3 illuminates the sample 11 from, in this example, another angle, thus highlighting certain features of the sample 11 under investigation that are not readily apparent from a raking light of a different intensity or incident angle.
It will be understood that the present invention advantageously provides an ability to precisely control the lighting angle and intensity and allow a repeatable way to examine and document surface features under different lighting conditions. The one or more images shown in FIG. 1 - FIG. 3 may be captured as a texture dataset (See FIG. 4, 414 ) for subsequent processing and comparison. For example, a texture dataset, as described herein, of a photograph, or painting, may be compared with later, or earlier captured texture datasets of the photograph or painting to determine deterioration rates, identity, and authenticity. Similarly, texture datasets, as described herein, of a painting or photograph may be compared with one or more standard texture datasets, as described herein, of known characteristics such as, for example, texture and surface composition.
It will be appreciated that the texture dataset of a sample described herein comprises a static or dynamic raking image. It will be understood that the static raking image is a function of the number of energized LEDs and each LED's angle and distance to the sample, and each LED's preset intensity and gain. It will be further understood that the dynamic raking image is a function of the aforementioned factors and LED exposure time and the LED's energizing or exposure sequence.
With reference also to FIG. 4 , a block diagram illustrating a computer architecture 300 for LED controller 16 incidence parameters and the CCD controller 12 is shown. System 300 employs a peripheral component interconnect (PCI) local bus architecture. Although the depicted example employs a PCI bus, other bus architectures such as Accelerated Graphics Port (AGP) and Industry Standard Architecture (ISA) may be used. Processor 302 and main memory 304 are connected to PCI local bus 306 through PCI bridge 308 . PCI bridge 308 also may include an integrated memory controller and cache memory for processor 302 . Additional connections to PCI local bus 306 may be made through direct component interconnection or through add-in boards.
In the depicted example, local area network (LAN) adapter 310 , SCSI host bus adapter 312 , and expansion bus interface 314 are connected to PCI local bus 306 by direct component connection. It will be understood that LAN adapter 310 may also include an internet browser. In contrast, audio adapter 316 , graphics adapter 318 , and audio/video adapter 319 are connected to local bus 306 by add-in boards inserted into expansion slots. Local bus may be any suitable bus architecture such as, for example, PCI or USB. Expansion bus interface 314 provides a connection for a keyboard and mouse adapter 320 , modem 322 , and additional memory 324 . Small computer system interface (SCSI) host bus adapter 312 provides a connection for hard disk drive 326 , tape drive 328 , and CD-ROM drive 330 . Typical PCI local bus implementations will support PCI expansion slots or add-in connectors.
An operating system runs on processor 302 and is used to coordinate and provide control of various components within data processing system 31 . Data processing sa processing system 31 may be configured to process dataset 414 as described herein. The operating system may be any suitable commercially available operating system. In addition, an object oriented programming system such as Java may run in conjunction with the operating system and provide calls to the operating system from Java programs or applications executing on data processing system 300 . “Java” is a trademark of Sun Microsystems, Inc. Instructions for the operating system, the object-oriented operating system, and applications or programs are located on storage devices, such as hard disk drive 326 , and may be loaded into main memory 304 for execution by processor 302 .
System 300 may be configured to regressively cluster texture dataset 414 to allocate data points within the dataset to a probable date range or a comparison confidence factor. In some embodiments, such an adaptation may be incorporated within system 300 . In particular, system 300 may include storage medium 324 with program instructions 413 executable by processor 302 to regressively cluster dataset 414 . In an embodiment in which dataset 414 is external to system 300 , however, the adaptation to regressively cluster dataset 414 may be additionally, or alternatively, incorporated within the respective data source/s of dataset 414 . In particular, the data source/s of dataset 414 , in such an embodiment, may include a storage medium with program instructions which are executable through a processor for regressively clustering data.
In general, input may be transmitted to system 300 to execute program instructions 413 within storage medium 324 . Storage medium 324 may include any device for storing program instructions, such as, for example, a read-only memory, a random access memory, a magnetic or optical disk, or a magnetic tape. Program instructions 413 may include any instructions by which to perform any suitable method or regression clustering and classification processes. In particular, program instructions 413 may include instructions for correlating variable parameters of a dataset and other instructions for clustering the dataset through the iteration of a regression algorithm. In this manner, program instructions 413 may used to generate a plurality of different functions correlating variable parameters of a dataset.
In addition, program instructions 413 may include instructions for determining directives by which to classify new data into the dataset with respect to the generated functions. In some cases, program instructions 13 may further include instructions by which to receive new data and predict values of variable parameters associated with the new data and dataset.
For example, the computer readable medium may contain a set of system instructions that, if executed by the processor 302 , are operable to cause the computer system 300 to capture a plurality of texture datasets associated with the sample 11 ; where each of the texture datasets may be captured at different times or under different conditions. In this manner the comparisons may be used to determine degradation or authenticity.
Similarly, the computer readable medium may contain a set of system instructions that, if executed by the processor 302 , are operable to cause the computer system 300 to generate a baseline texture dataset. The baseline texture dataset may be generated according to a predetermined formula or determined empirically with a sample having known characteristics.
Those of ordinary skill in the art will appreciate that the hardware in FIG. 1 through FIG. 4 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash read-only memory (ROM), equivalent nonvolatile memory, or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 1 - FIG. 4 .
The depicted example in FIG. 1 - FIG. 4 and above-described examples are not meant to imply architectural limitations. For example, system 300 also may be a notebook computer or hand held computer in addition to taking the form of a PDA.
It should be understood that the foregoing description is only illustrative of the invention. Thus, various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims. | A system and method for dating gelatin silver photographic paper is provided. The system and method includes providing a database management system having physical texture characteristic profiles. The system implements a program of instructions to determine a probable date range or source for each textural characteristic profile. The system includes LED sources disposed around an inner surface of a dome; an LED controller, and a CCD imager microscope. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits of European application No. 0881259.4 filed Jan. 23, 2008 and U.S. Provisional application 60/989,467 filed Nov. 21, 2007, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a module of a nacelle of a wind turbine, a nacelle of a wind turbine, a wind turbine and a method for the assembly of a nacelle of a wind turbine.
BACKGROUND OF THE INVENTION
[0003] Wind power becomes more and more important. Parallel with the increasing significance of wind power wind turbines are getting larger and larger, which makes it more difficult to transport the large, in general preassembled and integrated wind turbine parts from the place of manufacture to the sites of erection, this can be onshore or offshore.
[0004] Normally a wind turbine comprises a few larger parts in form of the blades, the hub, the tower and the nacelle. Particularly the nacelle comprises a number of integrated main components such as a main shaft, a main bearing assembly, a gearbox, a generator, some power/control components, a transformer, a cooling system and so on, which are all arranged on a common bedplate and in a common nacelle housing. The bedplate has a yaw system to orient the nacelle towards the wind direction. Typically the nacelle is completely preassembled at the place of manufacture.
[0005] When a wind turbine is erected the blades, the hub, the tower and the preassembled nacelle are transported to the site of erection. The tower is erected, the nacelle is mounted on the tower, the hub is mounted on the nacelle and the blades are attached to the hub by means of at least one crane. Thereby not only the transportation in particular the transportation of the large and heavy nacelle is difficult, but also the mounting on the tower, which requires sufficient crane capacity to handle the complete nacelle weight.
[0006] Moreover the servicing of such a wind turbine is often very complicated and time consuming, in particular when one or more components of the nacelle have to be replaced.
SUMMARY OF INVENTION
[0007] It is therefore an object of the present invention to lay the foundations that the transportation and/or the assembly of at least a part of a wind turbine is facilitated. It is a further object of the invention to indicate a method for the assembly of a part of a wind turbine.
[0008] The first object is inventively achieved by a module of a nacelle of a wind turbine, which is separately designed, separately manageable and comprises a housing part, wherein the module is connectable to at least one further module of the nacelle, which is also separately designed, separately manageable and has a housing part, and wherein the housing part of the module builds in the assembled status of the nacelle, which comprises several modules, a part of the housing of the nacelle. Thus the invention pursues a modular concept or a modular design of a nacelle, wherein the single modules build in the assembled status substantially the nacelle and wherein preferably each module comprise at least one functional unit of a wind turbine, e.g. a generator, a transformer, a power unit, a control unit etc. Thereby the external housing part of the module forms a part of the external housing of the whole nacelle. Having the nacelle of a wind turbine divided into such separate modules it becomes possible to manufacture the modules at separate locations and to assemble the modules for forming a complete nacelle first during the installation of a wind turbine. This will facilitate not only the transportation of the modules, but also the specialization of manufacturing of certain modules at competence centres. Thereby a module is able to be transported or shipped completely, wherein in particular the housing part of the module provides mechanical and weather protection during transportation and storage of the module.
[0009] Moreover it becomes easier to carry out the installation of the nacelle with limited crane capacity, since the assembly may be carried out at height, installing one module at a time, in which case the crane requirements are determined not by the complete nacelle weight but by the weight of the heaviest module.
[0010] Furthermore in case of a failure of a complete module the respective module is able to be replaced.
[0011] In a variant of the invention the module comprises connection means for connecting the module to at least a further module. Preferably the connection means of the module comprises at least one flange for connecting the module to the further module. Thus when a second module is arranged on a first module the flange of the second module and the flange of the first module, which are arranged oppositely to each other, are able to be bolted together. In such a way the nacelle is built stepwise until all required modules are arranged.
[0012] According to a further variant of the invention the module comprises as functional unit a generator, a retaining arrangement, a cooling unit, a control unit, a transformer or a main-shaft-bearing arrangement. According to this variant of the invention there are different specialised modules in form of a generator module, a retaining arrangement module, a cooling module, a control module, a transformer module and a main-shaft-bearing arrangement module.
[0013] In an embodiment of the invention the module comprises a substantially explosion and/or a fire resistant wall. In particular the transformer module comprises such an explosion and/or fire resistant wall next to a further module. Preferably the transformer or power-unit module is arranged on the rear end of the nacelle and comprise the mentioned explosion and/or fire resistant wall to the afore positioned module. According to a further embodiment of the invention a module, preferably the transformer or power-unit module comprises a bursting disc on its free end. In case of an explosion or a fire, the bursting disc, possibly being a part of the outer shell of the transformer or the power-unit module, will distort or be blown out to minimise blast effects in the nacelle and to protect the other modules and any personnel in the nacelle. In that situation the transformer or the power unit module is able to be replaced without replacing any other component.
[0014] According to a further variant of the invention the module comprises at least one functional mechanical and/or functional electrical interface for connecting the module functionally to a further module. In that way the whole mechanical and electrical interconnection throughout the nacelle is able to be achieved.
[0015] According to another embodiment of the invention the module and the housing part of the module respectively is self-supporting. So each module is able to be arranged on another module without the need of any supporting means for a module.
[0016] The object of the invention is also achieved by a nacelle of a wind turbine comprising several separately designed, manageable and replaceable modules, wherein each module is connectable to at least one further module and has a housing part, wherein the modules build in the assembled status substantially the nacelle, and wherein the housing parts of the modules build at least partially the housing of the nacelle. Thereby all variants and advantages mentioned in relation with a single module apply also to the nacelle.
[0017] According to a further variant of the invention at least one module comprises a helihoist platform. In this way it is possible to get to the nacelle by helicopter even under bad weather conditions.
[0018] In an embodiment of the invention the nacelle comprises on its one end an end plate, which can be a bursting disc.
[0019] The object of the invention is also achieved by a wind turbine comprising at least one module as disclosed before and/or a nacelle as disclosed before.
[0020] The further object of the invention is achieved by a method for the assembly of a nacelle of a wind turbine as disclosed before, wherein modules as disclosed before are arranged in series on a wind turbine tower, wherein a module comprising a retaining arrangement or a main-shaft-bearing arrangement is arranged on the tower and at least one further module is arranged on the module comprising the retaining arrangement or the main-shaft-bearing arrangement. In this way the nacelle of a wind turbine is able to be assembled stepwise during the erection of the wind turbine on site with limited crane capacity. Thereby the modules are mounted one by one aloft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention will in the following be explained in more detail with reference to the schematic drawings, wherein
[0022] FIG. 1 shows a nacelle comprising several single functional modules arranged on a tower of a wind turbine and
[0023] FIG. 2 shows another embodiment of a nacelle comprising several single functional modules.
DETAILED DESCRIPTION OF INVENTION
[0024] FIG. 1 shows schematically a nacelle 2 according to the invention arranged on tower 3 of an only partly shown wind turbine 1 . The nacelle 2 comprises several single, separately designed, separately manageable and separately replaceable modules 4 - 8 according to the invention.
[0025] In case of the present embodiment of the invention a module 5 comprising a retaining arrangement in form of a retaining arm 9 is arranged on the tower 3 . More precisely the module 5 and the retaining arm 9 respectively is attached to a tower flange 10 and turnable around the axis A of the tower 3 by means of a not explicitly shown yaw system to orient the nacelle 2 towards the wind direction. The module 5 comprises a housing part 51 . In case of the present embodiment of the invention the housing part 51 is self-supporting and comprises on the front end and the rear end connection means in form of flanges 52 , 53 .
[0026] A self-supporting module 4 comprising a generator and a housing part 41 with a connection flange 42 on the rear end of the housing part 41 is arranged on the front end of the module 5 . Thereby the flange 42 of the housing part 41 and the flange 52 of the housing part 51 as well as a stationary part of the generator and the retaining arm 9 of the module 4 are bolted together.
[0027] A conventional hub 13 is attached to the module 4 and a rotary part of the generator respectively by means of bolts.
[0028] A self-supporting module 6 , comprising a cooling unit and a housing part 61 is arranged on the rear end of the module 5 . The housing part 61 of the module 6 comprises on the front end and the rear end connections means in form of flanges 62 , 63 . The flange 53 of the housing part 51 of the module 5 and the flange 62 of the housing part 61 of the module 6 are bolted together, so that the module 6 is attached to the module 5 .
[0029] A further self-supporting module 7 comprising a control unit and a housing part 71 is arranged on the rear end of the module 6 . The housing part 71 of the module 7 comprises on the front end and the rear end connections means in form of flanges 72 , 73 . The flange 63 of the housing part 61 of the module 6 and the flange 72 of the housing part 71 of the module 7 are bolted together, so that the module 7 is attached to the module 6 .
[0030] A last self-supporting module 8 comprising a transformer and a housing part 81 is arranged on the rear end of the module 7 . The housing part 81 of the module 8 comprises on the front end and the rear end connections means in form of flanges 82 , 83 . The flange 73 of the housing part 71 of the module 7 and the flange 82 of the housing part 81 of the module 8 are bolted together, so that the module 8 is attached to the module 7 .
[0031] In case of the present embodiment of the invention the transformer module 8 comprises additionally a substantially explosion and/or fire resistant wall 15 on the front side next to the module 7 .
[0032] An end cap or end plate 14 is attached to the rear end of the module 8 . The end plate 14 closes the rear end of the module 8 . Thereby the end plate 14 is bolted with the flange 83 . In case of the present embodiment of the invention the endplate 14 is a bursting disc or a kind of bursting disc. Thus in case of explosion or fire in the transformer module 8 the bursting disc will distort or be blown out to minimise blast effects in the nacelle 2 and to protect the other functional modules 4 - 7 as well as any personal in the nacelle together with the explosion and/or fire resistant wall 15 . Because the transformer module 8 is the last module of the nacelle 2 it can be replaced in such a situation without replacing any other module or component of the wind turbine 1 .
[0033] If necessary also the other modules are able to have an explosion and/or fire resistant wall and/or a bursting disc.
[0034] As can be seen from FIG. 1 the single, separately designed, manageable and replaceable modules 4 - 8 are arranged in series in relation to a centre axis B on the tower 3 of the wind turbine 1 and build in the assembled status the nacelle 2 of the wind turbine 1 . The housing parts of the single modules 4 - 8 are in such a way aligned to each other, that the single housing parts 41 , 51 , 61 , 71 and 81 build together with the end plate 14 the housing or canopy of the nacelle 2 . Thus there is no separate or additional housing surrounding the single modules 4 - 8 necessary. In fact the housing parts 41 , 51 , 61 , 71 , 81 and the end plate 14 are connected with each other water tight, e.g. by means of appropriate sealings.
[0035] All or some modules 4 - 8 can in a not shown manner comprise functional mechanical and/or functional electrical interfaces as wells as mechanical components and cables for mechanical and/or electrical interconnections of the modules 4 - 8 . There is e.g. a not shown electrical interconnection comprising functional electrical interfaces and cables between the generator module 4 and the transformer module 8 . Examples of functional mechanical interfaces of modules are the stationary part of the generator of the module 4 as a first functional mechanical interface and the retaining arm 9 of the module 5 as a second functional mechanical interface.
[0036] A flange of a housing part preferably runs along the perimeter of the housing part, wherein the housing part is able to have a ring-shaped cross section or a cross section having a different form.
[0037] The module 5 comprising the retaining arm 9 , which can also be identified as a load-bearing module, is carrying the weight and the load of the hub 13 , the not shown three rotor blades attached to the hub 13 and the modules 4 - 8 , thereby transferring the load to the tower 3 .
[0038] As disclosed each module 4 - 8 can be self-supporting, wherein the housing part of each module typically is the weight- and load-carrying component of the respective module 4 - 8 .
[0039] As already mentioned, having the nacelle 2 of the wind turbine 1 divided into the single modules 4 - 8 it becomes possible to manufacture the single modules 4 - 8 at separate locations and to assemble the modules 4 - 8 for forming a complete nacelle 2 first during the installation of the wind turbine 1 . This facilitates the transportation of the modules 4 - 8 to the site of erection as well as the specialization of manufacturing of certain modules at competence centres. Each module 4 - 8 is able to be transported or shipped completely, wherein in particular the housing part and an additional packaging of the module at both ends of the module provides mechanical and weather protection during transportation of the module.
[0040] Further on in case of a failure of a complete module the respective module is able to be replaced.
[0041] FIG. 2 shows another embodiment of a modularised nacelle 12 of a wind turbine 21 in an exploded view.
[0042] In case of this embodiment a module 22 comprising a main shaft bearing arrangement or a load bearing arrangement including a main shaft 16 and two main bearings 17 , 18 is arranged on a schematically shown tower 33 . A module 23 comprising a generator is arranged on the rear end of the module 22 , wherein the rotor of the generator is connected to the pivotable main shaft of the main shaft bearing arrangement. A hub 13 is attached to the main shaft 16 of the module 22 .
[0043] A module 24 comprising a control unit is arranged on the module 23 , a module 25 comprising a cooling unit is arranged on the module 24 and a module 26 comprising a transformer is arranged on the module 25 . The transformer module 26 is closed with an end plate 27 .
[0044] As can be seen from FIG. 2 the nacelle 12 of a wind turbine can be modularised to such an extent that customised solutions are implemented simply by adding or deleting modules. The module 25 comprising a cooling unit can be e.g. an offshore cooling/climate control module 25 a or a hot climate cooling module 25 b . Also the transformer module 26 is available in different designs, e.g. as standard transformer module 26 a or as transformer module 26 b with helihoist platform 28 . In the same way there can exist alternative designs concerning the other modules 22 - 24 . The connection of the modules 22 - 26 can be achieved as disclosed in the context with the embodiment of FIG. 1 . The modules 22 - 26 b have preferably substantially the same properties as the modules 4 - 8 . | The invention concerns a module of a nacelle of a wind turbine, which is separately designed, manageable and comprise a housing part. The module is connectable to at least one further module of the nacelle, which is also separately designed, manageable and has a housing part, wherein the housing part of the module builds in the assembled status of the nacelle, which comprises several modules, a part of the housing of the nacelle. The invention concerns also a nacelle comprising several such modules, a wind turbine comprising such a nacelle as well as a method for the stepwise assembly of such a nacelle aloft. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to treatment of waste paper, waste paperboard or the like furnish to be recycled.
Due to the ecological and environmental considerations, the cost of virgin fibre and other factors, the optimizing of the recycling of waste paper etc. has now for some time been recognized as a very important aspect of papermaking technology.
One of the problems associated with paper recycling is the removal of print, coating or the like surface treatment to which the paper or cardboard may have been previously subjected. The removal of these components is subject of de-inking technology in paper making. The present invention is particularly, but not exclusively, directed to this field.
Industrial application of the presently available de-inking technologies is associated with relatively heavy use of de-inking chemicals which is expensive and environmentally undesirable. The known methods of deinking of waste paper or the like also require heavy use of cleaning and washing equipment which results in the requirement of a high investment capital. The demands for treatment water are also very high. Energy consumption associated with deinking and cleaning is also relatively high. And the presently available deinking technology has been shown to be inadequate for some furnished, so that the industry is not able to successfully reprocess all of the materials available.
Attempts have been made to alleviate at least some of the problems associated with the deinking of waste paper. For instance, in an article by H. Mamers. "The Siropulper--a new concept in wastepaper recovery" (APPITA, vol. 32, No. 2, pp. 124-128, September, 1978), the use of an explosive release digester is described for defibration purposes which may be used in de-inking. The article suggests that hydrodynamic forces of the explosive discharge combine with the chemical effects of the cooking process to release the ink particles from the fibres, reducing the chemical demand of the process. The increase of the pressure to achieve the required hydrodynamic conditions is effected by injecting pressurized inert gas into a reactor or digester.
The last mentioned method presents advance in that it contains the promise of reduced use of de-inking chemicals thus providing the potential for environmental improvement. The shortening of the processing period is another improvement over previous methods. Yet, certain disadvantages are still associated with this method. In particular, tests conducted in order to determine feasibility of the method described have shown that the quality of the final product of the method often does not reach the desired standard, particularly with respect to the appearance parameters of the final product.
SUMMARY OF THE INVENTION
It is an object of the present invention to further advance the art of recovery of wastepaper and the like material and in particular to maintain the lowest possible use of de-inking chemicals or to even entirely eliminate their use while providing a high quality of the appearance and other parameters of the final product.
In general terms, the present invention provides a method for treatment of waste paper, waste paperboard or the like furnish, or mixtures thereof, containing contaminants that had been introduced in printing, coating or the like surface treatment of the paper, paperboard or the like contained in said furnish, said method comprising the steps of:
i) feeding said furnish into a digester;
ii) feeding into said digester saturated steam at superatmospheric pressure and increasing the pressure in said digester to a superatmospheric pressure, substantially due to the saturated steam, to produce a furnish/steam mixture;
iii) raising the temperature of the furnish contained within the digester, substantially due to the superatmospheric saturated steam introduced in step ii), to a temperature ranging from about 160° C. to about 230° C.;
iv) maintaining said mixture within the digester at said temperature for a predetermined dwell time;
v) discharging the furnish from said digester; and
vi) subjecting the thus discharged furnish to further processing eventually resulting in the production of a recycled sheet of paper, paperboard or the like.
The term "surface treatment" as used in this specification includes techniques such as printing, coating or the like, all well known to those skilled in the art.
The invention is based on a surprising discovery that if wastepaper or the like furnish is cooked in a digester in saturated steam, then the cooking temperatures may be in a substantially higher range than previously accepted temperatures for this stock without impairment of mechanical quality of the final sheet produced from the recycled furnish.
It was further surprising that the high temperatures, in the range as defined above, result in significantly smaller residual contaminant particle sizes than those formed from convention repulping. The degree of reduction of the size of the particles is significant as smaller sized particles are more easily dispersed throughout the sheet. They are less offensive to the eye. Some of them are too small to be seen by the eye.
The smallness of particle size achieved by the inventive process appears to be accompanied by a more effective stripping of the particles from the fiber and, in many instances, in the ability of the papermaking cleaning and screening process to more effectively subsequently remove the particle.
Laboratory tests conducted with the inventive method further show that the need for de-inking chemicals is not only reduced but, in many instances, entirely eliminated, while the final products exhibit visual and other qualities equal to or surpassing those made by presently known methods including the above prior art reference.
In our research, we have found that the temperature, not the pressure used in the digester, is the main factor for achieving the desired quality. The injecting of inert gas was found unnecessary. Also surprisingly, while the explosive discharge from the digester (as opposed to a gradual release of pressure) is advantageous in some instances, it does not appear significantly to influence the de-inking efficiency in other tests conducted.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in detail with reference to the following examples based on laboratory tests, and also referring to the drawings, wherein:
FIG. 1 is a microscopic photograph of a sheet made from a control furnish of coated paper CP 15 C, as referred to hereinafter;
FIG. 2 is a microscopic photograph of a sheet made from furnish CP 15 referred to hereinafter;
FIGS. 3 and 4 are similar to FIGS. 1 and 2, but show the sheets of furnishes CP2C and CP2, respectively;
FIGS. 5 and 6 are diagrammatic representations of the definition of steam treatment severity showing the relationship between temperature and dwell time.
DETAILED DESCRIPTION
Test Conditions
The following data, tables and examples are the results of multiple experiments using multiple furnishes and evaluated by multiple evaluation techniques. As we progressed from one experiment to another we expanded and/or modified our experimental design frequently. Thus it will be seen that not all samples were prepared or tested in the same manner from one experiment to another.
The major evaluation techiques used include:
% Debris--a measure of the reduction in contaminant particle size by measuring the amount (%) of reject upon passage through a 0.006" slotted screen.
Image Analysis--a state-of-the-art computer assisted technique using a contrasting magnifier and integrator to identify and quantify residual contaminants in various size ranges. Data presented includes the averate spot size in mm 2 and the mm 2 dirt/ft 2 paper. Generally speaking, the two readings are most beneficial when interpreted together, but average spot size alone has consistently demonstrated the superiority of products made according to the present invention.
Bauer McNett fiber classification--a screening technique used to classify fiber by length. For purposes of the present experimentation, no significant changes in fiber length classifications suggest no changes or degradation to the fibers during repulping.
Tear, breaking length and stretch--common paper industry standard tests to evaluate strength of various pulps and papers.
Expert panel evaluation--Wisconsin Tissue Mills and Chesapeake Corp. belong to industry leaders in the fields of deinking and secondary fiber usage. Various experts within the two companies were used as panelists for sample evaluation. Evaluation techniques included paired comparisons between variables, paired comparisons between a variable and a control and simple judgement descriptions.
Three different furnishes were selected at first. They were groundwood (GR), coated paper (CP) and office waste (OW). Each furnish was processed independently through explosion pulping process using processing variables of consistency, soak chemistry, pulping temperature and pulping time. The pulps thus produced were made into handsheets. Control handsheets were made from the same furnish. Judgements as to handsheet qualities of the first tests conducted were made by visual estimations only. That is to say, the respective pulps were not tested for fibre strength, or general fibre quality. Rather, the judgements included brightness, whiteness, cleanliness, degree of ink dispersion, and the general overall appearance of the handsheets.
The pulping of the furnish was done by taking 50 g of furnish and subjecting it to a pre-processing chemical soak. The chemistries of the soak included:
a) water only;
b) 0.4% (w/w) of Wetsan WT-225 surfactant (a tradename of SANTEC Chemical Co.--active ingredients include <10% 2-butoxyethanol and <20% phosphoric acid) along with 1.25% (w/w) of caustic soda in water. (This is subsequently referred to as "WTM chemistry" for convenience);
c) 0.4% (w/w) Wetsan WT-225+1.25% (w/w) of caustic soda+2.0% (w/w) of hydrogen peroxide in water; and
d) 4% (w/w) citric acid in water.
The furnish consistency in the chemical soak was either 50% or 30%. Following the soak (generally about 1/2 hour), the pulp samples were inserted into the laboratory reactor.
The laboratory reactor was the product of Stake Technology. It is a jacketed, enclosed stainless steel container with a capacity of about 1 liter. Raw, presoaked material furnish was added via a top Kamyr ball valve. The discharge valve opened into a reservoir for the recovery of the processed material.
Saturated steam (up to 450 psig) was produced by a high pressure boiler and introduced via an accumulator into the reactor. Two inlets of steam were present, one located immediately below the sampling lid and the other immediately above the Kamyr ball valve.
In a typical operation, pre-soaked raw material was introduced into the reactor which was then closed. Saturated steam at a desired temperature (pressure) was added to bring the reactor and sample temperature and pressure to the desired setting. The controlled temperature variables were 160° C., 170° C., 190° C., 210° C. or 230° C. (corresponding to pressures of about 75, 100, 165, 261 and 391 psig, respectively).
For a predetermined duration of 1, 3, 4 or 10 minutes, the pulps were allowed to stay in the reactor chamber. The material was then discharged explosively across the bottom Kamyr valve by the sudden release of pressure from the pressure prevailing in the reactor to the atmospheric pressure in the reservoir. Test were also conducted in which the explosive release was substituted by gradual pressure release (bleed). The reservoir door was subsequently opened to recover the discharged material for further evaluation.
At the same time, the same furnishes were also pulped in a laboratory, according to the standard prior art technique: 30 g of shreddedfibre was placed in 500 ml H 2 O, to which has been added 0.5 ml of a 50% caustic soda solution and 0.1 ml of the Wetsan WT-225. The mixture was agitated by a Lightning mixer at a temperature of 160° F. for 20 minutes to 1 hour and then handsheets were prepared. Such samples were then labelled "controls" (e.g. GR2C).
For certain comparative tests referred to hereafter, the Stake Technology reactor was modified to enable injection of inert gases (such as nitrogen) into the reactor before or during the steam treatment of the raw material in the reactor. Gas was introduced from a regulated gas tank via a gas line which opened into the reactor. This setup permitted the simulation of the de-inking method as described in the reference mentioned at the outset by enabling increase in reactor pressure over the steam pressure used in the treatment.
The samples were removed and carefully washed three times to remove any residual chemicals. The pulping samples thus obtained were then made into handsheets for evaluation.
Paired comparisons of the various cells were then made, based on single processing variable changes. The winners of these comparisons were then judged by a panel of papermaking experts to be "acceptable" or "unacceptable" to Wisconsin Tissue of Menasha, Wis. (WTM) as a processed pulp furnish, and were then further compared to the WTM handsheets controls to see which was better. The ratings were based on visual inspection and included the collective and combined judgements of the experts. The experts noted samples on overall appearance, brightness, degree of uniformity, and general past experience and knowledge of the trade.
As a result of the encouraging observations made from these experiments, additional samples were then prepared and laboratory comparisons were made by checking Canadian Standard Freeness (Freeness, CSF), bulk, brightness and opacity, tear, breaking length, stretch. Bauer McNett fibre classification was used as a fibre length fractionation technique. Other evaluative techniques included image analysis by way of a computer aided technique identifying, quantifying, and integrating particles visible on the surface of a paper as they contrast with the background. The various options of evaluation used from image analysis in the experiments included mean particle size of residual contaminants and total sample area covered by residual contaminants. Other comparisons involved the % debris collected on a 0.006" screen and, as already mentioned, visual ratings by a panel.
Image analysis measurements show that the mean particle size of the residual contaminants had decreased from those evident in the controls. Furthermore, within the experimental ranges tried, there does not appear to be any serious or consistent change in fibre quality as a function of the processing variable used. Thus, it is assumed that the time, temperature and chemical ranges described are valid for the particular furnish.
Visual examination by experts, and image analysis of residual particle size consistently demonstrates the superiority of pulps and papers produced by the art disclosed in this invention. On a case by case basis, one can often actually pinpoint an optimum blend of processing conditions. In other cases it can be seen that extrapolation or interpolation within the available matrix points readily suggest the best processing conditions and/or limits.
The tests referred to in the following examples are taken from laboratory and industrial tests conducted jointly by the assignees of the present application, Stake Technology Ltd. of Norval, Ont., Canada; and Chesapeake Resources Company, of Richmond, Va., U.S.A. For easy reference the samples or cells referred to hereafter are designated with their original numbering allocated during the respective tests. The sample numbers appearing in some of the tables therefore are seemingly random and not in a consecutive order with certain numbers left out depending upon the particular Example mentioned. The particular designation numbers, however, are consistent throughout the disclosure.
EXAMPLE 1
A total of nine (9) different cells of office waste furnish (post-consumer waste, consisting of office files, computer printouts, envelopes, etc.) were run, encompassing variations of two consistencies, two chemical pre-treatments, four pulping temperatures and three dwell times. Seven paired comparisons were made. The trial matrix and cell comparison data are shown in TABLE 1 and TABLE 2.
TABLE 1______________________________________OFFICE WASTE FURNISH TRIAL SOAK SOAK PULPING PULPINGSAMPLE CONSIS- CHEM- TEMPER. TIMENUMBER TENCY ISTRY °C. (MIN)______________________________________18 30 WTM 190 119 30 WTM 170 120 30 WTM 170 327 30 WTM 190 4137 50 WTM 210 4138 50 WTM 230 4139 50 H.sub.2 O 230 4 5 50 WTM 190 1 6 50 H.sub.2 O 190 1______________________________________
Table 1 shows that the tests conducted with samples or cells 18-20; 27; 137-139; 5 and 6 were soaked at different consistencies. The soak chemistry corresponded to the WTM chemistry referred to above. In two cells, Nos. 139 and 6, no chemicals were added to the presoak water. The range of temperatures shown is from 170° to 230° C. and the pulping or dwell time range 1 to 4 minutes.
Various pairs of the above cells were then compared with each other to obtain indication of the superiority of the inventive technology and to compare the possible influence of the different processing variables. Expert panel rankings showed that samples preapred by the inventive technology were superior to the controls and that some directions in processing technology variables could be suggested.
With the preliminary results at hand, a larger scale of laboratory tests were conducted with a number of samples, referred to as runs OW 1-18, which included two comparison runs OW2C and OW13C which were processed by way of standard deinking procedure as referred to above. The results are contained in TABLES 2A and 2B, the latter being the continuation of the former. TABLES 2A, 2B also show the process conditions including the chemicals added.
TABLE 2A__________________________________________________________________________DEINKING OF OFFICE WASTES (PART ONE)DESIG.: OW; RUN NO: 1 2 2C 3 4 5 6__________________________________________________________________________(a) YIELDS (%): 69.32 65.9(b) FREENESS (CSF, ml.): 416 430 558 432 431 469 470(c) BULK (cm.sup.2 /g): 1.97 1.87 2.07 1.91 1.89 1.99 2.12(d) BRIGHTNESS (3.0 g, %): 60.5 -- -- 60.2 61.4 59.3 55.4(e) BRIGHTNESS (1.2 g, %): 61.0 61.5 73.3 60.2 61.7 59.7 55.9(f) OPACITY (%): 92.5 90.3 86.6 93.2 91.9 93.0 93.6(g) HANDSHEET BASE WT (g): 63.3 62.0 59.5 61.8 58.8 59.2 60.7(h) TEAR (mN*M.sup.2 /g): 10.4 10.5 11.8 10.6 10.5 10.2 10.9(i) BREAKING LENGTH (km): 3.7 3.3 3.5 3.7 3.7 3.2 3.8(j) STRETCH (%): 2.4 2.8 2.4 2.5 2.5 2.3 2.0 FIBER CLASSIFICATION (BAUER MCNETT %):(k) +14 7.1 7.1 5.0 5.6 11.2 8.0 113(l) +28 10.7 20.3 16.5 16.6 17.3 19.7 17.2(m) +48 36.0 22.6 22.4 26.2 30.1 29.3 26.5(n) +100 19.3 23.0 19.1 20.0 19.1 19.4 15.8(o) +200 7.9 8.6 6.7 9.3 7.7 7.9 7.0(p) -200 19.0 18.4 30.3 22.3 14.6 15.7 22.2 PROCESSING CONDITIONS:(q) CONSISTENCY: 50 50 5.4 50 50 50 50 CHEMICALS:(r) WETSAN (% W/W) 0.4 0.4 0.4 0.4 -- -- --(s) NaOH (% W/W) 1.25 1.25 1.25 1.25 -- -- --(t) Na.sub.2 CO.sub.3 (% W/W) -- -- -- -- -- -- --(u) TEMPERATURE (°C.): 203 203 71 203 203 203 190(v) TIME (MIN): 2 4 60 6 2 4 6__________________________________________________________________________
TABLE 2B__________________________________________________________________________DEINKING OF OFFICE WASTES (CONT.)# 7 8 9 10 11 12 13 13C 14 15 16 17 18__________________________________________________________________________(a)(b) 423 391 367 415 481 410 442 470 456 474 510 458 454(c) 1.93 1.97 2.09 2.04 2.04 1.85 1.99 2.04 1.99 1.98 1.88 2.11 2.23(d) 64.4 54.2 49.6 59.6 64.1 69.1 -- -- 64.7 63.2 67.5 62.2 66.3(e) 63.9 56.2 47.6 59.8 64.8 69.0 66.3 61.6 65.2 63.0 67.6 63.4 67.9(f) 88.0 94.4 98.3 93.9 90.0 90.6 92.2 88.6 92.1 92.6 89.4 92.9 92.3(g) 60.8 59.8 61.6 57.9 60.4 61.8 60.3 60.4 62.3 61.2 60.8 57.8 58.4(h) 10.6 10.8 7.4 9.0 11.5 10.5 11.4 10.3 11.7 11.9 8.7 11.5 12.2(i) 4.6 3.0 2.2 3.3 3.2 3.6 2.8 3.6 3.2 3.4 3.4 4.0 2.8(j) 2.6 2.5 2.0 2.4 2.6 2.6 2.5 2.2 2.4 2.8 2.7 2.6 2.5(k) 11.1 9.7 7.3 8.7 12.3 10.2 9.0 10.1 9.9 12.2 8.1 9.2(l) 21.5 17.6 16.7 16.5 14.9 16.7 18.8 9.8 16.8 16.2 14.7 14.6(m) 32.5 28.5 27.0 28.4 29.9 28.6 22.4 15.5 27.7 25.9 26.1 26.5(n) 19.0 17.3 18.1 17.9 17.5 16.8 21.7 12.2 17.5 15.6 16.9 17.2(o) 2.8 9.8 11.3 7.8 7.7 7.6 8.7 5.4 7.0 6.8 7.9 8.1(p) 13.1 17.1 19.6 20.7 17.7 20.0 19.4 37.0 21.1 23.3 26.3 24.4(q) 50 50 50 50 50 50 50 5.3 50 50 50 50 50(r) 0.4 0.4 0.4 -- -- -- -- -- 0.4 -- -- 0.4 --(s) 1.25 1.25 1.25 -- -- -- 1.25 1.25 -- 1.25 -- 1.25 1.25(t) -- -- -- -- -- -- * * -- -- * -- *(u) 190 190 190 190 190 190 203 71 203 203 203 210 210(v) 2 4 6 2 4 6 4 60 4 4 4 4 4__________________________________________________________________________ *to pH 11
TABLE 3 shows some results of image analysis conducted for the runs OW1-OW18, utilising a state of the art quantitative photographic analysis of background spots (contaminants). The particular program used differentiated and quantified the spots in classes ranging from 0.0400 mm 2 to 500.00 mm 2 . The data presented in the table includes four important counts used in image analysis. The accumulated field area was 15731.49 sq. mm (0.1693 sq. ft.) for each sample.
TABLE 3______________________________________IMAGE ANALYSIS OF PROCESSED OF OFFICE WASTE AVER. SPOT SQ. MM DIRT/RUN SIZE (mm.sup.2) SQ. FT PAPER______________________________________OW1 0.2886 839OW2 0.2736 903OW3 0.293 746OW4 0.2888 517OW5 0.2878 707OW6 0.2795 577OW7 0.2729 1350OW8 0.286 785OW9 0.4727 324OW10 0.3687 1145OW11 0.2678 429OW12 0.3287 598OW13 0.3368 549OW14 0.3321 804OW15 0.3078 275OW16 0.2944 563OW17 0.2698 400OW18 0.2715 545OW2C 1.5911 987OW13C 0.5148 875______________________________________
The surprising result is to be seen in several aspects apparent from the tables. First, very high temperatures, much higher than the accepted norm--see the control samples, when used under the conditions of the present invention, do not result in noticeably higher degradation of the fibre, as witnessed by the values of items (a) through (p) of TABLES 2. Secondly, the absence of any added chemicals in runs OW4-OW6 and OW10-OW12 further indicates the potential of reduced chemical costs and reduced costs of treatment of effluents. Finally, the substantial shortening of the pulping time is also to be noted. TABLE 3 shows that image analysis demonstrates them to be superior to products of conventional deinking methods in that the mean residual particle size is significantly smaller than those found in the control samples.
EXAMPLE 2
Eight different cells of coated furnish (numbered 21-23, 28, 135, 136, 3 and 4) were run encompassing variations of two (2) consistencies, two (2) chemical pre-treatments, three (3) pulping temperatures and three pulping times. The furnish contained bleached sulphite or sulphate papers, printed or unprinted in sheets, shavings, guillotined books or quire waste. A reasonable percentage of papers containine fine groundwood may be present. Eight (8) paired comparisons were made. Matrix processing variables may be found in Table 5.
TABLE 4______________________________________COATED FURNISH TRIAL MATRIX SOAK SOAKSAMPLE CONSIS- CHEM- PULPING PULPINGI.D. TENCY ISTRY TEMP. TIME______________________________________21 30 WTM 170° 122 30 WTM 170° 323 30 WTM 190° 128 30 WTM 190° 4135 50 H.sub.2 O 190° 4136 50 H.sub.2 O 210° 4 3 50 WTM 190° 1 4 50 H.sub.2 O 190° 1______________________________________
The encouraging results seen by a panel of experts dictated further experimentation.
A subsequent upscale trial of coated furnish was conducted with samples CP1 to CP16, and compared with control runs CP2C and CP15C. The procedure used and results obtained are tabulated in TABLES 5A and 5B, the latter being a continuation of the former. Likewise, TABLE 6 shows the result of the results of image analysis of the samples CP1-CP16. Reference may also be had to FIGS. 1-2 and 3-4 showing microscopic photographs of the sheets made from the respective furnishes. Each unit on the scale shown in the drawings corresponds to 25/1000 mm.
TABLE 5A__________________________________________________________________________DEINKING OF COATING PAPER RUN NO: CP1 CP2 CP2C CP3 CP4 CP5 CP6__________________________________________________________________________(a) YIELDS (%):(b) FREENESS (CSF, ml.): 508 495 531 508 529 538 536(c) BULK (cm.sup.2 /g): 1.67 1.69 1.72 1.70 1.65 1.72 162(d) BRIGHTNESS (3.0 g, %): 54.5 -- -- 54.6 56.4 55.8 55.2(e) BRIGHTNESS (1.2 g, %): 52.6 53.0 49.6 52.6 54.4 54.1 53.8(f) OPACITY (%): 99.3 98.7 99.2 98.8 99.2 99.3 98.5(g) HANDSHEET BASE WT (g): 60.2 62.6 60.0 60.2 61.4 61.5 59.7(h) TEAR (mN*M.sup.2 /g): 10.9 10.7 11.3 11.4 10.8 10.1 10.6(i) BREAKING LENGTH (km): 4.6 3.9 4.3 4.4 3.9 3.7 3.6(j) STRETCH (%): 2.6 2.9 2.4 2.6 2.6 2.7 2.8 FIBER CLASSIFICATION (BAUER MCNETT %):(k) +14 3.4 5.0 3.1 4.7 11.2 2.6 4.3(l) +28 14.5 17.7 14.7 13.5 17.3 11.3 14.9(m) +48 18.6 13.7 13.6 20.9 30.1 12.1 15.0(n) +100 20.3 22.7 18.5 15.8 19.1 17.2 20.6(o) +200 7.7 11.8 8.7 6.6 7.7 8.1 8.6(p) -200 16.5 29.1 41.4 38.5 39.7 48.7 36.6 PROCESS CONDITIONS:(q) CONSISTENCY: 30 30 5.4 30 30 30 30 CHEMICALS:(r) WETSAN (% W/W) 0.4 0.4 0.4 0.4 -- -- --(s) NaOH (% W/W) 1.25 1.25 1.25 1.25 -- -- --(t) Na.sub.2 CO.sub.3 (% W/W) -- -- -- -- -- -- --(u) H.sub.2 O.sub.2 -- -- -- -- -- -- --(v) Na.sub.2 SiO.sub.3 -- -- -- -- -- -- --(w) Na.sub.2 S.sub.2 O.sub.4 -- -- -- -- -- -- --(x) TEMPERATURE (°C.): 190 190 71 190 190 190 190(y) TIME (MIN): 2 4 60 6 2 4 6__________________________________________________________________________
TABLE 5B__________________________________________________________________________DE-INKING OF COATED PAPER (CONT.)CP 7 8 9 10 11 12 13 14 15 15C 16__________________________________________________________________________(a)(b) 572 580 528 519 523 541 528 556 481 5351.93 508(c) 1.76 1.74 1.56 1.65 1.66 1.61 1.64 1.68 1.68 -- 1.67(d) 53.6 56.5 56.9 52.6 54.3 53.2 54.3 54.4 -- 51.7 54.7(e) 54.6 54.9 54.0 51.7 52.2 52.6 52.6 53.7 54.9 98.4 51.7(f) 98.3 98.5 99.0 98.6 99.4 98.7 98.6 99.0 98.0 60.7 99.2(g) 58.7 59.9 60.4 60.4 60.8 61.9 61.3 60.7 60.5 13.9 60.6(h) 12.3 8.3 9.6 11.9 11.2 11.6 11 11.4 11.3 3.9 10.2(i) 3.2 3.1 4.3 5.3 4.2 4.3 4.7 4.1 4.7 2.4 4.6(j) 2.2 2.6 2.6 3.0 2.7 2.9 2.8 2.9 3.1 2.6(k) 3.0 4.0 4.5 6.4 5.1 5.7 5.5 4.0 6.5 4.2(l) 13.4 13.6 14.9 16.0 13.9 15.3 14.5 13.3 18.9 12.4(m) 13.8 14.4 15.0 24.5 21.6 18.5 21.5 18.4 17.4 20.5(n) 20.5 21.3 20.1 18.9 15.8 21.4 17.6 16.5 24.9 16.2(o) 8.3 9.8 8.3 7.2 6.3 7.4 6.6 6.7 9.3 6.4(p) 41.0 36.9 37.2 27.0 37.3 31.7 34.3 41.1 23.0 40.3(q) 50 50 340 30 30 30 30 30 30 5.4 30(r) 0.4 -- 0.4 -- -- -- -- -- 0.4 0.4 0.4(s) 1.25 -- -- 1.25 1.25 1.25 -- -- 1.25 1.25 1.25(t) -- -- -- -- -- pH 1 pH 1 -- -- --(u) -- -- -- 2.0 -- -- -- -- 2.0 2.0 --(v) -- -- -- 3.0 -- -- -- -- 3.0 3.0 --(w) -- -- -- -- -- -- -- 1.0 -- -- --(x) 190 190 190 190 190 190 190 190 190 71 170(y) 4 4 4 4 4 4 4 4 4 60 4__________________________________________________________________________
TABLE 6______________________________________IMAGE ANALYSIS OF COATED PAPER AVER. SPOT SQ. MM DIRT/RUN SIZE (mm.sup.2) SQ. FT PAPER______________________________________CP1 0.1151 13.59CP2 0.0657 1.94CP3 0.1023 5.44CP4 0.1105 16.31CP5 0.1262 18.64CP6 0.0958 19.80CP7 0.1388 14.75CP8 0.1377 60.18CP9 0.1188 37.69CP10 0.0986 1.16CP11 0.1315 10.87CP12 0.07 0.41CP13 0.0877 1.55CP14 0.2893 8.54CP15 0 0.00CP16 0.1315 10.87CP2C 0.1681 295.30CP15C 0.2486 1860.88______________________________________
EXAMPLE 3
The third series of tests was conducted with groundwood furnish. The furnish was comprised of coated groudwood sections including new printed coated groundwood papers in sheet, section, or shavings, or guillotined books. This grade does not include news quality groundwood papers. In this example, ten (10) different cells were run, encompassing variations of two (2) consistencies, three (3) chemical pre-treatments, four (4) pulping temperatures, and three (3) pulping times. Ten (10) paired comparisons were made. The trial pulping temperatures and three (3) pulping or dwell times. Ten (10) paired comparisons were made. The trial matrix and cell comparison data may be found in TABLE 7.
TABLE 7______________________________________GROUNDWOOD FURNISH, TRIAL MATRIX SOAK SOAKSAMPLE CONSIS- CHEM- PULPING PULPINGI.D. TENCY ISTRY TEMP. TIME______________________________________24 30 WTM 190° 125 30 WTM 170° 126 30 WTM 170° 329 30 WTM 190° 430 30 WTM & 190° 1 H.sub.2 O.sub.2131 50 WTM 210° 4132 50 WTM 230° 4133 50 H.sub.2 O 210° 4134 50 H.sub.2 O 230° 4 7 50 WTM 190° 1 8 50 H.sub.2 O 190° 1______________________________________
Again, a series of panel comparisons were rated by a panel of experts and the inventive technology gave superior quality products warranting further experimentation.
A subsequent upscale trial of groundwood furnish was conducted with samples GR1 to GR11, and compared with control runs GR2C and GR10C. The procedure used and results obtained are tabulated in TABLES 8A and 8B, the latter being a continuation of the former. Likewise, TABLE 9 shows the result of image analysis of the samples GR1-GR11.
TABLE 8A__________________________________________________________________________DEINKING OF GROUNDWOOD RUN NO: GR1 GR2 GR2C GR3 GR4 GR5__________________________________________________________________________(a) YIELDS (%):(b) FREENESS (CSF, ml.): 219 205 239 249 283 259(c) BULK (cm.sup.2 /g): 1.91 1.93 1.91 1.74 1.83 1.78(d) BRIGHTNESS (3.0 g, %): 63.2 64.5 -- 63.7 64.0 63.2(e) BRIGHTNESS (1.2 g, %): 61.8 63.1 61.8 62.8 63.5 62.6(f) OPACITY (%): 98.2 98.5 98.2 98.4 97.9 98.1(g) HANDSHEET BASE WT (g): 60.7 60.5 60.7 60.4 59.6 59.0(h) TEAR (mN*M.sup.2 /g): 9.7 9.6 9.7 9.7 9.4 9.1(i) BREAKING LENGTH (km): 3.3 4.3 3.3 4.2 4.0 4.0(j) STRETCH (%): 2.1 2.8 2.1 2.5 2.6 2.6 FIBER CLASSIFICATION (BAUER MCNETT %):(k) +14 7.3 5.3 4.2 15.5 5.5 5.7(l) +28 15.8 16.2 17.5 15.1 15.1 12.2(m) +48 6.8 15.5 15.8 18.8 20.1 8.9(n) +100 26.9 14.3 14.2 12.3 12.9 14.0(o) +200 8.4 6.7 9.3 7.5 8.0 7.8(p) -200 34.8 42.0 39.0 30.8 38.4 51.4 PROCESS CONDITIONS:(q) CONSISTENCY: 30 30 5.4 30 30 30 CHEMICALS:(r) WETSAN (% W/W) 0.4 0.4 0.4 0.4 -- --(s) NaOH (% W/W) 1.25 1.25 1.25 1.25 -- --(s1) H.sub.2 O.sub.2 (% W/W) -- -- -- -- -- --(s2) Na.sub.2 SiO.sub.3 -- -- -- -- -- --(t) Na.sub.2 S.sub.2 O.sub.4 (% W/W) -- -- -- -- -- --(u) TEMPERATURE (°C.): 190 190 71 190 190 190(v) TIME (MIN): 2 4 60 6 2 4__________________________________________________________________________
TABLE 8B__________________________________________________________________________DEINKING OF GROUNDWOOD (CONT.) RUN GR NO: 6 7 8 9 10 10C 11__________________________________________________________________________(a) YIELDS (%):(b) FREENESS (CSF, ml.): 261 274 254 218 175 280 200(c) BULK (cm.sup.2 /g): 1.82 1.80 1.84 1.80 2.01 1.93 1.89(d) BRIGHTNESS (3.0 g, %): 63.7 61.9 61.2 64.5 65.8 -- 64.7(e) BRIGHTNESS (1.2 g, %): 63.4 61.3 54.3 64.0 64.3 65.0 63.7(f) OPACITY (%): 98.3 97.7 99.4 97.6 97.9 97.8 98.1(g) HANDSHEET BASE WT (g): 60.2 59.9 60.8 60.2 60.4 62.8 60.6(h) TEAR (mN*M.sup.2 /g): 9.0 9.7 9.6 9.7 10.8 9.2 9.3(i) BREAKING LENGTH (km): 3.9 3.7 3.7 4.5 4.9 3.5 4.5(j) STRETCH (%): 2.6 2.8 2.7 2.7 2.6 2.3 2.7 FIBER CLASSIFICATION (BAUER MCNETT %):(k) +14 5.4 7.8 5.1 5.3 6.8 5.1(l) +28 1.40 15.9 14.4 14.9 18.2 14.7(m) +48 19.3 18.1 18.3 19.8 15.6 19.7(n) +100 10.9 13.3 7.9 7.1 15.4 12.3(o) +200 8.2 8.3 12.8 11.9 7.7 7.4(p) -200 42.2 36.6 41.5 41.0 36.3 40.8 PROCESS CONDITIONS:(q) CONSISTENCY: 30 50 50 30 30 5.4 30 CHEMICALS:(r) WETSAN (% W/W) -- 0.4 -- -- 0.4 0.4 --(s) NaOH (% W/W) -- 1.25 -- 1.25 1.25 1.25 --(s1) H.sub.2 O.sub.2 (% W/W) -- -- -- 2.0 2.0 2.0 --(s2) Na.sub.2 SiO.sub.3 -- -- -- 3.0 3.0 3.0(t) Na.sub.2 S.sub.2 O.sub.4 (% W/W) -- -- -- -- -- -- 1.0(u) TEMPERATURE (°C.): 190 190 190 190 190 71 190(v) TIME (MIN): 6 4 4 4 4 60 4__________________________________________________________________________
TABLE 9______________________________________IMAGE ANALYSIS OF GROUNDWOOD AVER. SPOT SQ. MM DIRT/RUN SIZE (mm.sup.2) SQ. FT PAPER______________________________________GR2 0.2137 5.05GR3 0.263 12.42GR4 0.3068 32.61GR5 0.2475 24.85GR6 0.1863 6.60GR7 0.2959 10.48GR8 0.2446 36.11GR10 0.263 7.77GR11 0.526 21.74GR2C 0.5917 27.96______________________________________
The tests of groundwood also included experiments with old newsprint (ONP) and old telephone books (OTB) with very promising results.
EXAMPLE 4
Two samples of ONP--old newsprint (Nos. 1/2 and 3/4) were processed in accordance by the inventive method using explosive release.
Test sample 1/2 was cooked for 2 minutes at 160° C. Water only was used as chemistry, and temperature was the only processing variable. The following appearance values prevailed: % debris1.7; mean particle size after release: 1.0649; total particle area: 508.818. The expert rating was "excellent".
Subsequent sample 3/4 was cooked at 170° C. for 2 minutes. Water only was used chemistry, and temperature was the only processing variable. The following appearance values prevailed: % debris:0.56; mean particle size in mm 2 :0.8484; total particle area in mm 2 :285.09. The rating by the panel of experts was "excellent".
EXAMPLE 5
The testing series of groundwood also included samples Nos. 5, 6, 7, 10 and 11, all being furnishes of old telephone books. It is known that the processing of telephone books is severly hindered by the bindings. This prevents the majority of waste paper recyclers from enjoying the benefits of using old telephone books as a cheap and commodeous furnish. We have found that the re-processing of the pages of telephone books posed no problem for the inventive technology, so we challenged the inventive technology with a furnish of concentrated old telephone book binders only. The test results are tabulated in the following TABLE 10. The table shows that the temperature range tested was from 200° to 220° C. All telephone book furnishes listed have been processed with water only, with no chemicals added. However, it can be reasonably assumed that certain chemicals, if added, would improve the results still further.
TABLE 10__________________________________________________________________________OLD PHONE BOOKS - PROCESS AND TEST RESULTS MEAN TOTAL PARTICLE PARTICLE %SAMPLE TIME TEMP. SIZE AREA DEBRIS RANKINGS__________________________________________________________________________#11 6 220° C. 0.4334 49.843 0.25 browning#9 2 220° C. .2297 49.843 1.7 excellent#7 6 210° C. .2794 38.003 0.91 very good#6 2 210° C. .2753 139.324 1.3 excellent#5 4 200° C. .3004 95.826 0.81 excellent#10 4 220° C. .2711 46.899 1.1 very good__________________________________________________________________________
Old telephone books are primarily groundwood, but are more difficult to repulp because of the bindings. The success generated by the low mean particle sizes, low % debris and "very good" to "excellent" panelist ratings agains shows the superiority of the inventive technology and process. It can be reasonably assumed from the following discussion and process severity formula establishing the relationship between temperatures and dwell time, that 180° C. is the lower limit for OTB.
EXAMPLE 6
The invention was also tested extensively with the old corrugate container furnish (OCC) (baled corrugate containers having liners of either test liner, jute or kraft) with surprisingly good results tabulated in TABLE 14, together with the respective process data.
TABLE 11__________________________________________________________________________OLD CORRUGATE CONTAINERS MEAN TOTAL PARTICLE PARTICLE % EXPERTFURNISH TIME TEMP. SIZE (mm.sup.2) AREA (mm.sup.2) DEBRIS RATINGS__________________________________________________________________________Good OCC 220° C. 0.2924 426.627 -- ETC*LFHD control -- -- 0.2653 44.313 -- averageSFHD control -- -- 0.3727 99.145 -- averageBad OCC 2 230° C. -- -- 3.4% excellentBad OCC 2 210° C. -- -- 12.6% excellentUMc, OCC 2 215° C. -- -- -- SCQ**waxy OCC 6 220° C. -- -- -- ***Wet strength 8 220° C. 0.4432 17.726 0.16% excellentOCC__________________________________________________________________________ *ETC = equivalent to commercial **SCQ = superior to commercial quality *** = better than possible with conventional commercial equipment
In TABLE 11, LFHD and SFHD stand for long fibre high density and short fibre high density, respectively. These represent fibres which have been fully cleaned and screened in a conventional commercial deinking system and which have also then been fractionated by fibre length as the last processing prior to use. The fact that the experimental sample shows a roughly equivalent mean residual particle size without any cleaning clearly demonstrates the superiority of the pulps processed by this invention.
Processing treatment for all samples in Table 11 was water only. The combination of image analysis and expert ratings has shown that the inventive technology works for furnishes such as wet strength OCC where it is known that conventional processing is inadequate.
EXAMPLE 7
In this group of examples and tests, comparisons were made to establish the influence of explosive release on the overall de-inking efficiency of the method according to the present invention.
The testing was performed using a batch steam explosion reactor which was modified to accommodate inert gas injection. Shredded office waste and coated paper were used as furnishes for de-inking. Only water was used to give a moisture content of 50% (w/w) in the furnish before processing. The processing was performed based on the publication referred to above for relatively clean wastepaper: 100°-180° C. with nitrogen gas addition to give a 300 psig pressure in the reactor prior to explosive decompression. To test the effect of explosion, a study was performed by slowly releasing the pressure of the reactor (bleed-down) to atmospheric pressure to material discharge. The condition is described as "no explosion".
All treated furnish without further treatment was sent to a laboratory for evaluation of % debris; image analysis (sq. mm of direct per sq. ft. of paper); this is an and average spot size (sq. mm).
The following Table 12 shows the result of tests performed with office waste. Tests A1 and A2 were conducted in accordance with the present invention at high temperatures bringing the pressure within the digester to 261 psig.
The second group of tests B1 and B2 was conducted in accordance with the literature referred to above, the pressurization of the digester to 300 psig having been made by N 2 .
TABLE 12__________________________________________________________________________OW - HIGH PRESSURE VS. HIGH TEMPERATUREPROCESS % IMAGE ANALYSIS AVERAGE SPOTCONDITIONS DEBRIS (SQ. MM/SQ. FT.) SIZE (SQ. MM)__________________________________________________________________________A. High Temperature 210° C./4 min no 0.45% 185 0.31 N.sub.2 (261 psig) explosion 210° C./4 min no 0.70% 302 0.39 N.sub.2 (261 psig) no explosionB. Low Temperature 100° C./4 min add 25.2% 4635 2.69 N.sub.2 to 300 psig explosion 180° C./4 min add 1.30% 557 0.42 N.sub.2 to 300 psig explosion__________________________________________________________________________
Table 12 shows several interesting aspects of the present invention. Firstly, even with the raising of the pressure by N 2 , but at a increased temperature of 180°, the result was drastically superior to the processing in similar way a mere 100° C. By the same token, the data of the present invention at a lower pressure but higher temperature were superior to the higher pressure and lower temperature of the method described in literature.
Data from the use of the present invention in this comparison further suggest that with explosive discharge, there is only a marginal improvement over non-explosion. This would appear to suggest that pressure is not the major factor in determining the de-inking deficiency.
A similar comparison was made with coated paper and the result from this comparison is tabulated in Table 13. Table 13 points out again to the importance of high temperature, not high pressure for the de-inking efficiency.
TABLE 13__________________________________________________________________________CP - HIGH PRESSURE VS HIGH TEMPERATUREPROCESS % IMAGE ANALYSIS AVERAGE SPOTCONDITIONS DEBRIS (SQ. MM/SQ. FT.) SIZE (SQ. MM)__________________________________________________________________________A. High Temperature 190° C./4 min (167 0.36% 111 0.28 psig) no N.sub.2 explosion 190° C./4 min Add 0.34% 116 0.40 N.sub.2 to 300 psig explosion 190° C./4 min no 0.24% 56 0.82 N.sub.2 no explosionB. High Pressure 100° C./4 min add 1.6% 1330 0.78 N.sub.2 to 300 psig explosion 180° C./1 min add 0.50% 129 0.35 N.sub.2 to 300 psig explosion 180° C./4 min add 0.41% 118 0.24 N.sub.2 to 300 psig explosion__________________________________________________________________________
The tests with coated paper lead to the same general conclusion which can be summarized as follows:
(1) steam temperature (and time) and not pressure is the predominant factor in determining de-inking effectiveness;
(2) injection of inert gases to increase operating pressure does not lead to enhanced de-inkability;
(3) explosive decompression from high pressure may not be an absolute prerequisite to effective de-inking.
Other furnishes, not listed in the above examples and test results, including UV-ink coated papers, latex-bonded air laid cellulosic nonwovens and milk cartons such as were tested during the tests, all with promising results, at least matching and mostly surpassing comparative samples processed by the presently used methods.
The conditions and limits suggested by the experiments described above are not meant to be absolute. Rather, they are intended to show to those skilled in the art that careful balances are necessary between time, temperature, and chemistry in order to optimize the condition of the pulp with specific regard to the attributes required in the final grade of paper, paperboard or the like produced therefrom. For instance, those skilled in the art will quickly recognize that the percentage added of any given chemical is not to be taken as an absolute limiting factor in this invention. The functional specificity of the chemical and its relative strength both play an important role in the determination of exactly how much chemical is added. For example, it is often desirous to raise the pH of the furnish in the deinking operation. It is also well known that there are any number of acceptable chemicals available for this purpose including sodium hydroxide, potassium hydroxide and sodium carbonate. The cationic group (sodium or potassium) may be changed while still yielding the same final effect on the furnish. Or the anionic group (hydroxide or carbonate) may be changed while still yielding the same final effect on the furnish. And of course, there are also the entire spectrum of both inorganic and organic chemicals to chose from. However, due to strength differences and ionization constants of different chemicals different amounts may be required to achieve the same effect. For example, a 0.1N solution of sodium hydroxide in water will be expected to yield a pH of 13. Whereas a 0.1N solution of sodium carbonate in water will be expected to yield a pH of 11.6. Therefore, theoretically, it should take over 10 times as much sodium carbonate as it would sodium hydroxide to achieve the same high pH. But it is also known to those skilled in the art that the addition of further quantities of some chemicals does not bring about a further change in pH, but instead results in a buffering action. Yet, the net effect on the furnish with regards to deinking may be the same.
Furthermore, it will also be recognized that matters are complicated by the sort of dual functionality exhibited by some chemicals. Does one add sodium carbonate to raise the pH? Or does one add sodium carbonate to act as a buffer? Or does one use it for both purposes? Should it therefore be called an alkalating agent, buffer, or both?
As regards the scope of temperatures and dwell times, Stake Technology, one of the co-assignees of the invention, has adopted the concept of severity parameter as recently proposed by Overend and Chornet (Overend, R. P. and E. Chornet, 1987. Fractionation of lignocellulosics by steam-aqueous pretreatments. Phil. Trans. R. Soc. London. Volume A 321, Pages 523-536). Steam treatment severity is defined as:
Ro=t* exp.sup.[(T-100)/14.75]
where
Ro is the severity parameter;
t is the residence time in the reactor (in minutes); and
T is the steam temperature (in °C.)
The equation basically states that a particular treatment severity could be achieved by using various combinations of steam temperatures and residence times. It is expected that similar (though not identical) process results (including product quality, downstream processing performance, etc.) will be achieved when the same process severity is used for a particular raw material under conditions which are constant in all other aspects. The Ro as a function of the temperatures and times for the range of 200°- 230° C. for 1-6 minutes was illustrated by FIGS. 5 and 6.
The concept of treatment severity is particularly valuable in that it unifies the two major parameters involved in steam treatment: steam temperature and residence times, into a single concept in determining the process conditions. The validity of the concept has been convincingly demonstrated in various applications utilizing Stake Tech's steam-explosion technology. It is likely that the same concept will hold for the wastepaper recycling application even though the concept to data applies primarily to situations which does not involve the use of exogenous chemicals.
In view of the above comments, it will be appreciated that many different combinations may exist in different temperature and dwell time ranges which may differ from the ranges described in the Examples, without departing from the scope of the present invention.
Accordingly, we wish to protect by Letters Patent issued on this application all such embodiments of the method as reasonably fall within the scope of our contribution to the art. | Method is disclosed of treatment of waste paper or the like at high temperatures in the range of 160° C. to about 230° C. The furnish is treated in a digester with or without added chemicals but in the presence of saturated steam. The preferred dwell times are in the range of about 1 minute to about 6 minutes. The treated furnish is then discharged from the digester, preferably, but not exclusively, by an explosive discharge.
The advance in the art is in an improved de-inking effect, reduced consumption of chemicals and power. Also, some furnishes previously unsuitable for re-cycling, have been successfully processed by the method of the invention. | 3 |
FIELD OF THE INVENTION
This invention relates generally to plant watering and feeding systems and particularly to those intended to remain unattended for substantial lengths of time.
BACKGROUND OF THE INVENTION
A wide variety of plants have been utilized in various dwelling, workplace, and entertainment environments to beautify and enrich the appearance of the area. A great variety of plant species have been used through the years in such areas which vary in the extent of care and attention required by the plants to maintain their strong healthy and enjoyable appearance. In many instances, such plants are located in environments which render them easy to maintain and care for. However, often such plants are utilized in environments or situations which render their attention and care difficult and/or sporadic. For example, such plant enhancements are frequently located in areas which are difficult to access such as upper portions of rooms or building exteriors. Similarly, such plants are also frequently used within the dwelling places of persons travelling a great deal and therefore absent for prolonged periods of time.
The need to maintain the care and feeding of such plants under such difficult situations has prompted practitioners in the art to devise a number of devices which in varying degrees are intended to provide for the needs and care of such plants with little or no attention.
For example, U.S. Pat. No. 3,261,125 issued to Arkebauer sets forth a motion controlling system for plants which utilizes a wooden block as sensing means for the control and operation of the watering system.
U.S. Pat. No. 3,534,498 issued to Herrli sets forth a plant watering system which utilizes a porous elongated wick to communicate water to the plant soil from the reservoir by capillary action of the wick.
U.S. Pat. No. 3,747,399 issued to Treirat sets forth a plant watering system utilizing a capillary material in combination with a porous wick to control soil moisture.
U.S. Pat. No. 3,775,904 issued to Peters sets forth a double-walled plant supporting device within which a vacuum in created and thereafter relieved in a controlled process to flow water to the plant soil at the appropriate rate.
British Application No. 2,095,083 in the name of Fah published in 1982, but subsequently withdrawn, describes a plant container having a double wall and double bottom in which a supply of water is maintained at a controlled level between the device bottoms by a float system and in which a porous wick extends from the water supply to the plant soil.
U.S. Pat. No. 4,557,071 issued to Fah sets forth a automatic watering and feeding system for plants in which a plant container includes a soil section supporting soil and plants and a reservoir section for accommodating water. A porous wick communicates water from the reservoir to the soil and a pair of floats in communication with the reservoir operate first and second magnetic means which cooperate to maintain the appropriate water level and provide for periodic operation of a food dispenser.
While the foregoing described prior art devices have with varying degree of success attempted to provide environments for plants utilizing and requiring less care and attention, there remains a need in the art for a fully automated reliable and self-sustaining automatic system for plant watering and feeding.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide an improved automatic plant watering and feeding system. It is more particular object of the present invention to provide an improved automatic plant watering and feeding system which is operable when coupled to water systems having different residual pressures. It is a still more particular object of the present invention to provide an improved automatic plant watering and feeding system in which the plant fertilizer dispenser operates consistently notwithstanding wide temperature variations and which is easier to maintain and refill.
In accordance with the invention, there is provided an improved automatic plant watering and feeding system having a soil retaining vessel and a water reservoir in communication via a porous wick. Water level control means are coupled to a conventional water supply and are operative to maintain the water level in the reservoir within a predetermined range. A plant food reservoir includes means for periodically dispensing a quantity of plant food when the water level in the water reservoir reaches a predetermined level.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention, which are believed to be novel, are set forth with particularly in the appended claims. The invention, together with further objects and advantages thereof, may best by understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:
FIG. 1 sets forth a pictorial view of the present invention improved automatic plant watering and feeding system following the completion of a replenishment cycle;
FIG. 2 sets forth a pictorial drawing of the present invention improved automatic plant watering and feeding system following an extended period of water usage;
FIG. 3 sets forth a pictorial drawing of the present invention improved automatic plant watering and feeding system in which the water has been consumed to the minimum water level;
FIG. 4 sets forth a pictorial drawing of the present invention improved automatic plant watering and feeding system at the initiation of a replenishing cycle; and
FIG. 5 sets forth a pictorial drawing of the present invention improved automatic plant watering and feeding system near the completion of a replenishing cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 sets forth a pictorial view of the present invention improved automatic plant watering and feeding system generally referenced by numeral 10. Watering system 10 includes a side wall 45, a side wall 49 and a bottom wall 48 joined to form a continuous surrounding container having an open top portion. A floor member 44 extends inwardly from wall 45 and defines a recess 47. A wall 46 is spaced from wall 49 and extends downwardly to join bottom 48. Floor 44 joins wall 46 forming a soil cavity 17 between wall 46, bottom floor 44 and wall 45. A quantity of soil 28 is deposited within soil cavity 17 and in accordance with conventional planting techniques a plant 18 is supported within soil 28 such that a plurality of roots 19 extend outwardly to substantially permeate soil 28. A continuous wall 35 forms an interior chamber 14 having an aperture 34 and an inwardly extending flange 16. Wall 35 further defines an input passage 40 which is coupled to a water supply input 15. Water supply input 15 may, for example, comprise a conventional coupling to a standard municipal water supply. A water valve 12 is supported by wall 35 and defines a valve seat 41 and a valve seat 42. A float 11 includes an elongated arm 31 coupled to flange 16 by a hinge 13. In accordance with conventional fabrication techniques, float 11 is substantially lighter than the water it displaces and therefore is pivotally moved about hinge 13 in response to changes in water level within chamber 14. A valve rod 32 terminates in a valve stop 43 within water valve 12 at one end and a pivotal attachment 36 at the other end. Pivot 36 is secured to arm 31 of float 11 in a pivotal attachment.
An air valve 22 is defined within wall 35 and includes a valve seat 53 within chamber 14 and a valve seat 54 exterior to chamber 14. A wall 37 extends across bottom 48 and upwardly therefrom to floor 44 to form a chamber 25. Chamber 25 receives and continuously surrounds chamber 14 and defines an aperture 24 and an aperture 27. Wall 37 further defines an inwardly extending flange 26. A float 20 includes a balancing weight 23 and an elongated arm 51. Arm 51 terminates in a hinge 21 which is pivotally secured to flange 26. A valve rod 52 having a pivot 50 at one end is secured to arm 51 and defines a valve stop 53 supported within air valve 22 at the other end.
A plant food reservoir 70 is formed between walls 46 and 49 and maintains a quantity of plant food therein having a plant food level 76. Plant food reservoir 70 further includes a downwardly extending passage 71. A valve 72 includes a valve seat 73 in communication with passage 71 and a valve seat 74 extending downwardly therefrom. A chamber 75 is formed between walls 46 and 49 and is separated from plant food reservoir 70 by a wall 78. Chamber 75 further defines an aperture 64 and a recess 65. Recess 65 is surrounded by an inwardly extending lip 80. A float 81 is configured to correspond generally to chamber 75 and defines a downwardly extending recess 82. A float 83 having a generally convex configuration is adapted to generally fit within recess 82 and defines an upwardly extending valve rod 84. Rod 84 further defines a valve stop 85.
A chamber 55 is formed between wall 37 of chamber 25 and wall 46 of chamber 75 and receives downwardly extending recess 47. Recess 47 defines a plurality of apertures 60 communicating chamber 55 with soil cavity 17. In accordance with an important aspect of the present invention, an elongated porous wick 30 is received partially within chamber 55 and extends through a selected one of apertures 60 and therefrom extends upwardly into soil cavity 17.
An overflow passage 90 extends upwardly from chamber 55 and is coupled to a similar overflow passage 91 exterior to chamber 55 by a coupling 92. Overflow passages 90 and 91 together with coupling 92 provide an overflow mechanism limiting the water level within chamber 55 in accordance with the operation set forth below in greater detail.
In operation, a quantity of water is received within chambers 55, 14, 25 and 75 during the replenishment cycle described below. As mentioned above, FIG. 1 sets forth the configuration of the present invention system 10 which results following the completion of a replenishment cycle. Accordingly, a quantity of water is present within chambers 55, 14, 25 and 75 having water levels 62, 33, 61 and 63 respectively. It should be noted that in accordance with the system operation set forth below in greater detail at the completion of a replenishment cycle, water levels 62, 33, 61 and 63 within the system are substantially equal. In the positions shown, float 11 is submerged beneath water level 33 and due to its buoyancy exerts an upward force upon rod 32 which in turn forces stop 43 against valve seat 41 of water valve 12 causing a closure of input passage 40 and inhibiting the flow of water through input passage 40 from water supply 15. Thus, water valve 12 is closed and remains so until the upward force upon float 11 caused by water level 33 is removed. Similarly, float 20 is buoyantly supported by the water within chamber 25 causing arm 51 to assume a generally horizontal position about hinge 21. It should be noted that weight 23 is selected to provide the proper angular position of arm 51 when water level 61 reaches the level shown at the completion of a replenishment cycle. Rod 52 coupled to arm 51 is maintained in the intermediate position shown such that stop 53 is spaced from both seats 53 and 54 of air valve 22. Thus, air valve 22 is open providing an air passage between chambers 25 and 14. Within chamber 55 the quantity of water provided by the previously occurring replenishment cycle is present at water level 62. The water within chamber 55 is carried by wick 30 upwardly in accordance with conventional capillary action within wick 30 and is drawn into soil 28 within soil cavity 17. The capillary action of wick 30 provides the primary movement of water to soil 28 for use by plant 18.
With a quantity of water within chamber 75 rising to water level 63 as shown, float 81 is urged upward by its buoyant force which in turn provides an upward force against float 83. Thus, in accordance with an important aspect of the present invention, floats 81 and 83 are generally coupled together as a single unit so long as a buoyant force is applied to float 81 urging it upwardly. The upward force upon float 83 produces an upward motion of rod 84 within valve 72 forcing valve stop 85 against valve seat 73. The pressure of stop 83 against valve seat 73 closes passage 71 and isolates chamber 75 from plant food reservoir 70. Thus, in the position shown, water supply valve 12 is closed precluding the flow of water from water supply input 15 into chamber 14. Air valve 22 is open permitting an air coupling between chambers 14 and 25 and valve 72 is closed which cuts off the flow of plant food from plant food reservoir 70 into chamber 75. With the situation as depicted in FIG. 1, the passage of time causes water to be steadily drawn upward through wick 30 for absorption into soil 28 as needed by plant 18. This process continues which gradually depletes the water supply from chambers 55, 14, 25 and 78 until the configuration set forth in FIG. 2 results.
FIG. 2 sets forth the present invention system following an extending period of time during which a quantity of water has been drawn upwardly through wick 30 by the action of plant 18. It should be noted that the system set forth in FIG. 2 is identical to that set forth in FIG. 1 with the sole differences between FIG. 1 and 2 being those positional changes in the present invention apparatus which result from the foregoing absorption of water by plant 18. By comparison of FIGS. 1 and 2, it should be noted that water level 62 within chamber 55 has been substantially reduced from the level shown in FIG. 1 following replenishment. Correspondingly, the communication of water between chambers 25 and 55 via aperture 24 and the equalizing of air pressure therebetween via aperture 27 provides that water levels 61 and 62 remain equal to each other. Similarly, the communication between chambers 75 and 55 via aperture 64 causes water level 63 within chamber 75 to be similarly reduced and equal to water levels 61 and 62. The reduction in water level 63 within chamber 75 permits float 81 to move downwardly which in turn removes the upward pressure upon float 83 causing stop 85 to be removed from valve seat 73 which in turn permits a flow of plant food from plant food reservoir 70 through passage 71 and valve 72 into chamber 75. The flow of plant food from reservoir 70 is carried generally downwardly across the upper portion of float 83 and accumulates within recess 82 of float 81. As the flow of liquid plant food through passage 71 and valve 72 downwardly into recess 82 continues, float 83 is force upwardly by its own buoyant force within recess 82 due to the accumulated liquid plant food within recess 82. At some point, the upward force upon float 83 becomes sufficient to again force stop 85 against valve seat 73 and thereby close passage 71 and terminates any further flow of plant food from plant food reservoir 70. As a result, floats 81 and 83 assume the positions shown in FIG. 2 in which an accumulated supply of liquid food has collected within recess 82 and supports float 83. Concurrently, the reduction of water level 61 permits float 20 to pivot about hinge 21 in a counterclockwise direction which in turn forces rod 52 downwardly within air valve 22 until stop 56 is forced against seat 53 closing air valve 22. With air valve 22 closed, the flow of equalizing water through aperture 34 which would otherwise maintain water level 33 at the same level as water level 61 is precluded. Thus, the continued absorption of water by plant 18 through wick 30 is carried forward without further reducing water level 33 within chamber 14. As a result, notwithstanding the further drops in water levels 61, 62 and 63 in chambers 25, 55 and 75 repsectively, the maintenance of water level 33 at a higher level due to the closure of air valve 22 provides a continued closure of water valve 12 precluding the addition of any more water to the system. The above-described absorption of water by plant 18 through wick 30 continues to deplete the supply of water in chambers 25, 55 and 75 until the system reaches the situation shown in FIG. 3.
FIG. 3 sets forth the present invention system as it appears when the use of water by plant 18 has caused the reduction of system water levels to reach their minimum levels. As is seen in FIG. 3, the continued absorption of water by wick 30 has reduced water level 62 within chamber 55 to a point below aperture 64 causing a retention of water within recess 65. Correspondingly, the reduction of water level 63 within recess 75 causes float 81 to rest upon lip 80 above recess 65 prohibiting further downward movement of float 81. As float 81 is moved downward in the transition from the water levels shown in FIG. 2 to the minimum water levels shown in FIG. 3, the above-described operation of float 83 and valve 72 continue to transport quantities of liquid plant food from plant food reservoir 70 to recess 82 of float 81. As a result, a substantial quantity of liquid plant food now resides within recess 82 of float 81. Concurrently, the reduction of water level 62 has reached a point below apertures 34 and 24. The reduction of water level 61 within chamber 25 causes float 20 to continue to maintain closure of air valve 22. However, the reduction of water level 61 beneath aperture 34 permits the bubbling via air bubbles 66 into chamber 14. Thus, as air bubbles 66 diffuse upwardly within chamber 14, sufficient air pressure is provided above water level 33 notwithstanding the closure of air valve 22 to permit water to flow outwardly through aperture 34 into chambers 25 and 55 to supply wick 30 with additional water for absorption by plant 18. This operation continues as air bubbles 66 diffuse upwardly permitting the flow of water from chamber 14 and causing a gradual reduction in water level 33. This process continues until the reduction of water level 33 reaches a sufficiently low level to permit float 11 to move downwardly causing a counterclockwise rotation of arm 31 about hinge 13 which in turn relieves the closing force of stop 43 against valve seat 41 of water valve 12 allowing the system to initiate a replenishing cycle and assume the positions shown in FIG. 4.
FIG. 4 sets forth the present invention system at the initiation of a replenishing cycle. As can be seen, the downward motion of float 11 described above has resulted in the opening of water supply valve 12. With the opening of valve 12, pressurized water flows from water supply input 15 through input passage 40 and valve 12 into chamber 14. As water flows into chamber 14, water level 33 is raised which in turn causes closure of aperture 34 causing a cessation of the above-described air bubbling action. Because float 20 remains in its downward position within chamber 25, air valve 22 remains closed and chamber 14 is once again sealed and a body of air is captivated within chamber 14 above water level 33. Because of the pressure within the water supply system to which water supply input 15 is coupled, the flow of water through water valve 12 continues causing water level 33 to rise and causing the trapped air within chamber 14 to become pressurized. Thereafter, the combination of pressure of the trapped air within chamber 14 and the water pressure of the water supply to which input 15 is coupled, causes water to flow outwardly from chamber 14 through aperture 34 into chamber 25 and through aperture 24 into chamber 55. As water flows outwardly from chamber 14 into chambers 25 and 55, water levels 61 and 62 respectively again begin rising. As water levels 61 and 62 continue to rise, water level 62 rises above the lower portion of aperture 64 permitting water to once again flow into chamber 75. The flow of water into chamber 75 forces float 81 upwardly which in turn forces float 83 into recess 82 such that liquid plant food is displaced from recess 82 and flows downwardly within chamber 75 to mix into the accumulated water within chambers 75 and 55. Thus, liquid plant food is mixed into the system's water reservoir and particularly within chamber 55. The filling process continues and water levels 61, 62 and 63 continue to rise until water level 61 again reaches float 20 and begins moving float 20 upward.
FIG. 5 sets forth the near completion of the above-described replenishing cycle in which water level 61, 62 and 63 have risen to a sufficient level that water level 61 within chamber 25 begins raising float 20 causing a rotation of arm 51 in the clockwise direction. It should be noted that weight 23 is selected to control the point at which water level 61 again raises float 20. The raising of float 20 and the clockwise rotation of arm 51 caused thereby raises rod 52 which removes stop 56 from seat 53 of air valve 22. As a result, the air passage to chamber 14 is again opened and the pressurized air trapped above water level 33 is released which in turn permits water level 33 to rise to the same levels as water levels 61, 62 and 63. As water level 33 rises, float 11 is carried upward rotating arm 31 in the clockwise direction about hinge 13 and causing stop 43 to be forced against valve seat 41 and close input passage 40 prohibiting any further flow of replenishing water into the system. During the time that water levels 61, 62 and 62 are raised to the final water levels shown in FIG. 1, float 81 is forced upwardly against float 83 causing the displacement of virtually all of the plant food collected within recess 82. The displaced plant food continues to flow downwardly about the exterior of float 81 within chamber 75 and is mixed with the water supplies within chambers 75 and 55 and to a lesser extent, chambers 25 and 14. As a result, once the system completes its replenishing cycle and returns to the positions shown in FIG. 1, a complete fresh charge of plant food and water mix has once again been stored within chambers 75, 55, 25 and 14 and the replenishing cycle is complete.
As can be seen, the above-described replenishing cycle takes place automatically without the need of any care or attendance and provides for a systematic and consistent infusion of plant food to the water supply to plant 18. As will be further apparent, the system is independent of water supply pressure in that the flow of water and the levels to which the water is permitted to rise within the system are controlled solely by the valve mechanisms and are independent of the water supply pressure. As a result, the system is not effected by changes in water supply pressure while left unattended. Similarly, it should be noted that the volume of liquid plant food dispensed during each replenishing cycle is consistent and is unaffected by the pressure of the water supply system and is equally unaffected by variations in ambient temperature and other like environmental circumstances. As a result, the system functions reliably, efficiently and consistently requiring nothing more than periodic replenishment of the supply of liquid plant food within plant food reservoir 70.
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore the aim in the appended claims is to cover all such changes and modifcations as fall within the true spirit and scope of the invention. | An automatic plant watering and feeding system includes a plant vessel supporting a quantity of soil and an underlying water reservoir in communication with the soil by a porous wick. The water reservoir is divided into four chambers. In one chamber a float mechanism controls an input water supply valve while in a second chamber a float mechanism controls the air venting of the first chamber. The third chamber is communicated with the soil by the porous wick and the fourth chamber utilizes a dual interlocking float mechanism to dispense a measured quantity of liquid plant food into the system reservoir during a replenishing cycle. | 0 |
FIELD OF THE INVENTION AND RELATED ART
The present invention relates to a process cartridge used for electrophotographic image formation. More specifically, it relates to a gap maintaining member with which a process cartridge is fitted to ensure that a gap is maintained between its photosensitive member and developer bearing member (inclusive of spacer rings) during the distribution of the process cartridge.
In the following description of the present invention, the term “process cartridge” means a cartridge in which at least a developing means and an electrophotographic photosensitive member are integrally disposed so that they can be removably mounted in the main assembly of an electrophotographic image forming apparatus.
Further, the term “electrophotographic image forming apparatus” means an apparatus which forms an image on recording medium, with the use of an electrophotographic image forming method. Examples of an electrophotographic image forming apparatus are an electrophotographic printer (laser printer, LED printer, etc., for example), a facsimile apparatus, a wordprocessor, etc.
As the cumulative usage of a conventional electrophotographic image forming apparatus, that is, an electrophotographic image forming apparatus in accordance with the prior art, exceeds a certain length of time, various maintenance operations have to be performed, for example, the operation for replacing its electrophotographic photosensitive drum, the operation for replenishing the apparatus with developer or replacing the developer, the operation for adjusting, and/or cleaning the other components (charging device, cleaning device, etc.), etc. In the past, the operations, such as the abovementioned ones, for maintaining an electrophotographic image forming apparatus have been very difficult for an average user. As a matter of fact, they have been virtually impossible to perform, unless a person who performs the operations is a service person having professional knowledge of an image forming apparatus.
In the field of an electrophotographic image forming apparatus, therefore, a process cartridge system has come to be employed. According to a process cartridge system, an electrophotographic photosensitive member, and means for processing the electrophotographic photosensitive member, are integrally disposed in a cartridge so that they can be removably mounted in the main assembly of an electrophotographic image forming apparatus. Thus, a process cartridge system makes it possible for an average user to maintain an electrophotographic image forming apparatus by himself, that is, without relying on a service person. In other words, it drastically improves an electrophotographic image forming apparatus in operability. Thus, a process cartridge system has come to be widely used in the field of electrophotographic image forming apparatus.
There are two types of developing method compatible with an electrophotographic image forming apparatus which employs a process cartridge system, that is, the type which places an electrophotographic photosensitive member in contact with a developer bearing member, and the type which does not place an electrophotographic photosensitive member in contact with a developer bearing member. In the case of the latter, a latent image on an electrophotographic photosensitive member is developed by transferring developer onto the photosensitive drum from the developer bearing member, with roughly a preset amount of gap provided between the photosensitive member and developer bearing member by the gap regulating members placed in contact with the peripheral surface of the photosensitive member. In other words, in the case of an electrophotographic image forming apparatus which employs a process cartridge system, the developer bearing member is kept in contact with the electrophotographic photosensitive member by a pressure applying means, such as a spring, or the gap regulating member is kept in contact with the electrophotographic photosensitive member by the pressure applying means, such as a spring.
Thus, even during the distribution of a process cartridge, that is, even during the period between the moment a process cartridge has been completed to the moment the process cartridge is mounted into the main assembly of an image forming apparatus, the developer bearing member or gap regulating member is kept in contact with the electrophotographic photosensitive member by a pressure applying means, such as a spring. Therefore, the following problems sometimes occur during the distribution of a process cartridge.
That is, if a process cartridge happens to be subjected to a large amount of impact, the portion of the electrostatic photosensitive member, which is in contact with the developer bearing member or gap regulating member, the portion of the developer bearing member, which is in contact with the photosensitive member, and/or the portion of the gap regulating member, which is in contact with the photosensitive member, is also subjected to a large amount of impact, making it possible for the electrophotographic photosensitive member, developer bearing member, and/or gap regulating member to be damaged.
Next, some process cartridges which employ the prior arts for solving the above described problem will be described.
In the case of the process cartridge proposed in Japanese Laid-open Patent Application H05-297646, a protective means, which is a piece of film, is placed between the electrophotographic photosensitive member and developer bearing member, which are positioned to maintain a gap of 250 μm between them, as shown in FIG. 2 of the abovementioned application.
In the case of the process cartridge proposed in Japanese Laid-open Patent Application 2003-241621, the electrophotographic photosensitive member is supported by the first frame, whereas the developer bearing member is supported by the second frame, which is connected to the first frame so that it can be rotationally moved relative to the first frame, as shown in FIG. 10 of the abovementioned application. This process cartridge is characterized in that as soon as it is produced, it is fitted with a gap maintaining member which remains engaged with both the first and second frames to keep a greater distance between the axial line of the photosensitive member and the axial line of the developer bearing member during the distribution of the process cartridge than the distance maintained between the axial line of the photosensitive member and the axial line of the developer bearing member by the gap regulating member during image formation.
More specifically, in the case of the process cartridge proposed by Japanese Laid-open Patent Application H05-297646, a protective means, which is roughly 200-300 μm in thickness, is placed between the photosensitive member and developer bearing member, which are kept separated by roughly 200-300 μm by the gap regulating member. This structural arrangement, however, is effective only when the impact to which the process cartridge subjected is subjected is small. That is, it is effective to prevent the problem that the peripheral surface of the photosensitive member is damaged by the friction caused between the peripheral surface of the photosensitive member and developer bearing member by the direct contact between the peripheral surface of the photosensitive member and the peripheral surface of the developer bearing member. In other words, it is not effective to prevent the damages, more specifically, the deformation of the photosensitive member, developer bearing member, and/or gap regulating member, which occur as the process cartridge is subjected to a large amount of impact.
In the case of the process cartridge proposed by Japanese Laid-open Patent Application 2003-241621, the second frame, that is, the frame which supports the developer bearing member, has a developer storage. Thus, as the developer storage (developer container) is increased in capacity to prolong a process cartridge in service life, the second frame increases in weight, which in turn increases the amount of the contact pressure generated between the photosensitive member and developer bearing member during the distribution of the process cartridge, and also, the amount of impact to which the portion of the peripheral surface of the photosensitive member, which is in contact with the peripheral surface of the developer bearing member, or the gap regulating member, is subjected during the distribution of the process cartridge. In the case of this process cartridge, therefore, in order to prevent the deformation of the gap regulating member and/or the damage to the photosensitive member, the process cartridge must be increased in the distance between the photosensitive member and developer bearing member, or the distance between the photosensitive member and gap regulating member. The increase in the distance between the photosensitive member and developer bearing member, or the increase in the distance between the photosensitive member and gap regulating member, requires the process cartridge and/or gap maintaining member to be increased in size, and the increasing the process cartridge and/or gap maintaining in size adds to the cost of the process cartridge.
SUMMARY OF THE INVENTION
Thus, the primary object of the present invention is to provide a combination of a process cartridge, and a gap maintaining member which is no greater in size than a gap maintaining member in accordance with the prior art, which can prevent the problem that an electrophotographic photosensitive member, a developer bearing member, and/or a gap regulating member is damaged during the distribution of the process cartridge.
Another object of the present invention is to provide a combination of a process cartridge of a large capacity, and a gap maintaining member which is not greater in size than a gap maintaining member for a process cartridge of a small capacity.
Another object of the present invention is to provide a combination of a process cartridge, and a gap maintaining member which can keep the electrophotographic photosensitive member and developer bearing member separated regardless of the capacity of the developer storage portion of the process cartridge.
According to an aspect of the present invention, there is provided a process cartridge detachably mountable to a main assembly of an electrophotographic image forming apparatus, said process cartridge comprising a photosensitive member unit having a photosensitive drum; a developer carrying member for developing an electrostatic latent image formed on said photosensitive drum with a developer; a toner accommodating unit having a developer accommodating portion accommodating the developer to be used for development of said electrostatic latent image, said toner accommodating unit being fixed to said photosensitive member unit; a movable frame which is movable relative to said toner accommodating unit and which supports said developer carrying member; an urging member for urging said movable frame in a direction in which said developer carrying member approaches said photosensitive drum; and a space maintaining member, demountably provided between said photosensitive member unit and said movable frame in contact to said photosensitive member unit and said movable frame, for maintaining a state in which a distance between said photosensitive drum and said developer carrying member is larger than that in an image formation.
According to another aspect of the present invention, there is provided a space maintaining member detachably mountable to a process cartridge detachably mountable to a main assembly of an electrophotographic image forming apparatus, said process cartridge including a photosensitive member unit having a photosensitive drum; a developer carrying member for developing an electrostatic latent image formed on said photosensitive drum with a developer; a toner accommodating unit having a developer accommodating portion accommodating the developer to be used for development of said electrostatic latent image, said toner accommodating unit being fixed to said photosensitive member unit; a movable frame which is movable relative to said toner accommodating unit and which supports said developer carrying member; an urging member for urging said movable frame in a direction in which said developer carrying member approaches said photosensitive drum: wherein said space maintaining member, when said space maintaining member is mounted to said process cartridge, contacts to said photosensitive member unit and said movable frame to maintain a state in which a distance between said photosensitive drum and said developer carrying member is larger than that in an image formation.
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 DRAWINGS
FIG. 1 is a schematic sectional view of a typical electrophotographic image forming apparatus which is compatible with a process cartridge in accordance with the present invention.
FIG. 2 is a schematic sectional view of a process cartridge in accordance with the present invention, showing the general structure of the cartridge.
FIG. 3 is a perspective view of the developing means container unit of the process cartridge in accordance with the present invention, showing the structure of the container unit.
FIG. 4 is a perspective view of one of the lengthwise end portions of the process cartridge in accordance with the present invention, showing the structure of the developing means container unit.
FIG. 5 is a perspective view of the combination of the process cartridge and gap maintaining member in the first embodiment of the present invention, showing the frame structure of the process cartridge, and how the gap maintaining member is engaged with the process cartridge.
FIG. 6 is a perspective view of one of the lengthwise end portions of the process cartridge, and corresponding portion of the gap maintaining member, in the first embodiment of the present invention, showing how the gap maintaining member is engaged with the process cartridge to maintain a preset amount of gap between the photosensitive member and developer bearing member, and also, between the photosensitive member and gap regulating member, during the distribution of the process cartridge.
FIG. 7 is a plan view of one of the lengthwise ends of the process cartridge, and corresponding portion of the gap maintaining member, in the first embodiment of the present invention, showing how the gap maintaining member engages with the process cartridge to maintain a preset amount of gap between the photosensitive member and developer bearing member, and also, between the photosensitive member and gap regulating member, during the distribution of the process cartridge.
FIG. 8( a ) is a plan view of the photosensitive member and developer bearing member, in the first embodiment of the present invention, which are not in their image forming positions because of the presence of the gap maintaining member, and FIG. 8( b ) is a plan view of the photosensitive member and developer bearing member, in the first embodiment, which are in the image forming positions because of the absence of the gap maintaining member.
FIG. 9 is a schematic sectional view of a typical electrophotographic image forming apparatus which is compatible with a process cartridge in accordance with the present invention, showing what happens if the process cartridge in accordance with the present invention is mounted into the main assembly of the image forming apparatus without removing the gap maintaining member from the process cartridge.
FIG. 10 is a perspective view of the gap maintaining member in the second embodiment of the present invention.
FIG. 11 is a perspective view of the combination of one of the lengthwise end portions of the process cartridge, and the corresponding portion of the gap maintaining member properly engaged with the process cartridge, in the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the process cartridges and gap maintaining member, which are in accordance with the present invention, will be described in detail with reference to the appended drawings.
Embodiment 1
First, referring to FIGS. 1-9 , the first embodiment of the present invention will be described.
FIG. 1 is a schematic sectional view of a typical electrophotographic image forming apparatus compatible with a process cartridge in accordance with the present invention. FIG. 2 is a schematic sectional view of a process cartridge in accordance with the present invention, and shows the general structure of the cartridge. FIG. 3 is a perspective view of the developing means container unit 15 of the process cartridge in accordance with the present invention, showing the structure of the container. FIGS. 4( a ) and 4 ( b ) are FIG. 4 are perspective views of one of the lengthwise end portions of the developing apparatus unit 8 of the process cartridge in accordance with the present invention, showing the structure of the developing apparatus unit 8 . FIGS. 5( a ) and 5 ( b ) are perspective views of the combination of the process cartridge and gap maintaining member 100 in the first embodiment of the present invention, showing the frame structure of the process cartridge, and how the gap maintaining member 100 is engaged with the process cartridge. FIGS. 6( a ) and 6 ( b ) are perspective views of one of the lengthwise end portions of the process cartridge, and corresponding portion of the gap maintaining member 100 , in the first embodiment of the present invention, showing how the gap maintaining member 100 is engaged with, or disengaged from, the process cartridge. FIG. 7 is a plan view of one of the lengthwise ends of the process cartridge, and corresponding portion of the gap maintaining member 100 , showing how the gap maintaining member 100 is engaged with the process cartridge to maintain a preset amount of gap between the photosensitive member and developer bearing member, and also, between the photosensitive member and gap regulating member. FIG. 8( a ) is a plan view of the photosensitive member and developer bearing member, which are not in the image forming positions because of the presence of the gap maintaining member 100 , and FIG. 8( b ) is a plan view of the photosensitive member and developer bearing member, which are in the image forming positions because of the absence of the gap maintaining member 100 . FIG. 9 is a schematic sectional view of a typical electrophotographic image forming apparatus which is compatible with a process cartridge in accordance with the present invention, showing what happens if the process cartridge in accordance with the present invention is mounted into the main assembly of the image forming apparatus without removing the gap maintaining member 100 from the process cartridge.
In the following description of the preferred embodiments of the present invention, the term “widthwise direction” of a process cartridge B means the direction in which the process cartridge B is mounted into, or removed from, the main assembly A 1 of an image forming apparatus 1 . The widthwise direction of the process cartridge B coincides with the direction in which a recording medium P is conveyed. The term “lengthwise direction” of the process cartridge B means the direction perpendicular (roughly perpendicular) to the direction in which the process cartridge B is mounted into, or removed from, the apparatus main assembly A 1 . The lengthwise direction of the process cartridge B is parallel to the surface of the recording medium P, and is perpendicular to the direction in which the recording medium P is conveyed. Further, the referential symbols used in the description are only for designating the various components, portions, etc., of the image forming apparatus and process cartridge, which are shown in the drawings. They are not intended to limit the present invention in terms of the structures of an image forming apparatus and a process cartridge.
<General Structure of Electrophotographic Image Forming Apparatus>
Referring to FIG. 1 , an electrophotographic image forming apparatus A in this embodiment is a laser printer. It is made up of its main assembly A 1 and a process cartridge B. It has a cartridge cover 4 , which is a part of the external shell of the laser printer A. Opening the cartridge cover 4 makes it possible for the cartridge B to be mounted into, or removed from the apparatus main assembly A 1 . The laser printer A forms an image on the recording medium P (recording paper, OHP sheet, fabric, etc.) using an electrophotographic image formation process, which uses developer (which hereafter will be referred to as toner). The electrophotographic image forming process is carried out by the process cartridge B.
More specifically, first, the peripheral surface of the electrophotographic photosensitive member 10 (which hereafter will be referred to as photosensitive drum) is uniformly charged by a charge roller 11 , which is a charging means. Then, the uniformly charged peripheral surface of the photosensitive drum 10 is exposed to a beam of laser light L projected onto the peripheral surface of the photosensitive drum 10 from an exposing apparatus 1 (optical means) while being modulated with pictorial information. As a result, an electrostatic latent image, which reflects the pictorial information, is effected on the peripheral surface of the photosensitive drum 10 . The latent image on the photosensitive drum 10 is developed by the developing means 8 into a toner image. The developing means 8 will be described later.
Meanwhile, the recording mediums P in the sheet feeder cassette 6 a are sequentially fed into the apparatus main assembly A 1 by the pickup roller 6 b , a pair of recording medium conveying rollers 6 c and 6 e . Then, each recording medium P is conveyed to the nip between a transfer roller 3 (transferring means) and the photosensitive drum 10 , by a pair of recording medium conveying-and-turning guides 6 d and 6 f and a pair of registration rollers 6 g , in synchronism with the formation of the toner image. Thus, the conveyance of the recording medium P from the sheet feeder cassette 6 a to the nip puts the recording medium P upside down.
Then, the recording medium P is conveyed through the nip formed between the photosensitive drum 10 and transfer roller 3 (transferring means), while a preset amount of voltage is applied to the transfer roller 3 . As the recording medium P is conveyed through the nip, the toner image developed on the photosensitive drum 10 is transferred onto the recording medium P.
After the transfer of the toner image onto the recording medium P, the recording medium P is guided to the fixing means 5 by a recording medium conveyance guide 6 h . The fixing means 5 is made up of a driver roller 5 c and a heater 5 a . The driving roller 5 c also functions as a pressure applying means. While the recording medium P is conveyed through the fixing means 5 , the fixing means 6 applies heat and pressure to the recording medium P and the toner image thereon. As a result, the toner image is fixed to the recording medium P.
Thereafter, the recording medium P is conveyed further by a recording medium conveyance guide 6 i , and then, is discharged into a delivery tray 7 by a pair of discharge rollers 6 j , with the image bearing surface facing downward.
<Process Cartridge>
The process cartridge B is made up of the photosensitive drum 10 , means for processing the photosensitive drum 10 , and a cartridge in which the photosensitive drum 10 and processing means are integrally disposed. The processing means are a charging means for charging the peripheral surface of the photosensitive drum 10 , a developing means for developing an electrostatic latent image formed on the peripheral surface of the photosensitive drum 10 , and a cleaning means for removing the toner remaining on the peripheral surface of the photosensitive drum 10 . The process cartridge B is required to have the photosensitive drum 10 and at least one of the processing means.
Referring to FIG. 2 , in this embodiment, the process cartridge B is made up a photosensitive member unit 9 and a developing apparatus unit 8 (developing means).
The photosensitive member unit 9 of the process cartridge B has a first frame portion 12 (which hereafter will be referred to as waste toner container), the photosensitive drum 10 , and the charge roller 11 . The photosensitive drum 10 is for forming an electrostatic latent image. The charge roller 11 is for uniformly charging the peripheral surface of the photosensitive drum 10 . The photosensitive drum unit 9 also has a cleaning blade 14 , which scrapes the peripheral surface of the photosensitive drum 10 to remove from the peripheral surface, the residual toner T, that is, the toner remaining adhered to the peripheral surface of the photosensitive drum 10 without being transferred onto the recording medium P. The removed residual toner T collects in the waste toner container 12 .
The developing apparatus unit 8 of the process cartridge B is a developing means, as described above. It has a toner storage unit 25 , a development blade 17 , a developer bearing member 19 (which hereafter will be referred to as development sleeve), and a developing means container unit 15 , etc. There is a magnetic roller 16 (magnetic field generating means) in the hollow of the development sleeve 19 .
The toner storage unit 25 has a developer storage portion 20 (which hereafter will be referred to as toner storage container), and a second frame portion 26 (which hereafter will be referred to as guiding frame) ( FIG. 4( a )). The toner storage container 20 stores the toner T. It is solidly connected to the guiding frame 26 .
There is a toner seal 13 between the toner storage container 20 and guiding frame 26 . The toner seal 13 prevents the unused toner T from leaking from the toner storage container 20 . Pulling out the toner seal 13 allows the toner T in the toner storage container 20 to flow into the developing means container unit 15 .
In this embodiment, the toner storage container 20 and the guiding frame 26 , which make up the toner storage container unit 25 by being solidly attached to each other, are independently formed. However, they may be integrally formed.
(Image Formation Process)
The developing apparatus unit 8 (developing means) sends the toner T in the toner storage container 20 to the development sleeve 19 through the opening 15 a of the developing means container unit 15 a , by rotating a pair of stirring means 23 a and 23 b . It has a developer stirring member 24 for circulating the toner T in the developing means container unit 15 . The developer stirring member 24 is rotatably disposed in the adjacencies of the development sleeve 19 . The developing apparatus unit 8 also has a blowout prevention seal 21 for keeping sealed the gap between the development sleeve 19 and the bottom portion of the developing means container unit 15 . That is, the blowout prevention seal 21 prevents the toner T from leaking downward relative to the position of the development sleeve 19 .
The developing apparatus unit 8 has a pair of magnetic seals 22 , which are located at the lengthwise ends of the development sleeve 19 , one for one, with the provision of a preset amount of gap between the peripheral surface of the development sleeve 19 and the magnetic seal 22 . The magnetic seal 22 prevents the toner T from leaking from the developing apparatus unit 8 through the gap between the lengthwise end of the development sleeve 19 and the developing means container unit 15 . More specifically, the magnetic seal 22 forms a magnetic field between itself and the magnetic roller 16 to form a brush of the toner T, in the abovementioned gap to prevent the toner T from leaking.
As described above, the toner T is sent to the development sleeve 19 , which is rotating, with the presence of the stationary magnetic roller 16 supported in the hollow of the development sleeve 19 . Thus, the toner T is borne on the peripheral surface of the development sleeve 19 , and is formed into a uniform layer of toner with a preset thickness, by the development blade 17 , while being frictionally charged by the development sleeve 19 and development blade 17 .
The lengthwise end portions of the development sleeve 19 are fitted with a pair of gap maintaining members 27 a and 27 b (which hereafter will be referred to as spacer ring), one for one ( FIG. 3 ). The spacer rings are roughly coaxial and are larger in radius than the development sleeve 19 , by the amount equal to the preset amount of clearance which the spacer rings are required to provide between the peripheral surface of the photosensitive drum 10 and the peripheral surface of the development sleeve 19 . The spacer rings 27 a and 27 b are kept pressed upon the peripheral surface of the photosensitive drum 10 by a pair of pressure generating members 28 a and 28 b (which hereafter will be referred to simply as spring) ( FIG. 8 ). With the presence of the spacer rings 27 a and 27 b between the peripheral surface of the development sleeve 19 and the peripheral surface of the photosensitive drum 10 , and also, the presence of the pressure from the springs 28 a and 28 b , the preset amount of clearance is maintained between the peripheral surface of the development sleeve 19 and the peripheral surface of the photosensitive drum 10 .
The toner layer formed on the peripheral surface of the development sleeve 19 is moved by the rotational of the development sleeve 19 into the development area, in which the toner in the toner layer is transferred onto the peripheral surface of the photosensitive drum 10 in a manner to reversely reflect the electrostatic latent image on the peripheral surface of the photosensitive drum 10 . As a result, an image is formed of toner, on the peripheral surface of the photosensitive drum 10 .
The photosensitive drum 10 is rotated in the direction indicated by an arrow mark R 1 , while a preset amount of voltage is being applied to the charge roller 11 which is in contact with the peripheral surface of the photosensitive drum 10 . As a result, the portion of the photosensitive layer of the photosensitive drum 10 , which is in contact with the charge roller 11 , is uniformly charged. Then, the uniformly charged portion of the peripheral surface of the photosensitive drum 10 is exposed to a beam of laser light L projected onto the photosensitive drum 10 while being modulated with pictorial information. As a result, an electrostatic latent image is effected on the peripheral surface of the photosensitive drum 10 . Thereafter, the electrostatic latent image is developed into a toner image by the developing means.
The toner image formed on the peripheral surface of the photosensitive drum 10 is transferred onto the recording medium by applying such voltage that is opposite in polarity to the abovementioned toner image, to the transfer roller 3 , with which the laser printer A is provided. Thereafter, the residual toner T, that is, the toner T remaining on the peripheral surface of the photosensitive drum 10 after the toner image transfer, is removed by the cleaning blade 14 . More specifically, the cleaning blade 14 is placed in contact with the peripheral surface of the photosensitive drum 10 to scrape the peripheral surface of the photosensitive drum 10 to remove the residual toner T on the photosensitive drum 10 . After being removed from the peripheral surface of the photosensitive drum 10 by the cleaning blade 14 , the residual toner T collects in the waste toner container 12 .
(Frame Structure of Process Cartridge)
Referring to FIG. 3 , the developing means container unit 15 is made up of a slide frame 29 , a right side frame 30 , and a left slide frame 31 . The right and left slide frames 30 and 31 are integrally attached to the slide frame 29 . The development sleeve 19 is rotatably supported by the right and left slide frames 30 and 31 , with the positioning of a pair of sleeve bearings (unshown) between the lengthwise ends of the development sleeve 19 and the right and left slide frame 30 and 31 , respectively. The development blade 17 is solidly attached to the slide frame 29 .
Referring to FIGS. 3 , 4 ( a ), and 4 ( b ), the top and bottom surfaces 30 a and 30 b of the right slide frame 30 of the developing means container unit 15 are parallel to each other, and control the direction in which the developing means container unit 15 slides (direction indicated by arrow mark S in FIG. 4( a )). Next, referring to FIG. 4( b ), the guiding frame 26 has a pair of guiding surfaces 26 a and 26 b , which oppose the slide surfaces 30 a and 30 b , respectively, when the developing means container unit 15 remains properly engaged in the guiding frame 26 . There is a spring 28 a (pressure generating member) between the developing means container unit 15 and guiding frame 26 . Thus, the developing means container unit 15 is kept pressed toward the photosensitive member unit 9 . That is, the spring 28 a presses the developing means container unit 15 in the direction to keep the development sleeve 19 virtually in contact with, or truly in contact with the photosensitive drum 10 . The slide surfaces 31 a and 31 b of the left slide frame 31 , and the guiding surfaces 26 d and 26 e of the guiding frame 26 (which opposes slide surfaces 31 a and 31 b , respectively), and a spring 28 b , are the same in structure and positioning as those of the right slide frames 31 and right guiding frame 26 , and the spring 28 a ( FIG. 6( b )).
Further, the developing means container unit 15 is provided with a hole 15 c , which is rectangular in cross section, whereas the guiding frame 26 is provided with a boss 26 c ( FIGS. 4( a ) and 4 ( b )). The hole 15 c and boss 26 c are for accurately positioning the developing means container unit 15 and guiding frame 26 relative to each other in terms of their lengthwise direction.
Since the developing means container unit 15 and guiding frame 26 are structured as described above, the developing means container unit 15 slides straight in the widthwise direction (indicated by arrow mark S in FIG. 4( a )), relative to the guiding frame 26 .
Referring to FIG. 5( a ), the photosensitive member unit 9 , and the toner storage unit 25 of the developing apparatus unit 8 are kept solidly attached to each other, by first and second side covers 32 and 33 , which are located at one lengthwise end of the process cartridge B and the other, respectively. Hereafter, the first side cover 32 will be referred to as the right side cover, whereas the second side cover will be referred to as the left side cover.
Since the process cartridge B is structured as described above, the developing means container unit 15 is allowed to slide straight in the direction indicated by the arrow mark S in FIG. 4( a ), relative to the toner storage unit 25 . As the developing means container unit 15 is moved toward the toner storage unit 25 as described above, the spacer rings 27 a and 27 b , with which the lengthwise end portions of the development sleeve 19 supported by the developing means container unit 15 are fitted, one for one, are placed in contact with the peripheral surface of the photosensitive drum 10 supported by the photosensitive member unit 9 . As a result, the developing means container unit 15 becomes fixed in position in terms of its widthwise direction. Therefore, the development sleeve 19 is pressed toward the photosensitive drum 10 , with the presence of the spacer rings 27 a and 27 b between the development sleeve 19 and photosensitive drum 10 , while the developing means container unit 15 and toner storage container 20 remain in the state in which the weight of the toner T in the toner storage container 20 is likely to rest on the developing means container unit 15 .
<Gap Maintaining Means>
In this embodiment, the process cartridge B is provided with a gap maintaining means, that is, a means for keeping the distance between the axial line of the photosensitive drum 10 and the axial line of the development sleeve 19 greater when the process cartridge B is distributed than when the process cartridge 5 is being used for image formation, that is, a means for keeping the spacer rings 27 a and 27 b , with which the lengthwise ends of the development sleeve 19 are fitted one for one, separated from the photosensitive drum 10 during the distribution of the process cartridge B.
Referring to FIG. 5( a ), the gap maintaining means in this embodiment is a gap maintaining member 100 , which has a pair of gap maintaining portions 100 a and 100 b , and a handgrip portion 100 c which is gripped by a user to take hold of the gap maintaining member 100 . The gap maintaining member 100 is removably attachable to the process cartridge B. The gap maintaining member 100 is shaped ( FIG. 5( b )) to cover the exposure window 12 c , with which the waste toner container 12 is provided to allow the beam of laser light L to be projected onto the peripheral surface of the photosensitive drum 10 while being modulated with pictorial information. The process cartridge B may be structured so that the exposure window 12 c is provided between the waste toner container 12 and guiding frame 26 .
The handgrip portion 100 c of the gap maintaining member 100 is on the opposite side of the gap maintaining member 100 from the portion of the gap maintaining member 100 , which is for covering the exposure window 12 c . Next, referring to FIG. 5( b ), the gap maintaining member 100 is shaped so that when the gap maintaining member 100 remains attached to the process cartridge B, the handgrip portion 100 c extends from the process cartridge B by a substantial distance beyond the top surface of the waste toner container 12 .
Next, referring to FIGS. 6( a ) and 6 ( b ), in this embodiment, the waste toner container 12 is provided with a pair of contact surfaces 12 a and 12 b , which come into contact with the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 , respectively. The waste toner container 12 is structured so that when the gap maintaining member 100 remains attached to the process cartridge B, the contact surfaces 12 a and 12 b are perpendicular to the straight line connecting the axial line O 1 of the photosensitive drum 10 and the axial line O 2 of the development sleeve 19 (Line Y-Y in FIG. 7) .
The gap maintaining means is a the means for keeping the distance between the axial line of the photosensitive drum 10 and the axial line of the development sleeve 19 greater when it remains attached to the process cartridge B than when the process cartridge B is being used for image formation, and also, for keeping the spacer rings 27 a and 27 b , with which the lengthwise ends of the development sleeve 19 are fitted one for one, separated from the photosensitive drum 10 when it remains attached to the process cartridge B. It works in the following manner.
That is, the gap maintaining member 100 is to be positioned, as shown in FIG. 5( a ), relative to the process cartridge B, and then, is to be moved in the direction indicated by an arrow mark M in FIG. 5 so that its gap maintaining portions 100 a and 100 b follow a pair of gap maintain member insertion guides 32 a and 32 b , with which the right and left side covers 32 and 33 are provided, respectively. In other words, the gap maintaining member 100 is to be positioned, as shown in FIG. 5( a ), relative to the process cartridge B, and then, is to be moved in the direction indicated by the arrow mark M in FIG. 5 so that its gap maintaining portions 100 a and 100 b enter the gaps between the contact surfaces 12 a and 12 b of the waste toner container 12 , and the right and left side frames 30 and 31 of the developing means container unit 15 , respectively. Then, the gap maintaining member 100 is to be pressed further inward of the process cartridge B so that the developing means container unit 15 is separated from the waste toner container 12 against the resiliency of the springs 28 a and 28 b ( FIG. 8( a )).
The direction in which the developing means container unit 15 is slid as the gap maintaining member 100 is pressed further into the process cartridge B is the direction indicated by an arrow mark S in FIG. 7 . The direction in which the gap maintaining member 100 is pressed into the process cartridge B, or pulled out of the process cartridge B, is the direction indicated by an arrow mark M or N, respectively, in FIG. 7 . The relationship between the developing means container unit 15 slides and the direction in which the gap maintaining member 100 is pressed into, or removed from, the process cartridge B, is such that the weight of the developing means container unit 15 and the resiliency of the springs 28 a and 28 b press the gap maintaining member 100 on the contact surfaces 12 a and 12 b . Therefore, the gap maintaining member 100 is secured between the contact surfaces 12 a and 12 b of the waste toner container 12 and the developing means container unit 15 , by the weight of the developing means container unit 15 and the force generated by the resiliency of the springs 28 a and 28 b.
The gap maintaining portions 100 a and 100 b of the gap maintaining member 100 are subjected to the force generated by the resiliency of the springs 28 a and 28 b through the developing means container unit 15 . They are also indirectly subjected, through the developing means container unit 15 , to the impact to which the process cartridge B is subjected during the distribution of the process cartridge B.
Therefore, the width and thickness of the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 are set to ensure that when the gap maintaining member 100 remains properly attached to the process cartridge B, the distance between the axial line of the photosensitive drum 10 and the axial line of the development sleeve 19 remains greater than when the process cartridge B is being used for image formation, or to ensure that when the gap maintaining member 100 remains properly attached to the process cartridge B, the spacer rings 27 a and 27 b , with which the lengthwise ends of the development sleeve 19 are fitted one for one, remain separated from the photosensitive drum 10 , even if the process cartridge B is subjected to a substantial amount of impact during the distribution of the process cartridge B.
The gap maintaining member 100 has to be removed from the process cartridge B before the process cartridge B is mounted into the laser printer A. The gap maintaining member 100 can be removed by pulling it by gripping the handgrip portion of the gap maintaining member 100 (direction in which gap maintaining member 100 is to be moved is indicated by arrow mark N in FIG. 7 ). As the gap maintaining member 100 is pulled out in the abovementioned direction, the developing means container unit 15 is slid straight toward the photosensitive member unit 9 by the force generated by the resiliency of the springs 28 a and 28 b . As a result, the spacer rings 27 a and 27 b , with which the lengthwise end portions of the development sleeve 19 are fitted, are pressed upon the peripheral surface of the photosensitive drum 10 ( FIG. 8( b )). At the same time, the exposure windows 12 c becomes exposed, allowing the beam of laser light L projected while being modulated with the pictorial information, to reach the peripheral surface of the photosensitive drum 10 . It is only when the process cartridge B is in the above described condition that the process cartridge B can be mounted into the laser printer A.
In the case of a process cartridge, such as the process cartridge B, structured as described above, the weight of the toner T in the toner storage container 20 is unlikely to rest on the developing means container unit 15 . Therefore, in practical terms, it is only the developing means container unit 15 itself that affects the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 .
Therefore, in the case of a process cartridge structured as described above, the effect which the weight of the toner T in the toner storage container 20 has on the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 when the process cartridge B is subjected to impact during the distribution of the process cartridge B, is significantly smaller than in the case of a process cartridge structured in accordance with the prior art.
Further, the gap maintaining means in this embodiment is also very effectively usable with a process cartridge of a large capacity. That is, even when the gap maintaining member 100 is produced for a process cartridge of a large capacity, the width and thickness of the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 may be the same as those when the gap maintaining member 100 is produced for a process cartridge of a small capacity. In other words, the gap maintaining means in this embodiment can be used even with a process cartridge of a large capacity to ensure that when the gap maintaining member 100 remains properly attached to the process cartridge B, the distance between the axial line of the photosensitive drum 10 and the axial line of the development sleeve 19 remains greater than when the process cartridge B is being used for image formation, or to ensure that when the gap maintaining member 100 remains properly attached to the process cartridge B, the spacer rings 27 a and 27 b , with which the lengthwise ends of the development sleeve 19 are fitted one for one, remain separated from the photosensitive drum 10 . In other words, regardless of process cartridge capacity, the gap maintaining means in this embodiment can prevent the problem that the photosensitive drum 10 , development sleeve 19 , and/or spacer rings 27 a and 27 b are damaged during the distribution of the process cartridge B.
The force to which the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 are subjected when the gap maintaining member 100 is disengaged from the process cartridge B is only the force generated by the resiliency of the springs 28 a and 28 b , and the weight of the developing means container unit 15 . Therefore, the amount of force necessary to disengage the gap maintaining member 100 from the process cartridge B is significantly smaller than that required to disengage a gap maintaining member ( 100 ) in accordance with the prior art from a process cartridge (B) in accordance with the prior art.
Further, while the gap maintaining member 100 remains properly engaged with the process cartridge B, the exposure window 12 c remains covered with the gap maintaining member 100 . Therefore, until the gap maintaining member 100 is disengaged from the process cartridge B (inclusive of while process cartridge B is distributed), the dust and light have no chance to enter the process cartridge B, being thereby prevented from derogatorily affecting the photosensitive drum 10 .
Further, unless the gap maintaining member 100 is completely disengaged from the process cartridge B, the process cartridge B cannot be mounted into the laser printer A. More specifically, referring to FIG. 9 , if an attempt is made to mount the process cartridge B into the laser printer A without removing the gap maintaining member 100 , the handgrip portion 100 c of the gap maintaining member 100 , which protrudes in the opposite direction from the exposure window 12 c , comes into contact with the internal cover 4 a of the laser printer A, and prevents the process cartridge B from being inserted further into the laser printer A. In other words, the handgrip portion 100 c of the gap maintaining member 100 reminds a user that the user forgot to remove the gap maintaining member 100 from the process cartridge B, preventing thereby the user from improperly mounting the process cartridge B into the laser printer A.
Incidentally, in this embodiment of the present invention, the process cartridge B and gap maintaining member 100 were structured so that the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into contact with the contact surfaces 12 a and 12 b of the waste toner container 12 . However, the process cartridge B and gap maintaining member 100 may be structured so that the right and left side cover 32 and 33 are provided with the contact surfaces, with which the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into contact, respectively. The effect of such structural arrangement is the same as that of this embodiment, that is, the structural arrangement which uses the contact surfaces 12 a and 12 b of the waste toner container 12 as the surfaces with which the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into contact.
Also in this embodiment of the present invention, the process cartridge B and gap maintaining member 100 were structured so that as the gap maintaining member 100 is engaged with the process cartridge B, the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into, and remain in, contact with a part of the right frame 30 of the developing means container unit 15 , and a part of the left frame 31 , respectively. However, the process cartridge B and gap maintaining member 100 may be modified in structure so that the slide frame 29 functions as the portion of the process cartridge B, with which the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into contact, and remain in contact. Also in this case, the gap maintaining member 100 can function as the gap maintaining means just as effectively as in the case in which the process cartridge B and gap maintaining member 100 are structured so that the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 come into contact, and remain in contact, with the right and left slide frames 30 and 31 , respectively.
Embodiment 2
Next, referring to FIGS. 10 and 11 , the second embodiment of the present invention will be described. FIG. 10 is a schematic perspective view of the gap maintaining member in this embodiment, and depicts the structure of the gap maintaining member. FIG. 11 is a perspective view of the lengthwise end portion of the process cartridge when the gap maintaining member in this embodiment is properly engaged with the process cartridge in this embodiment.
The gap maintaining member 100 A, that is, the gap maintaining member in this embodiment, is the same in structure as the gap maintaining member 100 , that is, the gap maintaining member in the first embodiment. Thus, the portions of the gap maintaining member 100 A, which are the same in structure and function as the counterparts of the gap maintaining member 100 , are given the same referential symbols as those given to the counterparts, so that the description of the counterparts of the gap maintaining member 100 can be employed to avoid the repetition of the same description.
Referring to FIG. 10 , the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 A have portions 100 d and 100 e , which come into contact, and remain in contact, with the right and left slide frame 30 and 31 , respectively. These portions 100 d and 100 e are in the form of a recess (or bulge), the depth (or height) direction of which is roughly perpendicular to the direction (indicated by arrow mark M) in which the gap maintaining member 100 A is engaged into the process cartridge B, and the direction (indicated by arrow mark N) in which the 100 A is disengaged from the process cartridge B. Thus, the portion of the right slide frame 30 , which engages with the portion 100 d of the gap maintaining portion 100 a of the gap maintaining member 100 , and the portion of the left slide frame 31 , which engages with the portion 100 e of the gap maintaining portion 100 b of the gap maintaining member 100 , are in the form of a bulge (or recess). Although FIG. 11 does not show the left slide frame 31 , the left slide frame 31 is the same in structure as the right slide frame 30 .
In the first embodiment of the present invention, the force which is generated by the resiliency of the springs 28 a and 28 b and presses on the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 through the developing means container unit 15 , was used to prevent the gap maintaining member 100 from unexpectedly moving in the direction in which the gap maintaining member 100 is to be engaged into, or disengaged from, the process cartridge B. Further, the weight of the developing means container unit 15 itself is utilized to prevent the gap maintaining member 100 from unexpectedly moving in the direction in which the gap maintaining member 100 is to be engaged into, or disengaged from, the process cartridge B, by keeping the gap maintaining portion 100 a sandwiched between the contact surface 12 a of the waste toner container 12 , and the right slide frame 30 , and keeping the gap maintaining portion 100 b sandwiched between the contact surface 12 b of the waste toner container 12 , and the right slide frame 30 .
However, this setup suffers from the following problem if the amount of the friction generated between the gap maintaining member 100 and the process cartridge B by the force which is generated by the resiliency of the springs 28 a and 28 b and presses on the gap maintaining member 100 through the developing means container unit 15 , and the force which is generated by the weight of the developing means container unit 15 and pressed on the gap maintaining member 100 , is smaller than the amount of the force generated by the impact to which the process cartridge B is subjected during the distribution of the process cartridge B.
That is, it is possible that the moment the process cartridge B is impacted during its distribution, the gap maintaining member 100 will be moved in the direction in which it is to be disengaged (direction indicated by arrow N), and will not return to the original position.
In this embodiment, therefore, the gap maintaining portions 100 a and 100 b of the gap maintaining member 100 A are provided with portions 100 d and 100 e , which are in the form of a recess (or bulge), the depth (or height) direction of which is roughly perpendicular to the direction (indicated by arrow mark M) in which the gap maintaining member 100 A is engaged into the process cartridge B, and the direction (indicated by arrow mark N) in which the 100 A is disengaged from the process cartridge B. The provision of these recesses (bulges) increases in size the area of contact between the gap maintaining member 100 A and the right slide frame 30 , and the area of contact between the gap maintaining member 100 A and the left slide frame 31 , increasing thereby the amount of friction between the gap maintaining member 100 A and right slide frame 30 , and the amount of friction between the gap maintaining member 100 A and left slide frame 31 . In other words, the employment of the structural arrangement, in this embodiment, for the process cartridge B and gap maintaining member 100 A makes it possible to increase the amount of force necessary to move the gap maintaining member 100 A, making thereby the process cartridge B and gap maintaining member 100 A more resistant to the external impact, in terms of the amount of impact. Therefore, the combination of the process cartridge B and gap maintaining member 100 A in this embodiment is superior to the combination of the process cartridge B and gap maintaining member 100 in the first embodiment, in terms of the prevention of the disengagement of a gap maintaining member from a process cartridge.
Incidentally, the impact to which the process cartridge B is subjected during the distribution of the process cartridge B may sometimes exceed in magnitude even the abovementioned increased friction, that is, may be large enough to displace the gap maintaining member 100 A. However, as long as the amount of the displacement is slight, the force generated by the resiliency of the springs 28 a and 28 b , and the weight of the developing means container unit 15 , function to move the gap maintaining member 100 A back to where it was. Therefore, the combination of the process cartridge B and gap maintaining member in this embodiment is far superior to the combination of the process cartridge B and gap maintaining member in the first embodiment, in terms of the prevention of the disengagement of a gap maintaining member from a process cartridge in the direction in which the process cartridge is to be disengaged (direction indicated by arrow mark N).
The present invention relates to a process cartridge, which is made up of a photosensitive member unit, a toner storage unit solidly attached to the photosensitive member unit, and a developer bearing member supporting frame movable relative to the toner storage unit, and which is characterized in that it can significantly reduce the effect which the weight of the developer storage portion has upon the portion of the peripheral surface of the electrophotographic photosensitive member, which is in contact with the developer bearing member, when a process cartridge is subjected impact during its distribution. More specifically, according to the present invention, a combination of a process cartridge and a gap maintaining member is structured so that after the completion of the process cartridge, the process cartridge is fitted with the gap maintaining member to displace the developer bearing member supporting frame against the force generated by a pair of pressure generating members, in order to keep the distance between the rotational axis of the electrophotographic photosensitive member and the rotational axis of the developer bearing member greater during the distribution of the process cartridge than when the process cartridge is being used for image formation, or to keep the electrophotographic photosensitive member separated from a pair of gap regulating members, with which the lengthwise end portions of the developer bearing member are fitted, one for one, during the distribution of the process cartridge.
Thus, the present invention makes it possible to reduce the distance by which a developer bearing member needs to be moved to increase the distance between an electrophotographic photosensitive member and the developer bearing member for the distribution of a process cartridge, compared to the distance which is kept between the electrophotographic photosensitive and developer bearing member when the process cartridge is being used for image formation, or to reduce the distance which needs to be kept between an electrophotographic photosensitive member and a pair of gap regulating members with which the lengthwise end portions of the developer bearing member are fitted, for the distribution of a process cartridge. Therefore, the present invention can make it possible to reduce in size the gap maintaining member for preventing an electrophotographic photosensitive member, a developer bearing member, and/or a gap regulating member from being damaged (deformed) during the distribution of a process cartridge, even for a process cartridge of a large size. Further, according to the present invention, the force to which the gap maintaining member is subjected is only the force generated by the resiliency of the pressure generating members, and the weight of the movable frame. Therefore, the employment of the present invention can make it possible to reduce the amount of force necessary to disengage the gap maintaining member from a process cartridge.
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.
This application claims priority from Japanese Patent Application No. 105689/2007 filed Apr. 13, 2007, which is hereby incorporated by reference. | A process cartridge is detachably mountable to a main assembly of an electrophotographic image forming apparatus. The process cartridge includes a photosensitive member unit having a photosensitive drum, a developer carrying member for developing an electrostatic latent image formed on the photosensitive drum with a developer, and a toner accommodating unit having a developer accommodating portion accommodating the developer to be used for development of the electrostatic latent image. A movable frame supports the developer carrying member, and an urging member is provided for urging the movable frame in a direction in which the developer carrying member approaches the photosensitive drum. A space maintaining member, is also provided for maintaining a state in which a distance between the photosensitive drum and the developer carrying member is larger than that in an image formation. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a material having good low-temperature impact strength and comprising, besides polyester as matrix polymer, at least two other polymers which act synergistically to improve the impact strength of the material. The invention further relates to moldings made from this material.
[0003] 2. Discussion of the Background
[0004] Engineering components such as those used in the automotive industry sector nowadays have to fulfill very strict requirements with respect to low-temperature impact strength. To this end, tests are carried out using a variety of methods at test temperatures of, for example, −40° C.
[0005] However, thermoplastic polyesters that are used for automotive engineering components, for example as a barrier layer material for suppressing diffusion of fuel components through the wall of, for example, fuel lines, are to some extent brittle. Therefore, the developer is forced to modify these barrier layer materials in order to fulfill the appropriate requirements placed upon low-temperature impact strength. The modifiers commonly used for low impact strength, for example, EPM rubbers or EPDM rubbers, are materials which have a specific adverse effect on the barrier properties of polyesters with respect to fuels. Therefore, the content of modifiers for low-temperature impact strength cannot be increased as desired. Impact-modified polyesters are described in, for example, DE-A 26 22 876 or DE-A4401 165.
[0006] Another difficulty facing the developer of moldings is that thermoplastic polyesters have poor compatibility with the usual modifiers for low-temperature impact strength, for example, EPM or EPDM, even when these have been functionalized and contain anhydride groups, which is usually accomplished by free-radical grafting of the rubber with an ethylenically unsaturated anhydride. Poor compatibility is seen in poor bonding of the dispersed rubber to the matrix of the material at the phase boundary. Therefore, to achieve the desired low-temperature impact strength effect, very high concentrations of an EPM- or EPDM-based impact modifier have to be used. However, there is an adverse effect on other important properties, such as barrier action, resistance to solvents or to chemicals.
[0007] Therefore, a critical need exists to provide polyester molding compositions with improved low-temperature impact strength, and in particular to provide polyester molding compositions with good low-temperature impact strength but with the lowest possible content of impact modifiers, so that there is the smallest possible effect on other important properties. Furthermore, there is a need to provide moldings which have good low-temperature impact strength without making the barrier action with respect to fuel components, the solvent resistance or the chemicals resistance, unacceptably poorer than those of the matrix material.
SUMMARY OF THE INVENTION
[0008] These objects are achieved with a molding composition which comprises the following components:
[0009] I. from 60 to 96.6 parts by weight of thermoplastic polyesters,
[0010] II. from 3 to 39.5 parts by weight of an impact-modifying component which contains anhydride groups, where the impact-modifying component is selected from the group consisting of ethylene/α-olefin copolymers and styrene-ethylenelbutylene block copolymers,
[0011] III. from 0.4 to 20 parts by weight of a copolymer which contains units of the following monomers:
[0012] a) from 20 to 94.5% by weight of one or more α-olefins having from 2 to 12 carbon atoms,
[0013] b) from 5 to 79.5% by weight of one or more acrylic compounds, selected from the group consisting of
[0014] acrylic acid and methacrylic acid and salts thereof,
[0015] esters of acrylic acid and/or of methacrylic acid with a C 1 -C 12 alcohol, which may carry, where appropriate, a free hydroxyl or epoxide function
[0016] acrylonitrile and methacrylonitrile,
[0017] acrylamides and methacrylamides, and
[0018] c) from 0.5 to 50% by weight of an olefinically unsaturated epoxide, carboxylic anhydride, carboximide, oxazoline or oxazinone,
[0019] where the total of the parts by weight of components I, II and III is 100.
[0020] In preferred embodiments, the molding composition comprises:
[0021] I. from 70 to 94 parts by weight, particularly preferably from 75 to 92 parts by weight, of polyester,
[0022] II. from 5 to 28 parts by weight, particularly preferably from 6 to 23 parts by weight, and particularly preferably from 7 to 22 parts by weight, of the impact-modifying component, and
[0023] III. from 0.6 to 15 parts by weight, particularly preferably from 0.7 to 10 parts by weight, of the copolymer, which preferably contains units of the following monomers:
[0024] a) from 30 to 80% by weight of β-olefin(s),
[0025] b) from 7 to 70% by weight, particularly preferably from 10 to 60% by weight, of the acrylic compound(s), and
[0026] c) from 1 to 40% by weight, particularly preferably from 5 to 30% by weight, of the olefinically unsaturated epoxide, carboxylic anhydride, carboximide, oxazoline, or oxazinone.
[0027] Other objects of the present invention include methods of preparing the molding compositions, methods of using the molding composition to make moldings and the molding prepared therein.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Polyesters that may be used are thermoplastic polyesters of linear structure. These are prepared by polycondensing diols with dicarboxylic acid or with polyester-forming derivatives of these, such as dimethyl esters. Suitable diols have the formula HO—R—OH, where R is a divalent, branched or unbranched aliphatic and/or cycloaliphatic radical having from 2 to 40 carbon atoms, preferably from 2 to 12 carbon atoms. Suitable dicarboxylic acids have the formula HOOC—R′—COOH where R′ is a divalent aromatic radical having from 6 to 20 carbon atoms, preferably from 6 to 12 carbon atoms.
[0029] Examples of diols include ethylene glycol, trimethylene glycol, tetramethylene glycol, hexamethylene glycol, neopentyl glycol, cyclohexane-dimethanol, and also the C 36 diol dimer diol. The diols may be used alone or as a diol mixture.
[0030] Examples of aromatic dicarboxylic acids include terephthalic acid, isophthalic acid, 1,4-, 1,5-, 2,6- or 2,7-naphthalenedicarboxylic acid, diphenic acid and diphenyl ether 4,4′-dicarboxylic acid. Up to 30 mol% of these dicarboxylic acids may have been replaced by aliphatic or cycloaliphatic dicarboxylic acids having from 3 to 50 carbon atoms and more preferably having from 6 to 40 carbon atoms, e.g. succinic acid, adipic acid, sebacic acid, dodecanedioic acid or cyclohexane-1,4-dicarboxylic acid.
[0031] Examples of suitable polyesters include polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, polyethylene 2,6-naphthalate, polypropylene 2,6-naphthalate and polybutylene 2,6-naphthalate.
[0032] The preparation of these polyesters has been described previously, for example, see DE-A 24 07 155, DE-A 24 07 156; Ullmanns Encyclopädie der technischen Chemie [Ullmann's Encyclopedia of Industrial Chemistry], 4 th Edn., Vol. 19, pp. 65 et seq, Verlag Chemie, Weinheim, 1980, the contents of which are incorporated by reference.
[0033] Preferred suitable ethylene/α-olefin copolymers of component II include:
[0034] ethylene/C 3 -C 12 -α-olefin copolymers containing from 20 to 96% by weight, preferably from 25 to 85% by weight, of ethylene. Examples of C 3 -C 12 -α-olefins used are propene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene or 1-dodecene. Typical examples of these materials are ethylene-propylene rubber and also LLDPE and VLDPE.
[0035] ethylene/C 3 -C 12 -α-olefin/unconjugated-diene terpolymers containing from 20 to 96% by weight, preferably from 25 to 85% by weight, of ethylene and up to at most about 10% by weight of an unconjugated diene, such as bicyclo[2.2.1]heptadiene, 1,4-hexadiene, dicyclopentadiene or in particular 5-ethylidenenorbornene. Examples of suitable C 3 -C 12 -α-olefins are propene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene or 1-dodecene.
[0036] The preparation of these copolymers or terpolymers with the aid of a Ziegler-Natta catalyst has been described previously (Kirk-Othmer, Encyclopedia of Chemical Technology, Fourth Edition, Vol. 8, pp. 978-989, John Wiley & Sons, Inc., New York, 1993).
[0037] The styrene-ethylene/butylene block copolymers preferably used include styrene-ethylene/butylene-styrene block copolymers (SEBS), which are obtainable by hydrogenating styrene-butadiene-styrene block copolymers. However, diblock systems (SEB) or multiblock systems may also be used. Block copolymers of this type have been described previously (Kirk-Othmer, Encylcopedia of Chemical Technology, Fourth Edition, Vol. 9, pp. 15-37, John Wiley & Sons, Inc., New York, 1993).
[0038] Component II contains anhydride groups which may be introduced by thermal or free-radical reaction with an unsaturated dicarboxylic anhydride, with an unsaturated dicarboxylic acid, or with an unsaturated monoalkyl dicarboxylate by methods known in the art (U.S. Pat. No. 4,174,358). Examples of suitable reagents include maleic acid, maleic anhydride, monobutyl maleate, fumaric acid, aconitic acid or itaconic anhydride. Using this method, it is preferable to graft from 0.1 to 4% by weight of an unsaturated anhydride onto impact-modifying component II. Furthermore, as known in the art it is also possible for another unsaturated monomer, such as styrene, α-methylstyrene or indene, to be grafted on together with the unsaturated dicarboxylic anhydride or its precursor.
[0039] Examples of monomers used in the makeup of the copolymer of component III include, among others:
[0040] a) α-olefins, such as ethylene, propene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene or 1-dodecene;
[0041] b) acrylic acid, methacrylic acid or salts thereof, for example with Na + or Zn 2+ as counterions; methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, isobutyl acrylate, n-hexyl acrylate, n-octyl acrylate, 2-ethylhexyl acrylate, isononyl acrylate, dodecyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, 2-ethylhexyl methacrylate, hydroxyethyl acrylate, 4-hydroxybutyl methacrylate, glycidyl acrylate, glycidyl methacrylate, acrylonitrile, methacrylonitrile, acrylamide, N-methylacrylamide, N,N-dimethylacrylamide, N-ethylacrylamide, N-hydroxyethylacrylamide, N-propylacrylamide, N-butylacrylamide, N-(2-ethylhexyl)acrylamide, methacrylamide, N-methylmethacrylamide, N,N-dimethylmethacrylamide, N-ethyl-methacrylamide, N-hydroxyethylmethacrylamide, N-propylmethacrylamide, N-butylmethacrylamide, N,N-dibutylmethacrylamide, N-(2-ethylhexyl)methacrylamide;
[0042] c) vinyloxirane, allyloxirane, glycidyl acrylate, glycidyl methacrylate, maleic anhydride, aconitic anhydride, itaconic anhydride, and also the dicarboxylic acids arising from these anhydrides by reacting with water; maleimide, N-methylmaleimide, N-ethylmaleimide, N-butylmaleimide, N-phenylmaleimide, aconitimide, N-methylaconitimide, N-phenylaconitimide, itaconimide, N-methylitaconimide, N-phenylitaconimide, N-acryloylcaprolactam, N-methacryloylcaprolactam, N-acryloyllaurolactam, N-methacryloyllaurolactam, vinyloxazoline, isopropenyloxazoline, allyloxazoline, vinyloxazinone or isopropenyloxazinone. If glycidyl acrylate or glycidyl methacrylate are used, these may serve simultaneously as an acrylic compound b), and if the amount of glycidyl (meth)acrylate is adequate, therefore, there is no need for another acrylic compound to be present. Preferably, the adequate amount is at least 5.5 % by weight.
[0043] A prefered copolymer includes:
[0044] a) from 20 to 94.5% by weight of one or more α-olefins having from 2 to 12 carbon atoms,
[0045] b) from 0 to 79.5% by weight of one or more acrylic compounds, selected from the group consisting of
[0046] acrylic acid and methacrylic acid and salts thereof,
[0047] esters of acrylic acid and/or of methacrylic acid with a C 1 -C 12 alcohol,
[0048] acrylonitrile and methacrylonitrile,
[0049] acrylamides and methacrylamides, and
[0050] c) from 0.5 to 80% by weight of an ester of acrylic acid or methacrylic acid, where the ester contains an epoxy group,
[0051] where the total of b) and c) is at least 5.5% by weight.
[0052] The copolymer of component III may also contain a small amount of other copolymerized monomers, such as dimethyl maleate, dibutyl fumarate, diethyl itaconate or styrene, as long as these do not significantly adversely affect the desired effects.
[0053] The preparation of these copolymers are known in the art (Hans-Georg Elias, Makromolekule, Vol. 1, 6 th Ed., Wiley-VCH, Weinheim, 1999, pages 376-416 and Hans-Georg Elias, Markromolekule, Vol. 3, 6 th Ed., Wiley-VCH, pages 163 ff). These copolymers may also be obtained from commercial sources, for example as LOTADER® (Elf Atochem; ethylene/acrylate/tercomponent or ethylene/glycidyl methacrylate).
[0054] In one advantageous embodiment, some of the polyester of component I is replaced by a polyamine-polyamide copolymer, specifically from 0.1 to 10 parts by weight, preferably from 0.2 to 5 parts by weight and particularly preferably from 0.25 to 3 parts by weight. The polyamine-polyamide copolymer is prepared using the following monomers:
[0055] a) from 0.5 to 25% by weight, preferably from 1 to 20% by weight, and particularly preferably from 1.5 to 16% by weight, based on the polyamine-polyamide copolymer, of a polyamine having at least 4 nitrogen atoms, preferably at least 8 nitrogen atoms, and particularly preferably at least 11 nitrogen atoms and a number-average molar mass M n of at least 146 g/mol, preferably at least 500 g/mol, and particularly preferably at least 800 g/mol, and
[0056] b) polyamide-forming monomers selected from the group consisting of lactams, ω-aminocarboxylic acids and/or equimolar combinations of diamine and dicarboxylic acid.
[0057] In one embodiment, the amino group concentration in the polyamine-polyamide copolymer is in the range from 100 to 2500 mmol/kg.
[0058] Examples of classes of substances which may be used as polyamine are the following:
[0059] polyvinylamines (Römpp Chemie Lexikon [Römpp's Chemical Encyclopedia], 9th edition, Vol. 6, p. 4921, Georg Thieme Verlag Stuttgart, 1992);
[0060] polyamines which are prepared from alternating polyketones (DE-A 196 54 058);
[0061] dendrimers, such as ((H 2 N—(CH 2 ) 3 ) 2 N—(CH 2 ) 3 ) 2 —N(CH 2 ) 2 —N((CH 2 ) 2 —N ((CH 2 ) 3 —NH 2 ) 2 ) 2 (DE-A-196 54 179) or tris(2-aminoethyl)amine, N,N-bis(2-aminoethyl)-N′,N′-bis[2-[bis(2-aminoethyl)amino]ethyl]-1,2-ethanediamine, 3,15-bis(2-aminoethyl)-6,12-bis[2-[bis(2-aminoethyl)amino]ethyl]-[2[bis[2-[bis(2-aminoethyl)amino]ethyl]amino]ethyl]-3,6,9,12,15-pentaaza-heptadecane-1,17-diamine (J. M. Warakomski, Chem. Mat. 1992, 4, 1000-1004);
[0062] linear polyethyleneimines, which can be prepared by polymerizing 4,5-dihydro-1,3-oxazoles, followed by hydrolysis (Houben-Weyl, Methoden der Organischen Chemie [Methods in organic chemistry], Vol. E20, pp. 1482-1487, Georg Thieme Verlag Stuttgart, 1987);
[0063] branched polyethyleneimines, which can be obtained by polymerizing aziridines (Houben-Weyl, Methoden der Organischen Chemie [Methods in organic chemistry], Vol. E20, pp. 1482-1487, Georg Thieme Verlag Stuttgart, 1987) and generally have the following distribution of amino groups:
[0064] from 25 to 46% of primary amino groups,
[0065] from 30 to 45% of secondary amino groups, and
[0066] from 16 to 40% of tertiary amino groups.
[0067] In the preferred case, the polyamine has a number-average molar mass M n of not more than 20 000 g/mol, particularly preferably not more than 10 000 g/mol, and in particular preferably not more than 5000 g/mol.
[0068] Lactams or ω-aminocarboxylic acids which are used as polyamide-forming monomers contain from 4 to 19 carbon atoms, in particular from 6 to 12 carbon atoms. It is particularly preferable to use ω-caprolactam, ω-aminocaproic acid, caprylolactam, ω-aminocaprylic acid, laurolactam, ω-aminododecanoic acid and/or ω-aminoundecanoic acid.
[0069] Examples of combinations of di amine and dicarboxylic acid are hexamethylenediamine/adipic acid, hexamethylenediamine/dodecanedioic acid, octamethylenediamine/sebacic acid, decamethylenediamine/sebacic acid, decamethylenediamine/dodecanedioic acid, dodeca-methylenediamine/dodecanedioic acid and dodecamethylene-diamine/2,6-naphthalenedicarboxylic acid. Furthermore, other combinations may be used, such as decamethylenediamine/dodecanedioic acid/terephthalic acid, hexamethylenediamine/adipic acid/terephthalic acid, hexamethylenediamine/adipic acid/caprolactam, decamethylenediamine/dodecanedioic acid/ω-aminoundecanoic acid, decamethylenediamine/dodecanedioic acid/laurolactam, decamethylenediamine/terephthalic acid/laurolactam or dodecamethylenediamine/2,6-naphthalenedicarboxylic acid/laurolactam.
[0070] In one preferred embodiment, the polyamine-polyamide copolymer is prepared with the additional use of an oligocarboxylic acid which has been selected from the class consisting of from 0.015 to about 3 mol % of dicarboxylic acid and from 0.01 to about 1.2 mol % of tricarboxylic acid, based in each case on the total of the other polyamide-forming monomers. When the equivalent combination of diamine and dicarboxylic acid is used, calculation of these proportions includes each of these monomers individually. If use is made of a dicarboxylic acid, it is preferable to add from 0.03 to 2.2 mol %, particularly preferably from 0.05 to 1.5 mol %, very particularly preferably from 0.1 to 1 mol % and in particular from 0.15 to 0.65 mol %. If use is made of a tricarboxylic acid, it is preferable to use from 0.02 to 0.9 mol %, particularly preferably from 0.025 to 0.6 mol %, very particularly preferably from 0.03 to 0.4 mol %, and in particular from 0.04 to 0.25 mol %. The concomitant use of the oligocarboxylic acid markedly improves resistance to solvents and to fuels, in particular resistance to hydrolysis and alcoholysis compared to the absence of the oligocarboxylic acid.
[0071] The oligocarboxylic acid used may comprise any desired di- or tricarboxylic acid having from 6 to 24 carbon atoms, such as adipic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, cyclohexane-1,4-dicarboxylic acid, trimesic acid and/or trimellitic acid.
[0072] If desired, use may also be made of aliphatic, alicyclic, aromatic, aralkyl and/or alkylaryl-substituted monocarboxylic acids having from 3 to 50 carbon atoms, e.g. lauric acid, unsaturated fatty acids, acrylic acid or benzoic acid, as regulator. Using these regulators can reduce the concentration of amino groups without altering the structure of the molecule. This method can also be used to introduce functional groups, such as double bonds or triple bonds, etc. However, it is desirable for the polyamine-polyamide copolymer to have a substantial proportion of amino groups. The amino group concentration in this copolymer is preferably in the range from 150 to 1500 mmol/kg, particularly preferably in the range from 250 to 1300 mmol/kg and very particularly preferably in the range from 300 to 1100 mmol/kg. For the purposes of the present invention, amino groups here and below are not only amino end groups but also any secondary or tertiary amine functions which may be present in the polyamine.
[0073] The polyamine-polyamide copolymers of the invention may be prepared by various processes.
[0074] One of these processes includes bringing the lactam and, respectively, ω-aminocarboxylic acid and polyamine together and then carrying out the polymerization or the polycondensation. The oligocarboxylic acid may be added either at the start or during the course of the reaction. However, one preferred method is a two-stage process in which the lactam cleavage and prepolymerization is first carried out in the presence of water (as an alternative, the appropriate ω-aminocarboxylic acids and, respectively, diamines and dicarboxylic acids are used directly and prepolymerized). In the second step, the polyamine is added, while any oligocarboxylic acid used concomitantly is metered in prior to, during or after the prepolymerization. The pressure is then released at temperatures between 200 and 290° C. and polycondensation takes place in a stream of nitrogen or in vacuo.
[0075] Another preferred method consists in the hydrolytic degradation of a polyamide to give a prepolymer, and simultaneous or subsequent reaction with the polyamine. It is preferable to use polyamides in which the end-group difference is approximately zero, or in which any oligocarboxylic acid used concomitantly has previously been incorporated by polycondensation. However, the oligocarboxylic acid may also be added at the start of, or in the course of, the degradation reaction.
[0076] Using these methods it is possible to prepare ultra-high-branched polyamides with acid values below 40 mmol/kg, preferably below 20 mmol/kg and particularly preferably below 10 mmol/kg. Almost complete conversion is achieved after as little as from one to five hours of reaction time at temperatures of from 200 to 290° C.
[0077] If desired, a vacuum phase lasting a number of hours may follow, as another process step. This lasts for at least four hours, preferably for at least six hours, and particularly preferably for at least eight hours, at from 200 to 290° C. After an induction period of a number of hours, the melt viscosity is then observed to increase, probably due to a reaction of amino end groups with one another, with elimination of ammonia and chain-linkage. This further increases the molar mass, and this is particularly advantageous for molding compositions intended for extrusion.
[0078] If there is a desire not to complete the reaction in the melt, solid-phase postcondensation of the polyamine-polyamide copolymer as known in the art is also possible. Suitable reaction conditions include reaction temperatures of from about 140° C. to about 5 K below the crystalline melting point T m , preferably temperatures of from 150° C. to about 10 K below T m , using reaction times of from 2 to 48 hours, preferably from 4 to 36 hours, under vacuum or under a stream of inert gas, e.g., nitrogen.
[0079] Addition of this copolymer decreases the melt viscosity, and molding compositions of this type are therefore easier to process, while there is no loss of impact strength.
[0080] In addition to constituents I to III, the molding composition may also comprise relatively small amounts of additives which are needed to achieve certain properties. Examples of such additive include plasticizers, pigments or fillers, such as carbon black, titanium dioxide, glass beads, hollow glass beads, talc, zinc sulfide, silicates or carbonates, nucleating agents and crystallization accelerators, processing aids, such as waxes, zinc stearate or calcium stearate, long-chain fatty acids, fatty alcohols, fatty esters and fatty amides, and montanic esters, flame retardants, such as magnesium hydroxide, aluminum hydroxide or melamine cyanurate, glass fibers, antioxidants, UV stabilizers, hydrolysis stabilizers, and also additives which give the product antistatic properties or electrical conductivity, e.g. carbon fibers, graphite fibrils, stainless steel fibers or conductivity black.
[0081] The molding composition of the invention is used for producing moldings, e.g. for mechanical engineering, or for sports products, in particular for producing engineering components in the automotive industry sector. These are generally tubes, filler necks or containers, in particular for conducting or storing liquids or gases. A tube of this type may have a straight-line or corrugated shape, or may have corrugations only in some of its sections. Corrugated tubes have been described, e.g., see U.S. Pat. No. 5,460,771, which is incorporated herein by reference. Particularly, important applications are for use as a fuel line, as a tank-filling pipe, as a vapor line (i.e. a line which conducts fuel vapors, e.g. ventilation lines), as a coolant-fluid line, as an air-conditioning-system line, or as a fuel tank. The molding composition is also advantageously used for quick connectors, pump housings, fuel-filter housings, activated-carbon canisters, valve housings, anti-surge cups, connectors to plastic fuel tanks, tank filler necks, cable coatings for electrical cables, housings for hydraulic cylinders, windshield wash system lines, clutch lines, reduced-pressure lines, ventilation lines, hydraulic lines or air-brake lines.
[0082] The molding composition of the invention may also be used for producing fuel-pump lines or for producing water-supply lines.
[0083] All of these moldings may either be composed entirely of the molding composition of the invention or may comprise the molding composition of the invention as one of two or more layers, for example as a reinforcing outer layer or as an intermediate layer, or as an inner layer, for example in a tube having two or more layers or container having two or more layers. Preferably, the other layers will consist of a molding composition based on polyamide, for example, PA6, PA612, PA11, PA12; or on a polyolefin, for example, polyethylene or polypropylene.
[0084] Moldings containing the composition of the invention may be produced by any methods known in the art, for example by extrusion, coextrusion, blow molding or injection molding.
[0085] Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only, and are not intended to be limiting unless otherwise specified.
EXAMPLES
[0086] The following materials were used in the experiments:
[0087] PES 1: VESTODUR® 2000, a medium-viscosity polybutylene terephthalate (J value: 146 ml/g) from DEGUSSA-HÜLS AG,
[0088] PES2: Polybutylene 2,6-naphthalate with a J value of 150 ml/g,
[0089] EXXELOR® VA 1803: a maleic-anhydride-grafted ethylene/propylene rubber as impact-modifying component (EXXON Chemicals)
[0090] LOTADER® AX 8900: a random terpolymer made from ethylene, about 32% by weight of acrylates and about 7-9% by weight of glycidyl methacrylate from ATOCHEM
Comparative Example A
[0091] 89 parts by weight of PES1 and 11 parts by weight of EXXELOR® VA 1803 were mixed in the melt, extruded and pelletized using a Berstorff ZE 25 33D twin-screw kneader, at 260° C. and 200 rpm, with a throughput of 10 kg/h. The pellets were then used to produce extruded test specimens for impact testing.
Comparative Example B
[0092] 89 parts by weight of PES1 and 11 parts by weight of LOTADER® AX 8900 were mixed in the melt, extruded and pelletized using a Berstorff ZE 25 33D twin-screw kneader, at 260° C. and 200 rpm, with a throughput of 10 kg/h. The pellets were then used to produce extruded test specimens for impact testing.
[0093] Example 1
[0094] [0094] 89 parts by weight of PES1, 10 parts by weight of EXXELOR® VA 1803 and 1 part by weight of LOTADER® AX 8900 were mixed in the melt, extruded and pelletized using a Berstorff ZE 25 33D twin-screw kneader, at 260° C. and 200 rpm, with a throughput of 10 kg/h. The pellets were then used to produce extruded test specimens for impact testing.
[0095] Example 2
[0096] As example 1, but PES2 was used instead of PES1.
[0097] For measurement of low-temperature impact strength according to SAE J844 (impact weight 445 g, temperature −40° C.), monotubes were extruded with 8 mm external diameter and wall thickness of 1 mm.
TABLE 1 Impact strength at −40° C. SAE J844 Notched impact strength Number of according to ISO 179/1eA fractures in Molding Composition [kJ/m 2 ] 10 tubes) Comparative example A 5.7 10 Comparative example B 4.1 10 Comparison: PES1 5.0 10 Comparison: PES2 3.6 10 Example 1 11.7 0 Example 2 9.2 0
[0098] Obviously, numerous modifications and variations on 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.
[0099] The present application claim priority to German Application DE 10064336.1 filed Dec. 21, 2000, the contents of which are incorporated herein by reference. | The present invention relates to a molding composition containing thermoplastic polyesters, impact-modifying component which contains anhydride groups, a copolymer of α-olefin, acrylic compound, olefinically unsaturated epoxide, carboxylic anhydride, carboximide, oxazoline and/or oxazinone, which has improved low-temperature impact strength; methods of making molding with the molding composition and molding containing the composition. | 2 |
FIELD
The present disclosure relates to engine fuel systems, and more specifically to engine fuel pressure enhancement.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Engine fuel systems may include engine driven fuel pumps that are driven by a rotating engine component. The fuel pump may be indirectly driven by the engine crankshaft through engagement with a camshaft. During engine start conditions, the first several revolutions of the engine crankshaft may be at a speed that is less than a speed required to produce a desired fuel pressure from the fuel pump. This is particularly true in fuel systems such as direct injection fuel systems where fuel at high pressure is injected directly into an engine cylinder.
SUMMARY
A fuel system may include an auxiliary fuel pump, a fuel pressure amplifier, a first chamber defining a first fluid volume, a second chamber defining a second fluid volume, and a fuel injector. The auxiliary fuel pump may be in communication with a fuel source. The fuel pressure amplifier may be in communication with the fuel pump and may include a piston mechanism. The piston mechanism may include a first side having a first surface area and a second side that is generally opposite the first side and having a second surface area that is less than the first surface area. The first fluid volume may be in communication with the auxiliary fuel pump and may apply a first fluid pressure to the first surface area based on a pressurized fuel source provided by the auxiliary fuel pump to create a first force on the piston mechanism. The second fluid volume may apply a second fluid pressure to the second surface area to create a second force on the piston mechanism that is less than the first force resulting in displacement of the piston mechanism. The fuel injector may be in communication with the second fluid volume and may provide a pressurized fuel supply to an engine based on the displacement of the piston mechanism.
An engine assembly may include an engine block defining a cylinder, a fuel injector in communication with the cylinder to selectively provide a fuel flow to the cylinder, an auxiliary fuel pump in communication with a fuel source, a fuel pressure amplifier, and first and second chambers defining first and second fluid volumes. The fuel pressure amplifier may be in communication with the auxiliary fuel pump and may include a piston mechanism. The piston mechanism may include a first side having a first surface area and a second side that is generally opposite the first side and having a second surface area that is less than the first surface area. The first fluid volume may be in communication with the auxiliary fuel pump and may apply a first fluid pressure to the first surface area based on a pressurized fuel source provided by the auxiliary fuel pump to create a first force on the piston mechanism. The second fluid volume may be in communication with the fuel injector and may apply a second fluid pressure to the second surface area to create a second force on the piston mechanism that is less than the first force resulting in displacement of the piston mechanism.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a schematic illustration of an engine assembly in a first operating mode according to the present disclosure;
FIG. 2 is a schematic illustration of the engine assembly of FIG. 1 in a second operating mode;
FIG. 3 is a schematic illustration of the engine assembly of FIG. 1 in a third operating mode; and
FIG. 4 is a schematic illustration of an alternate fuel pressure amplifier according to the present disclosure.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to FIGS. 1-3 , an exemplary engine assembly 10 is schematically illustrated. The engine assembly 10 may include an engine 12 in communication with a fuel system 14 and a control module 16 . In the example shown, the engine 12 may include an engine block that defines a plurality of cylinders 18 in communication with the fuel system 14 .
The fuel system 14 may include a fuel tank 20 , first and second fuel pumps 22 , 24 , a pressure amplifier system 26 , a control valve system 28 , a fuel rail 30 , fuel injectors 31 , and first and second conduits 34 , 36 . The first fuel pump 22 may include an auxiliary fuel pump, for example, a lift pump, that is driven by an electric motor 32 and may be in fluid communication with fuel within the fuel tank 20 . The first fuel pump 22 may be in fluid communication with the second fuel pump 24 .
The second fuel pump 24 may include a variety of types of pumps that can be driven by the engine 12 , including but not limited to gerotor pumps, gear pumps, and reciprocating pumps. More specifically, the second fuel pump 24 may be rotationally driven by the engine 12 . The rotational drive may include engagement with a rotationally driven component of the engine 12 , such as a camshaft (not shown) or any other member having rotation powered by the engine 12 . The second fuel pump 24 may be in fluid communication with the pressure amplifier system 26 and the control valve system 28 via the first conduit 34 .
The pressure amplifier system 26 may include a housing 38 , a piston 40 , and a biasing member 42 . The housing 38 may include first and second chambers 44 , 46 that are isolated from one another. The first chamber 44 may be in fluid communication with the first conduit 34 and the second chamber 46 may be in fluid communication with the second conduit 36 .
The piston 40 may include first and second ends 48 , 50 . The first end 48 may have a first diameter (D 1 ) that is greater than a second diameter (D 2 ) of the second end 50 . Therefore, the first end 48 may have a first surface area (A 1 ) that is greater than a second surface area (A 2 ) of the second end 50 . The first and second ends 48 , 50 of the piston 40 may be sized for a desired pressurization of fuel within the fuel system 14 during an engine start condition. The biasing member 42 may include a compression spring and may initially bias the piston 40 toward the first chamber 44 to the position shown in FIG. 1 at an engine start condition.
Alternatively, as seen in FIG. 4 , a pressure amplifier system 126 may be incorporated into the engine assembly 10 in place of the pressure amplifier system 26 . The pressure amplifier system 126 may be generally similar to the pressure amplifier system 26 with the exception of the piston 140 . The piston 140 may include a passage 139 having a valve 141 disposed therein to selectively provide communication between the first and second chambers 144 , 146 . For example, the valve 141 may include a check valve that is calibrated to open when a fluid pressure within the first chamber 144 exceeds a fluid pressure within the second chamber 146 . The first chamber 144 may be in fluid communication with a first conduit 134 that is similar to the first conduit 34 and the second chamber 146 may be in fluid communication with a second conduit 136 that is similar to the second conduit 36 .
Referring back to FIGS. 1-3 , the control valve system 28 may include a solenoid valve that is in communication with the control module 16 . The control valve system 28 may include a valve member 52 that is displaceable between a first position (seen in FIGS. 1 and 2 ) and a second position (seen in FIG. 3 ). When the valve member 52 is in the first position the first and second conduits 34 , 36 may be generally isolated form one another. When the valve member 52 is in the second position, the first and second conduits 34 , 36 may be in communication with one another.
The fuel rail 30 may be in communication with the second conduit 36 . The fuel injectors 31 may be in fluid communication with the fuel rail 30 and may also be in communication with the control module 16 for commanded injection of fuel into the cylinders 18 . The control module 16 may selectively operate the first fuel pump 22 , actuate the control valve system 28 , and control operation of the fuel injectors 31 to adjust fuel delivery at an engine start condition. The control module 16 may additionally be in communication with an engine speed sensor 53 to determine an operating speed of the engine 12 and first and second pressure sensors 55 , 57 to determine a fuel pressure provided by the second pump 24 and a fuel pressure supplied to the fuel rail 30 , and therefore the fuel injectors 31 . The control module 16 may place the valve member 52 in the second position when the fuel pressure measured by the first pressure sensor 55 indicates a pump out pressure of the second pump 24 that is greater than a predetermined pressure and/or when the engine speed measured by the engine speed sensor 53 is greater than a predetermined engine speed.
In the present example, an engine start condition may correspond to a condition where the first and second conduits 34 , 36 and the first and second chambers 44 , 46 are filled with fuel and the valve member 52 is in the first (or closed) position. The first chamber 44 may define a first volume (V 1 ) and the second chamber 46 may define a second volume (V 2 ). The first fuel pump 22 may be powered by the electric motor 32 and may begin pressurizing fuel within the first conduit 34 and the first chamber 44 since the first conduit 34 and the first chamber 44 are isolated from the second fluid conduit 36 and the second chamber 46 . The second fuel pump 24 may be driven by the engine 12 and may additionally pressurize fuel within the first conduit 34 and the first chamber 44 . As the pressure increases within the first chamber 44 , the piston 40 may be displaced toward the second chamber 46 (as seen in FIG. 2 ), pressurizing the fuel within the second conduit 36 and the second chamber 46 . The fuel injectors 31 may be selectively opened to inject fuel into the cylinder 18 based on the pressurized fuel provided by the piston 40 during the engine start condition.
The first and second surface areas (A 1 , A 2 ), the first and second volumes (V 1 , V 2 ) and the stroke of the piston 40 may be sized to provide a desired fuel pressure to the fuel injectors 31 over a desired time. The duration and/or frequency of opening the fuel injectors 31 may be adjusted by the control module 16 based on the pressure measurement from the pressure sensor 57 and/or based on an engine speed measurement from the engine speed sensor 53 . For example, the fuel system 14 may include a direct injection fuel system. In direct injection fuel systems, relatively high fuel pressures are typically provided to the fuel injectors 31 . For example, fuel pressures in the range of 10,000 to 15,000 kilopascal (kPa) may be appropriate for a desired operation of the fuel injectors 31 .
The first fuel pump 22 may provide significantly less than the pressure needed for direct injection applications. For example, the first fuel pump 22 may provide fuel pressures of 100 to 400 kPa. During the engine start condition the first several rotations of the crankshaft may be at a rotational speed that is less than a speed needed to power the second pump 24 to achieve a desired operating pressure (for example, 10,000-15,000 kPa). The pressure amplifier system 26 may be used to increase the pressure provided to the fuel injectors 31 . If the pressure amplifier system 26 is unable to provide a desired fuel pressure, the duration and/or frequency of opening the fuel injectors 31 may be increased to provide a desired amount of fuel to the cylinders 18 .
Based on the displacement of the piston 40 , the fuel within the second conduit 36 and the second chamber 46 , and therefore the fuel provided to the fuel injectors 31 , may be at least ten times the fuel pressure within the first conduit 34 and the first chamber 44 , and more specifically greater than fifty times the fuel pressure within the first conduit 34 and the first chamber 44 . The piston 40 may be displaced to create this pressure differential due to the difference between the first and second surface areas (A 1 , A 2 ). The force (F 1 ) applied to the first end 48 of the piston 40 may generally be equal to the pressure (P 1 ) within the first chamber 44 multiplied by the first surface area (A 1 ) of the first end 48 (F 1 =P 1 *A 1 ). The force (F 2 ) applied to the second end 50 of the piston 40 may generally be equal to the pressure (P 2 ) within the second chamber 46 multiplied by the second surface area (A 2 ) of the second end 50 (F 2 =P 2 *A 2 ).
Therefore, the first surface area (A 1 ) may be at least ten times the second surface area (A 2 ), and more specifically greater than fifty times the second surface area (A 2 ) to provide the desired fuel pressure amplification. It is understood that a variety of alternate surface area and pressure relationships may be used to provide a desired fuel pressure amplification. Once the second fuel pump 24 has reached a desired operating speed and/or once the first and second forces (F 1 , F 2 ) are approximately equal to one another, the valve member 52 may move to the second position (seen in FIG. 3 ) to provide communication between the first and second conduits 34 , 36 . | A fuel system may include an auxiliary fuel pump in communication with a fuel source, a fuel pressure amplifier in communication with the fuel pump, a first chamber defining a first fluid volume in communication with the auxiliary fuel pump, a second chamber defining a second fluid volume, and a fuel injector in communication with the second fluid volume. The fuel pressure amplifier may include a piston mechanism having a first side defining a first surface area and a second side defining a second surface area that is less than the first surface area. The first fluid volume may apply a force to the first side of the piston mechanism that is greater than a second force to the second side resulting in displacement of the piston mechanism. The fuel injector may provide a pressurized fuel supply to an engine based on the displacement of the piston mechanism. | 5 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to the balancing of turbine rotors in gas turbine engines, and, more particularly, to boltless balance weights for rotor disks of such engines.
[0002] Gas turbine engines include one or more rotors comprising a disk carrying a plurality of airfoil-shaped turbine blades which extract energy from combustion gases. Because of the high rotational speeds of the disks and the large disk and blade masses, proper balancing of the rotors of the turbine is important. Unbalance may, in some cases, seriously affect the rotating assembly bearings and engine operation.
[0003] One known method of balancing a rotor disk is to provide the disk with dedicated balance planes incorporating extra material. These can be selectively ground away as needed. However, this process is difficult to implement efficiently and with repeatable results.
[0004] Another known method for balancing turbine disks is to add washers or other weights to select bolted joints of the rotors. The number, position, and mass of the weighted washers needed to balance the disk is dependent on the balance characteristics of each turbine disk being balanced. These balance characteristics are determined by a balance test on each rotor. After finding the unbalance of a turbine rotor, the weighted washers are added to designated bolted joints until the rotor is balanced. While this method works well for turbine rotors with bolted joints, not all turbine rotors have such joints.
BRIEF SUMMARY OF THE INVENTION
[0005] These and other shortcomings of the prior art are addressed by the present invention, which provides a boltless balance weight for use with turbine rotors.
[0006] According to one aspect of the invention, a balance weight for a rotor includes: (a) an arcuate body including a front wall and a rear wall interconnected by an end wall, the front, rear, and end walls collectively defining a generally U-shaped cross-sectional shape; and (b) a projection extending outwardly from the rear wall, the projection being adapted to engage an aperture extending through a flange of the rotor.
[0007] According to another aspect of the invention, a turbine rotor assembly includes: (a) a rotatable disk adapted to carry a plurality of turbine blades at its rim; (b) a flange arm extending axially from a surface of the disk; (c) a radially-extending flange disposed at a distal end of the flange arm, the flange having a plurality of apertures extending therethrough; and (d) a balance weight disposed in a slot cooperatively defined by the disk, the flange arm, and the flange, the balance weight having: (i) an arcuate body including a front wall and a rear wall interconnected by an end wall, the front, rear, and end walls collectively defining a generally U-shaped cross-sectional shape; and (ii) a projection extending outwardly from the rear wall, the projection engaging one of the apertures of the turbine rotor, so as to secure the balance weight to the turbine rotor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
[0009] FIG. 1 is a cross-sectional view of a portion of a gas turbine engine including two turbine rotor stages constructed according to an aspect of the present invention;
[0010] FIG. 2 is a front perspective view of a balance weight for use with a gas turbine rotor;
[0011] FIG. 3 is a rear perspective view of the balance weight of FIG. 2 ;
[0012] FIG. 4 is a partial perspective view of a disk with the balance weight of FIG. 2 installed therein;
[0013] FIG. 5 is a rear perspective view of a balance weight for use with a turbine rotor;
[0014] FIG. 6 is a front view of the balance weight of FIG. 5 ;
[0015] FIG. 7 is a side view of the balance weight of FIG. 5 ; and
[0016] FIG. 8 is a partial perspective view of a disk with the balance weight of FIG. 5 installed therein.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 depicts a portion of a gas generator turbine 10 , which is part of a gas turbine engine of a known type. The function of the gas generator turbine 10 is to extract energy from high-temperature, pressurized combustion gases from an upstream combustor (not shown) and to convert the energy to mechanical work, in a known manner. The gas generator turbine 10 drives an upstream compressor (not shown) through a shaft so as to supply pressurized air to a combustor.
[0018] In the illustrated example, the engine is a turboshaft engine and a work turbine (not shown) would be located downstream of the gas generator turbine 10 and coupled to an output shaft. This is merely one example of a possible turbine configuration, and the principles described herein are equally applicable to rotors of similar or different configuration used in turbofan and turbojet engines, as well as turbine engines used for other vehicles or in stationary applications, as well as rotors that require balancing in other types of machinery.
[0019] The gas generator turbine 10 includes a first stage nozzle 12 which comprises a plurality of circumferentially spaced airfoil-shaped hollow first stage vanes 14 that are supported between an arcuate, segmented first stage outer band 16 and an arcuate, segmented first stage inner band 18 . The first stage vanes 14 , first stage outer band 16 and first stage inner band 18 are arranged into a plurality of circumferentially adjoining nozzle segments that collectively form a complete 360° assembly. The first stage outer and inner bands 16 and 18 define the outer and inner radial flowpath boundaries, respectively, for the hot gas stream flowing through the first stage nozzle 12 . The first stage vanes 14 are configured so as to optimally direct the combustion gases to a first stage rotor 20 .
[0020] The first stage rotor 20 includes a array of airfoil-shaped first stage turbine blades 22 extending outwardly from a first stage disk 24 that rotates about the centerline axis of the engine. A segmented, arcuate first stage shroud 26 is arranged so as to closely surround the first stage turbine blades 22 and thereby define the outer radial flowpath boundary for the hot gas stream flowing through the first stage rotor 20 .
[0021] A second stage nozzle 28 is positioned downstream of the first stage rotor 20 , and comprises a plurality of circumferentially spaced airfoil-shaped hollow second stage vanes 30 that are supported between an arcuate, segmented second stage outer band 32 and an arcuate, segmented second stage inner band 34 . The second stage vanes 30 , second stage outer band 32 and second stage inner band 34 are arranged into a plurality of circumferentially adjoining nozzle segments that collectively form a complete 360° assembly. The second stage outer and inner bands 32 and 34 define the outer and inner radial flowpath boundaries, respectively, for the hot gas stream flowing through the second stage turbine nozzle 28 . The second stage vanes 30 are configured so as to optimally direct the combustion gases to a second stage rotor 38 .
[0022] The second stage rotor 38 includes a radial array of airfoil-shaped second stage turbine blades 40 extending radially outwardly from a second stage disk 42 that rotates about the centerline axis of the engine. A segmented arcuate second stage shroud 44 is arranged so as to closely surround the second stage turbine blades 40 and thereby define the outer radial flowpath boundary for the hot gas stream flowing through the second stage rotor 38 .
[0023] The first stage disk 24 includes a radially-extending annular flange 46 . The flange 46 is supported by a flange arm 48 that extends axially from the aft side 50 of the first stage disk 24 . Collectively, the first stage disk 24 , flange arm 48 , and flange 46 define an annular slot 52 . The flange 46 has an annular array of apertures 54 formed therethrough (see FIG. 4 ). The second stage disk 42 is similar in configuration to the first stage disk 24 and includes an annular flange 56 , flange arm 58 , and slot 60 .
[0024] FIGS. 2 and 3 illustrate an exemplary balance weight 62 for use with the disks 24 and 42 . The balance weight 62 is generally U-shaped in cross-section and includes spaced-apart front and rear walls 64 and 66 interconnected by an end wall 68 . The balance weight 62 is made from a suitable alloy and may be formed by methods such as casting, stamping, or machining. The balance weight 62 is slightly resilient, such that the front and rear walls 64 and 66 can be compressed towards each other for installation but will spring back to their original shape.
[0025] The rear wall 66 of the balance weight 62 includes a dimple 70 protruding outwardly therefrom. In the illustrated example, the front wall 64 includes a cutout 72 which is aligned with the lateral and radial position of the dimple 70 , to allow the dimple 70 to be formed in the rear wall 66 using a forming die or other similar tooling. Depending on the method of manufacture, the cutout 72 may be eliminated. The overall dimensions, material thickness, and specific cross-sectional profile of the balance weight 62 may be varied in size to increase or decrease its mass as required for a particular application.
[0026] FIG. 4 illustrates how the balance weight 62 is installed. It will be understood that the installation process is identical for the first and second disks 24 and 42 , and therefore will only be discussed with respect to disk 24 . The balance weight 62 is positioned in the slot 52 by compressing the balance weight 62 such that it slides between the aft side 50 of the first stage disk 24 and the flange 46 . The balance weight 62 is positioned such that the dimple 70 is aligned with one the apertures 54 in the flange 46 . Once the dimple 70 is aligned with the aperture 54 , the balance weight 62 is released to allow it to expand in the slot 52 , forcing the dimple 70 into the aperture 54 and thereby securing the balance weight 62 .
[0027] At a static condition, the balance weight 62 will be retained by the dimple engagement and friction forces. During operation of the turbine 10 , the balance weight 62 is further secured within the slot 52 by rotational forces caused by the rotation of the first stage disk 24 . In particular, there is a small space between the end wall 68 of the balance weight 62 and the inner diameter of the flange arm 48 . During engine operation, this allows the balance weight 62 to rotate aft with a “hammer head” effect under centrifugal force, urging the dimple 70 into the aperture 54 , thus providing redundant retention in the first stage disk 24 .
[0028] FIGS. 5-7 illustrate an alternative balance weight 162 which is similar in construction to the balance weight 162 and includes spaced-apart front and rear walls 164 and 166 interconnected by an end wall 168 . The balance weight 162 is made from a suitable alloy and may be formed by methods such as casting, stamping, or machining. The balance weight 162 is slightly resilient, such that the front and rear walls 164 and 166 can be compressed towards each other for installation but will spring back to their original shape.
[0029] The rear wall 166 includes a pin 170 protruding outwardly therefrom. The pin 170 may be a separate element which is attached to the rear wall 166 by brazing or welding, or it may be integrally formed with the rear wall 166 . As shown, an aft face 172 of the pin 170 is angled or sloped radially outward to ease installation of the balance weight 162 ; however, it should be appreciated that the aft face 172 may also be flat or have any other suitable geometry.
[0030] A lip 174 extends axially aft from a radially inner edge of the rear wall 166 . The lip 174 may be sized according to the amount of mass needed for balancing, and may also provide additional stability when the balance weight 162 is installed. The overall dimensions, material thickness, and specific cross-sectional profile of the balance weight 162 may be varied in size to increase or decrease its mass as required for a particular application.
[0031] FIG. 8 illustrates how the balance weight 162 is installed. As with the balance weight 62 , it will be understood that the installation process is identical for the first and second stage disks 24 and 42 , and therefore will only be discussed with respect to disk 24 . The balance weight 162 is positioned in the slot 52 by compressing it such that it slides between the aft side 50 of the first stage disk 24 and the flange 46 . The balance weight 162 is positioned such that the pin 170 is aligned with one the apertures 54 in the flange 46 . Once the pin 170 is aligned with the aperture 76 , the balance weight 162 is released to allow it to expand in the slot 52 , forcing the pin 170 into the aperture 54 and thereby securing the balance weight 162 .
[0032] At a static condition, the balance weight 162 will be retained by the pin engagement and friction forces. During operation of the turbine 10 , the balance weight 162 is further secured within the slot 52 by rotational forces caused by the rotation of the first stage disk 24 . In particular, there is a small space between the end wall 168 of the balance weight 162 and the inner diameter of the flange arm 48 . During engine operation, this allows the balance weight 162 to rotate aft with a “hammer head” effect under centrifugal force, urging the pin 170 into the aperture 54 , thus providing redundant retention in the disk.
[0033] The foregoing has described a balance weight for a turbine rotor. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation. | A balance weight for a rotor includes: (a) an arcuate body including a front wall and a rear wall interconnected by an end wall, the front, rear, and end walls collectively defining a generally U-shaped cross-sectional shape; and (b) a projection extending outwardly from the rear wall, the projection being adapted to engage an aperture extending through a flange of the rotor. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to game controllers, and more particularly, to a genre specific game controller for driving or steering applications.
[0003] 2. Description of the Prior Art
[0004] The concept of a genre specific game controller is well known in the gaming industry. Examples of such genre specific games that utilize genre specific game controllers are flight simulators, first person shooting games, and driving games.
[0005] Some examples of driving or steering assemblies for video gaming are shown in U.S. Pat. Nos. 5,829,745 and 6,083,106. The '745 patent discloses a video game control unit with self-centering steering wheel. This control unit includes a separable console and base sections, with the console section housing a steering wheel video game input device that automatically returns to a central, neutral position. This steering wheel controller is very cumbersome and is exclusively dedicated to driving games and cannot be used with other genres of games.
[0006] U.S. Pat. No. 6,083,106 discloses a video game race car simulator assembly for simulating sitting in the driver seat of a racing car when playing a driving video game. This simulator is not designed for home use, and as such prevents the implementation into home video gaming systems such as, for example, Sony PlayStation®, Sega DREAMCAST®, Nintendo 64®, etc.
[0007] U.S. Pat. No. 5,785,317 discloses an operation apparatus for a game machine. This game controller is a two-handed controller requiring the user to hold both sides simultaneously and thereby enable them to actuate controls on both sides of the housing. In addition, the housing of this game controller is designed to twist in the middle so as to provide the user with improved feeling controllers in the shape of a steering wheel promote the two-handed driving/steering experience, however fail to generally provide the other ergonomically preferred designs of two-handed controllers (e.g., U.S. Pat. Nos. 6,102,803 and 5,785,317)., including the disposition of other controls used in conjunction with the genre specific control.
SUMMARY OF THE INVENTION
[0008] It is therefore an object of the present invention to provide a game controller that includes additional driving/steering game controls for operation by the user without interfering with the other existing buttons or controls on a two-handed game controller.
[0009] It is another object of the invention to provide a game controller that may be selectively used with genre specific driving games, while remaining capable of performing all standard basic two-handed gaming functions.
[0010] Yet another object of the invention is to provide a game controller having dedicated driving/steering levers disposed on the underside of the controller that provide more accurate and reliable steering control to the user.
[0011] These and other objects are achieved in accordance with an embodiment of the invention, wherein a genre specific game controller for driving and steering applications includes a game controller housing adapted for two-hand operation, a plurality of game controls disposed on an upper side of said housing, and a steering lever disposed on an underside of said housing and having two lever ends each adapted to be actuated by fingers on one of the user's hands.
[0012] According to one embodiment, the steering lever is a single piece lever having a rotation axle rotatably connected to the game controller through said housing. The lever ends extend from the rotation axle and when one end is rotated about the rotation axle, the other end moves in an opposite direction. Electronic circuitry disposed within the game controller housing detects the position of the steering lever and outputs variable electrical control commands corresponding to the detected variable positions of the lever ends.
[0013] According to another embodiment, the steering lever is a two piece lever having a central axle. Each piece of the two piece lever is rotatably connected to the game controller about the central axle and through the housing. Each of the lever ends are formed by one of the two piece lever and each are independently operable with respect to the other. Electronic circuitry disposed within the game controller housing detects the independent position of each of the steering lever ends and outputs variable electrical control commands corresponding to the detected variable positions of the lever ends.
[0014] Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. It should be further understood that the drawings are not necessarily drawn to scale and that, unless otherwise indicated, they are merely intended to conceptually illustrate the structures and procedures described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In the drawings wherein like reference numeral denote similar components throughout the views:
[0016] [0016]FIG. 1 a is a front view of a game controller according to a first embodiment of the invention;
[0017] [0017]FIG. 1 b is a side view of the game controller according to the first embodiment of the invention;
[0018] [0018]FIG. 1 c is a bottom view of the game controller according to the first embodiment of the invention;
[0019] [0019]FIG. 2 a is a front view of a game controller according to a second embodiment of the invention;
[0020] [0020]FIG. 2 b is a bottom view of the game controller according to the second embodiment of the invention;
[0021] [0021]FIG. 3 a a front view of a game controller according to a third embodiment of the invention;
[0022] [0022]FIG. 3 b is a side view of the game controller according to the third embodiment of the invention;
[0023] [0023]FIG. 3 c is a bottom view of the game controller according to the third embodiment of the invention;
[0024] [0024]FIG. 4 a is a front view of a game controller according to a fourth embodiment of the invention;
[0025] [0025]FIG. 4 b is a bottom view of the game controller according the fourth embodiment of the invention;
[0026] [0026]FIG. 5 a is a partial cross section showing the internal operation of the game controller according to the first embodiment of the invention;
[0027] [0027]FIG. 5 b is a partial cross section showing the internal operation of game controller according to the second embodiment of the invention;
[0028] [0028]FIG. 6 a is a partial cross section showing the internal operation of the game controller according to the first embodiment of the invention;
[0029] [0029]FIG. 6 b is a partial cross section showing the internal operation of the game controller according to the first embodiment of the invention;
[0030] [0030]FIG. 7 is a partial cross section showing the internal operation of the game controller according to the third embodiment of the invention;
[0031] [0031]FIG. 8 a is a partial cross section showing another embodiment of the internal operation of the game controller according to the first embodiment of the invention;
[0032] [0032]FIG. 8 b is partial cross section of the lever arrangement of the embodiment of FIG. 8 a;
[0033] [0033]FIG. 9 a is a partial cross section showing another embodiment of the internal operation of game controller according to the second embodiment of the invention;
[0034] [0034]FIG. 9 b is a partial cross section of the lever arrangement of the embodiment of FIG. 9 a;
[0035] [0035]FIG. 10 a is a partial cross section showing another embodiment of the internal operation of the game controller according to the fourth embodiment of the invention;
[0036] [0036]FIG. 10 b is an exemplary implementation of the sensor arrangement for the embodiment depicted in FIG. 10 a;
[0037] [0037]FIG. 10 c is another exemplary implementation of the sensor arrangement for the embodiment depicted in FIG. 10 a;
[0038] [0038]FIG. 11 a is a block representation of the sensor configuration according to the embodiment invention;
[0039] [0039]FIG. 11 b is a block representation of the sensor configuration according to another embodiment of the invention; and
[0040] [0040]FIG. 11 c is a block representation of the sensor configuration according to another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0041] Referring to FIGS. 1 a - 1 c , there is shown a game controller 10 according to a first embodiment of the invention. Game controller 10 includes a housing 12 , a plurality of upper game controls 14 and a plurality of front control buttons 16 a - 16 d . A central axis 18 runs through game controller housing 12 transverse to the two-dimensional plane in which the D-pad or joystick operates. The aforementioned D-pad and/or joystick are included in the plurality of upper game controls 14 .
[0042] In accordance with the present embodiment, a driving/steering lever 20 is disposed on the underside of the controller housing 12 and is rotatably mounted about a rotation axle 22 which is coaxially aligned with central axis 18 . Lever 20 is spring biased into a center position and includes two lever ends 24 a and 24 b positioned to be actuated by the fingers of the user's right and left hands, respectively. Lever 20 is variably actuated based on the degree of depression applied by the user. Referring to FIG. 1 c , when lever end 24 b is actuated in the direction indicated by arrow A 1 , the opposing end 24 a is displaced an equal amount in the direction A 2 (as shown by dotted lines in FIG. 1 c ). The variable position ability of lever 20 in addition to its ergonomic disposition on the underside of the controller allows the user to more accurately and realistically apply steering control in response to the video game being played. The rotating action of lever 20 enables the steering/driving control to be accurately and variably controlled while allowing the user to maintain both hands on the controller at all times. This further allows the user to actuate any of the upper 14 or front 16 controls during steering/driving action.
[0043] [0043]FIG. 5 a shows one example of the electronic implementation of lever 20 into game controller 10 . As shown a potentiometer 42 is connected to a printed circuit board 40 contained within housing 12 . Rotation axle 22 of lever 20 is connected to or integral with the stem of potentiometer 42 , and a spring 44 , wound around axle 22 and held in place by notches 46 a and 46 b , biases lever 20 into its central operable position. Thus, the actuation of either lever end 24 a or 24 b changes the resistance output of potentiometer 42 and thereby allows for the variable steering/driving adjustment of a video game being played through a connected game console (not shown).
[0044] [0044]FIGS. 2 a and 2 b show a second embodiment where steering lever 20 is separated into two independently operable parts consisting of lever ends 24 a and 24 b . In this embodiment, each lever end 24 a and 24 b is independent of the other. Thus, when lever end 24 b is depressed in the direction indicated by A 1 , lever end 24 a does not move. This embodiment requires additional control circuitry as shown in FIGS. 5 b and 9 a.
[0045] Referring to FIG. 5 b , there is shown an embodiment for the independent control and actuation performed by independent levers 24 a and 24 b . As shown, separate potentiometers 42 a and 42 b are connected to circuit board 40 and to the respective lever end 24 a and 24 b via a gear mechanism made up of gears 47 a and 47 b . Those of skill in the art will recognize that the rotation axle 22 must now be configured to allow each lever end 24 a and 24 b to rotate independently of each other. Axle 22 can be configured to have an inner axle 26 connecting lever end 24 a to potentiometer 42 a via gears 47 a and 43 a . Accordingly, an outer axle 28 connects lever end 24 b to potentiometer 42 b via gears 47 b and 43 b . The spring 44 can be positioned as shown and notches 46 a and 46 b are disposed accordingly to allow each lever end 24 a and 24 b to be spring biased in a desired direction or position. Thus, when one lever end 24 a or 24 b is actuated, the corresponding potentiometer 42 a or 42 b will change its resistance output in response to that movement and thereby allow the variable, and increased accuracy of driving control in the desired direction.
[0046] The embodiment shown in FIG. 5 b is one example of how such configuration may be implemented. Those of ordinary skill will recognize that various other methods for allowing the independent rotation and actuation may be implemented without departing from the spirit of the invention.
[0047] [0047]FIGS. 6 a and 6 b show another circuitry implementation operable for the embodiment depicted in FIGS. 1 a , 1 b and 1 c . In this embodiment, a pair of hall effect sensors 48 a and 48 b are connected to the circuit board 40 , and an opposing pair of magnets 49 a and 49 b are positioned on a holder 59 mounted to the axle 22 . Thus, when either of the lever ends 24 a or 24 b are moved, the positions of the magnets 49 a and 49 b are detected by the corresponding hall effect sensors 48 a and 48 b (i.e., based on the strength of the magnetic fields created by the magnets), and the corresponding electrical steering/driving command is generated and output to the connected game console (not shown).
[0048] [0048]FIGS. 3 a - 3 c show a third embodiment where steering lever 30 is a one piece lever that pivots about a centrally disposed pivot line P, transverse to central axis 18 . Steering lever 30 is spring biased and includes lever ends 32 a and 32 b that are actuated by the user engaging and pulling the lever end in the direction indicated by arrow A 3 . When lever end 32 b is engaged as shown in FIG. 3 a , opposing end 32 a responds by moving in an opposite direction A 4 (shown in dotted lines). The pivotal action of lever 30 enables the steering/driving control to be accurately and variably controlled while allowing the user to maintain both hands on the controller at all times. This further allows the user to actuate any of the upper 14 or front 16 controls during driving action. FIGS. 4 a and 4 b show a modified embodiment where lever 30 is separated into two independently operable ends 32 a and 32 b , each being pivotal about pivot line P.
[0049] [0049]FIG. 7 shows the electrical implementation of the embodiments disclosed in FIGS. 3 a - 4 b . As shown, the lever arm 30 is connected to a pivot mount 50 by two legs 34 a and 34 b . The pivot mount 50 includes a pivot ball 52 pivoting upon a pivot indentation 53 within the controller housing, and magnets 49 a and 49 b arranged thereon. The pivot mount 50 , and thereby lever arm 30 , is biased into a center position by springs 36 a and 36 b . Corresponding hall effect sensors 48 a and 48 b are mounted on the circuit board 40 and are positioned so as to detect the movement of the respective magnets 49 a and 49 b and produce electrical control signals accordingly. In the independent arm operation embodiment of FIGS. 4 a and 4 b , the pivot mount 50 need not be separated into two parts, but rather the lever arm 30 separated into it's two lever ends 32 a and 32 b while retaining a flexible connection to prevent separation from each other. In this arrangement, the hall effect sensors 48 a and 48 b and magnets 49 a and 49 b will continue to operate as desired.
[0050] [0050]FIGS. 8 a and 8 b show another embodiment of the electronic implementation of lever 20 (made up of lever ends 24 a and 24 b ) into the game controller. As shown, lever ends 24 a and 24 b have interlocking teeth 64 a and 64 b , respectively, arranged around the rotation axle 22 . A cap or other securing mechanism 66 attached onto axle 22 and retains lever ends 24 a and 24 b in their operable position on the underside of the game controller. An arm or extension 60 is connected to rotation axle 22 and includes a sensor mechanism 62 for sensing the rotation motion of the lever ends 24 a and 24 b and providing output signals corresponding to the detected lever end movement. Sensor mechanism 62 is described later with reference to FIGS. 11 a - 11 c.
[0051] [0051]FIGS. 9 a and 9 b show another embodiment of the electronic implementation of lever 20 (made up of lever ends 24 a and 24 b ) into the game controller. This embodiment is particularly suited for the independent operation of lever ends 24 a and 24 b , as discussed above with respect to the embodiments of FIGS. 2 a and 2 b . As shown, each lever end 24 a and 24 b includes a corresponding rotation shaft 23 a and 23 b having an arm or extension 61 a and 61 b , respectively. Extensions 61 a and 61 b carry part of the sensor mechanism 62 used to detect the rotation position of each lever arm 24 a and 24 b , respectively. As with the embodiment of FIGS. 8 a and 8 b , a cap or other device 66 secures the levers 24 a and 24 b in their operable positions and onto rotation axles 23 a and 23 b , respectively.
[0052] [0052]FIGS. 10 a - 10 c show an alternative embodiment for implementing the pivoting steering lever 30 (made up of lever ends 32 a and 32 b ) into the game controller. Accordingly, each lever end 34 a and 34 b is pivotally connected to the circuit board 40 or controller housing 12 via pivot shafts 70 a and 70 b , respectively. A hall effect sensor 48 a and 48 b is mounted on the circuit board 40 , with correspondingly mounted magnets 49 a and 49 b on the respective levers 32 a and 32 b (FIGS. 10 and 10 b ). FIG. 10 c shows an alternative embodiment where a pressure sensor 58 is connected to the circuit board 40 and operable to detect the pressure applied to the levers and output corresponding control signals from the game controller
[0053] [0053]FIGS. 11 a - 11 c show various exemplary embodiments for the implementation of sensor mechanism 62 . FIG. 11 a shows the use of a hall effect sensor 48 mounted to the circuit board 40 and a correspondingly arranged magnet 49 carried by rotating extension 60 . FIG. 11 b shows the use of a light sensor 72 with light source 74 mounted on circuit board 40 . A slotted wheel 76 passes between the sensor 72 and light source 74 so as to provide the rotation detection capability required for the levers. FIG. 11 c shows another embodiment where a piezo sensor is mounted on the extension 60 and in electrical contact with the circuit board 40 .
[0054] Those of ordinary skill in the art will recognize that the implementation embodiments shown in FIGS. 5 a - 11 c are examples of such implementation and may be modified without departing from the spirit of the invention
[0055] While there have shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the methods described and devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | A steering/driving game controller integrates an additional steering lever to the underside of the game controller. The steering lever is spring biased in a center operable positions and is variably actuated such that it is responsive to varying degrees of depression. In response to the varying degree of user depression, the steering/driving controller is capable of outputting steering control signals of varying level to a connected game console, thereby enabling more selective and more accurate driving control within a video game being played on the connected game console. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of PCT Application No. PCT/EP2003/008336, filed Jul. 29, 2003, which claims priority from German Application No. 102 40 191.8, filed Aug. 28, 2002, which are hereby incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a spunbonded nonwoven made of thermoplastic material. The spunbonded nonwoven has filaments having a filament diameter of less than 2 μm, the filaments being made from bursted fibers.
A device for producing a nonwoven is known from European Patent Application 0 724 029 B1, in which a Laval nozzle is positioned downstream of a spinning nozzle. The thermoplastic material coming out of the spinning nozzle is drawn through the Laval nozzle using cold air, the air forming a laminar flow. Positioning a spinning nozzle and a Laval nozzle one behind the other is also known from European Patent Application 0 339 240 A2. In this case, however, a hot inert gas is used for cooling and stretching the fibers, the polyphenylene sulfide of the fibers used burst into individual filaments. A device is known from WO 01/00909 A1, which has a spinning nozzle and a Laval nozzle connected downstream. According to WO 01/00909 A1, a pressure difference over the Laval nozzle with simultaneous overpressure in the fiber ensures that the fiber bursts. A plurality of filaments is to result from one fiber.
The object of the present invention is to expand the technology and fields of application of bursted fibers.
SUMMARY OF THE INVENTION
The present invention provides a spunbonded nonwoven made of thermoplastic material having filaments, the filaments being made from bursted fibers. The filaments have a length of at least five centimeters, have a filament diameter of less than 1 μm, and are connected to one another at discrete points. The spunbonded nonwoven differs from previously known spunbonded nonwoven is in that it combines various properties of different spunbonded nonwoven methods. It has dimensions which are otherwise only known from meltblown spunbonded nonwovens. In addition, the plurality of fine filaments is produced by another mechanism, which in turn provides freedom in regard to the usable materials. The filaments, which are preferably made by bursting, have a filament diameter of less than 1 μm. For manufacture of the filaments, reference is made to the entire content of WO 01/00909 A1, particularly also in regard to the design of spinning nozzle, Laval nozzle, their dimensions, fluid supplies, and materials used.
A refinement provides that the filaments are only partially thermally oxidized on their surface, while other regions are not thermally oxidized. Preferably, after leaving a spinning nozzle, the not yet split fibers are kept at a temperature which allows the effect of a thermal and/or chemical oxidation to occur on the fiber surface. In particular, an oxidized layer thickness is generated which is less than 0.15 times the fiber diameter. For this purpose, the spinning speed in particular is appropriately set, as well as the distance of the mouth of the spinning nozzle to the following Laval nozzle. According to a refinement, the thermoplastic material is heated to a temperature above 300° C., particularly in a range between 305° C. and 330° C. The exiting thermoplastic material, which forms the fiber, preferably has a fluid which contains oxygen flowing around it immediately after leaving the spinning nozzle. The fluid preferably has a temperature which lies above the melting temperature of the thermoplastic material.
Furthermore, the spunbonded nonwoven, which has filaments made of bursted fibers, may additionally have at least one addition. The addition is particularly a corpuscle which does not dissolve in the heated polymer material. Rather, the corpuscle preferably forms a bond with the thermoplastic material. According to a further embodiment, the addition at least partially provides a type of parting plane for the burst of the fibers. The addition preferably has an oblong shape as the corpuscle.
According to a further embodiment, the filaments at least partially have a corpuscle as an addition which has a diameter between 0.3 and 0.8 times a diameter of a filament. The openings in the spinning plate preferably have a diameter between 1.2 mm and 0.8 mm. Dimensioning of this type allows, for example, additives to be used to which are otherwise not usable due to their behavior, their dimensions, or their other properties. Additions which are approximately as large as the openings are also usable. For example, additions are used which have a magnitude between 0.1 mm and 0.6 mm, particularly a size between a fifth and a half of the opening size.
According to a further embodiment, the filaments of the spun fiber have super-absorbent polymer (SAP), for example. The SAP is at least partially intercalated in the filaments and is bonded to the thermoplastic material of the filaments. At least approximately 15% to approximately 45% of the filament surface is preferably covered with SAP.
A refinement provides that the spunbonded nonwoven has an additive, particularly a pigment additive, as an addition. For example, the filaments may have titanium dioxide for pigmentation. Particularly with the use of appropriate opening parameters to generate the fibers, it is possible to achieve stable spinning even if the proportion of the addition is a very high percentage. The addition may preferably make up an approximately 15% to 50% proportion of the fiber. The spunbonded nonwoven preferably has a proportion of addition of at least 10 volume-percent in the filament, preferably between 15% and 35%.
According to a further exemplary embodiment of the present invention, a spunbonded nonwoven is produced using filaments, the filaments being made from bursted fibers. At least the fibers have at least two different materials. The two materials are preferably selected in such a way that they support burst of the fibers into filaments. In particular, both materials may be supplied to the spinning nozzle while mixed with one another. Another embodiment provides that the two materials are supplied separately from one another and the fibers are subsequently produced from them. For example, the materials are two thermoplastic materials, particularly two different polymers. One of the two materials is preferably a polypropylene, while the other material is a polyethylene. Both materials may also be a polyolefin mixture. A further embodiment provides that the thermoplastic materials have different MFI. One material preferably has an MFI in a range between 15 and 30, the other material has an MFI between 25 and 45 (measured at 230° C.; 2.16 kg).
A refinement provides that the different materials form different regions of the fiber. For example, the material having a lower melting point forms an inner region of the fiber, while the material having a higher melting point forms an outer region of the fiber. In this way, the filament formation may be controlled. The inner region remains in a quasi-liquid state longer than the outer region. In this way, burst may be controlled in a targeted way. There is also the possibility of positioning the material having the lower melting point in an outer region of the fiber, while the material having the higher melting point lies in an inner region of the fiber. This is particularly preferable if the filaments are to have a surface which is only partially oxidized or influenced by chemical reaction, for example. The external material still reacts with air, for example, while the inner material is already cooled sufficiently that a reaction is avoided during or directly after the burst.
Besides a core-sheath structure of the fiber, the fiber may also have segments, each having different materials. The segments are preferably at least partially separated from one another and each form filaments. In particular, for example, a spunbonded nonwoven may be produced in this way which has thorough mixing of filaments from at least partially different materials. In this way, different material properties such as different strengths may be combined with one another in one single nonwoven layer.
A barrier material which has a water column of at least 30 cm is preferably produced using the spunbonded nonwoven layer. The barrier material has a spunbonded nonwoven made of filaments which are made from bursted fibers. In particular, the entire barrier is made only of filaments produced in this way. The barrier preferably has a basic weight of less than 30 gsm with a water column of more than 40 cm at a filament diameter of less than 0.1 μm.
According to a refinement, the barrier material is an outer layer of a product. In particular, the barrier material has no film. Rather, it may have an additional support structure such as a fabric, a net, or even a further nonwoven. In this way, it is possible to combine a high strength with a high breathing activity of the material, in particular. The barrier material preferably has a spunbonded nonwoven layer made of meltblown thermoplastic material as a support material, onto which the filaments are applied and bonded at discrete locations through the effect of heat and pressure.
A preferred application of the filament nonwoven is as a building product, which is permeable to water vapor but impermeable to water. The building product preferably has the filaments which are made from bursted fibers as the barrier material. A two-layer or multilayer nonwoven may also be used as a building product, in which, for example, the filaments are embedded between two other nonwoven layers.
A further preferred application of the filaments is in hygiene products having at least one spunbonded nonwoven layer and a liquid-absorbing core. The spunbonded nonwoven layer forms a barrier for liquid coming out of the core, the barrier being made of filaments which are made from bursted fibers.
A further application of the filaments is in a hygiene product having at least one spunbonded nonwoven layer as the overlay and a liquid-absorbing core. The spunbonded nonwoven layer is made of filaments which are made from bursted fibers. The filaments are preferably made hydrophilic, through an additional additive, for example.
Another embodiment of a product provides that a medical product is equipped with at least one spunbonded nonwoven layer, the spunbonded nonwoven layer having filaments which are made from bursted fibers. The filaments form a barrier, which is permeable to air.
A further application provides using the filaments in a hook and loop fastener system closure system having a hook region and a region in which the hooks catch. The hooks catch in a spunbonded nonwoven made of filaments, the filaments being made from bursted fibers. The filaments are preferably at least 10 cm long and, due to an embossed pattern, produce bulges in which the hooks catch.
According to a further embodiment, a spunbonded nonwoven layer made of filaments which are made from bursted fibers is used as a filter. The filaments are preferably longer than 5 cm, particularly longer than 10 cm. In this way, one single filament may be connected to its surroundings multiple times and thus secured. Particularly in regions in which high security must be provided, filter materials using these filaments are therefore preferably usable. This may relate to blood filtration and air filtration for highly clean rooms, for example. Furthermore, this filter also has a high strength. It is therefore also particularly suitable as a particle separator in the event of highly active pressure difference. The filaments may particularly be used as an extremely fine filter. At least one prefilter, which holds back the coarse particles, is preferably connected upstream to the extremely fine filter.
A further application of the filaments relates to the use as a storage medium for liquids and particularly gases. The filaments may also dispense substances or even other agents, for example, fragrance or other things.
According to a further aspect of the present invention, a method of producing a spunbonded nonwoven from thermoplastic material is provided, the spunbonded nonwoven having filaments and the filaments being made from bursted fibers. The thermoplastic material is heated before spinning to a temperature which at least partially oxidizes the fibers produced on their surface during the subsequent spinning, the fibers only splitting when the temperature inside them is cooled sufficiently that oxidation of the filament is avoided. In this case, reference is made to the entire content of WO 01/00909 A1 in regard to the type of spinning, the filaments and fibers, and particularly in regard to the construction conditions.
According to a further aspect of the present invention, a method of manufacturing a spunbonded nonwoven from thermoplastic material is provided, the spunbonded nonwoven having filaments and the filaments being made from bursted fibers. The thermoplastic material is heated before the spinning to a temperature such that during the subsequent spinning the fibers produced at least partially oxidize on their surface, heat being supplied to the filaments, after the fibers split into filaments, in such a way that the filaments also at least partially oxidize on their surface.
The heat is preferably supplied via thermal radiation or convection. For example, the nozzle downstream from the spinning nozzle is heated, so that the air guided through it is heated. In addition, the air emits heat onto the fibers and/or filaments, so that reactions may play out on the fiber and/or filament surface.
In general, it may also be advantageous to heat the nozzle downstream from the spinning nozzle for other methods of producing filaments by bursting fibers.
A further idea for manufacturing filaments from bursted fibers provides that the fluid which flows around the fibers does not only stretch the fibers and/or filaments. Rather, this fluid is at least used as a carrier for a substance, so that the substance is bonded to the fiber and/or filament surface. The substance may particularly be deposited on the particular surface.
An additional idea for manufacturing filaments from bursted fibers provides that the filaments are twisted at least at the start, in the shape of a helix, for example. Twisting of the filaments is produced before depositing, for example, in that the filaments are stretched and/or cooled differently on their surface. This particularly occurs in the moment of the bursting of the fibers. Furthermore, there is the possibility of producing twisting through bicomponent filaments. Twisting may also be performed later, by heating the filaments, for example. Twisted filaments preferably have more than one contact point with neighboring filaments, in particular, two or more filaments are twisted with one another and thus provide additional stability to the nonwoven produced. According to a refinement, the curved filaments are not bonded further to one another. Rather, the only stabilization of the nonwoven is produced by the intersection points of the filaments obtained during manufacture.
According to an additional idea of the present invention, a spunbonded nonwoven system having a first spinning beam is provided, the first spinning beam being implemented in such a way that fibers produced burst into filaments before being deposited on a movable conveyor belt. The spunbonded nonwoven system has at least one feed for thermoplastic material which forms a laminate with the filaments, the spunbonded nonwoven system having a device for bonding the filaments to the thermoplastic material. The filaments and the thermoplastic material may preferably be bonded through the effect of heat and pressure. The thermoplastic material may also, for example, be applied to the filaments, poured on in at least not yet solidified form, for example, preferably as a film. The bonding of filaments and thermoplastic material into a laminate may be supported using electrostatic charge.
The laminate may be two-layer or multilayer. The individual layers of the laminate may be bonded to one another in identical or different ways. For example, the layers may be thermobonded, using adhesive means, or may even form the laminate via hydroentanglement, for example. Adhesive means are particularly adhesive fibers, polymers which are heated and form a bond between two layers upon cooling, and, for example, hotmelt adhesives. The application of the adhesive means is preferably performed via spraying or even in the form of a foam application.
A further embodiment of a spunbonded nonwoven system having a first spinning beam, which is implemented in such a way that fibers produced burst into filaments before being deposited on a movable conveyor belt, provides that the fibers have a fluid flow against them from one side before the fibers enter a nozzle downstream from the spinning nozzle. The flow preferably occurs from a side which is perpendicular to the exit direction of the thermoplastic material from a spinning nozzle. In this way, the fibers may be enveloped by the fluid. This offers the advantage that largely laminar flow is provided from the start and the fluid does not have to be deflected before it flows onto the thermoplastic material.
According to a further idea of the present invention, a spunbonded nonwoven system having a first spinning beam is provided, the first spinning beam being implemented in such a way that fibers produced burst into filaments before being deposited on a movable conveyor belt. The spunbonded nonwoven system has a heating device in order to heat the fluid streaming around the fibers to a temperature above the melting temperature of a thermoplastic material of the fibers. In this way, complete surface oxidation of the filaments may occur, for example. Also, agglutination of the filaments with one another may be produced in this way. Subsequent further stabilization of the nonwoven produced is preferably dispensed with in this way.
An additional idea of the present invention, which may also be refined independently thereof, provides a method of generating a film made of thermoplastic material. The thermoplastic material is guided through a slot in order to form a film, the film subsequently being guided through a nozzle in the not yet completely solidified state, a pressure difference over the nozzle acting on the not yet solidified film. Bodies, particularly solid bodies, which are partially exposed through subsequent partial burst of the film, are preferably enclosed in the not yet solidified film.
Furthermore, a film made of thermoplastic material having enclosed solid bodies is provided, the surface of the film being at least partially bursted. The film is preferably microporous. The microporosity is advantageously achieved in that during burst of the film surface, stretching of the film occurs and/or the thermoplastic material around the solid bodies remains in a quasi-liquid, and therefore movable state, longer than the remaining thermoplastic material. The solid bodies preferably have a higher heat capacity than the thermoplastic material. This principle is also usable for filament formation.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantageous embodiment and refinements, as well as features, are illustrated and described in the following drawing.
FIG. 1 shows a schematic view of a spunbonded nonwoven system;
FIG. 2 shows a schematic view of a filament;
FIG. 3 shows a schematic view of a hygiene product;
FIG. 4 shows a schematic view of a layered product having a barrier material;
FIG. 5 shows a schematic view of a medical product;
FIG. 6 shows a schematic view of a film manufacture device; and
FIG. 7 shows a schematic view of a hook and loop fastener system.
DETAILED DESCRIPTION OF THE INVENTION
The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
FIG. 1 shows a schematic view of a spunbonded nonwoven system 1 . A molten thermoplastic material 3 comes out of a spinning nozzle 2 and forms a fiber 4 . The fiber is surrounded by a fluid stream 5 , which is indicated by arrows. The fluid stream 5 advantageously encloses the fiber 4 directly after the thermoplastic material 3 leaves the spinning nozzle 2 . The fluid stream may be heated using a heater 6 , particularly above a melting temperature of the thermoplastic material. If multiple thermoplastic materials are used to form the fiber 4 , heating may also be performed in such a way that the melting temperature of only one of the thermoplastic materials is exceeded. The fiber 4 enters a nozzle 7 , which is preferably a Laval nozzle. The fluid stream 5 accelerates the fiber 4 , and stretches it at the same time. Simultaneously, due to the acceleration in the nozzle 7 , the pressure is reduced. As the fiber 4 exits and/or while it is inside the nozzle 7 , the fiber 4 bursts, multiple filaments 8 being formed from the single fiber 4 . The filaments 8 are deposited on a movable conveyor belt 9 and form a still unbonded spunbonded nonwoven 10 . A suction device 11 is preferably positioned below the conveyor belt 9 . The suction device 11 continues the fluid stream 5 , so that the filaments 8 may be deposited on the conveyor belt 9 with as little interference as possible. The conveyor belt is preferably positioned at a distance of less than 50 cm to the spinning nozzle 2 . This distance may particularly be varied in order to be able to adjust different product properties. In particular, the distance of the nozzle 7 to the spinning nozzle 2 may also be varied. A prebonded nonwoven, a film, a net, or another material is supplied to the conveyor belt 9 via a first feed 12 for thermoplastic material. This material may be used, for example, as a support structure. A molten thermoplastic material, for example, is applied to the filaments 8 via a second feed 13 , the thermoplastic material forming a film. A device 14 for bonding the filaments 8 to the thermoplastic material is positioned after the second feed.
FIG. 2 shows a schematic view of a filament 8 which is partially curved. A curvature may particularly be so strongly pronounced that the filament twists and assumes a three-dimensional shape at the same time. In this way, the overall length is reduced and the filament 8 simultaneously occupies a larger volume. Furthermore, it is shown that the filament 8 has corpuscles, for example, additives or other things, which may be located on the surface and also inside the filament 8 .
FIG. 3 shows a schematic view of a hygiene product 15 having a liquid-permeable top sheet 16 and a liquid-impermeable back sheet 17 . A liquid-absorbing and liquid-storing core 18 is positioned between the top sheet 16 and the back sheet 17 . Preferably, the top sheet and the back sheet have filaments as described above. The filaments of the top sheet are preferably made hydrophilic, while the filaments of the back sheet are preferably made hydrophobic.
FIG. 4 shows a schematic view of a layered product 19 having a barrier material 20 . The barrier material has filaments as described above. A reinforcement nonwoven 21 is positioned neighboring the barrier material 20 , for example. The barrier material 20 and/or the layered product 19 may be used in different products, for example, in building products, in medical products, in filter applications, in hygiene products, as a storage medium, as a noise absorbing device, in sanitary products, in household products, in packaging, etc.
FIG. 5 shows a schematic view of a medical product. As indicated here, the medical product is an adhesive bandage 22 , for example. The plaster has filaments 8 as a wound dressing. These are capable of covering the wound with active breathing and simultaneously letting through moisture in vapor form and/or liquid to a storage layer, for example. On the other hand, particles or other things are held back. According to an embodiment which is not shown in greater detail, at least the predominant part of the medical product may also have filaments 8 . Besides the use for adhesive bandages, the filaments may also be used in operating garments, parts thereof, in gloves, protective overalls, covers, etc.
FIG. 6 shows a schematic view of a film manufacture device having a slot nozzle 23 , from which the molten thermoplastic material exits and forms a film 24 . The film 24 is guided through a neighboring nozzle 25 and stretched by air (not shown in more detail). Due to a pressure difference over the nozzle 25 , the film 24 at least partially bursts on its surface 26 .
FIG. 7 shows a schematic view of a hook and loop fastener system 27 . The filaments 8 are partially bonded to a carrier 28 and form hooking zones for corresponding hooks 29 of the system 27 .
Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | This invention relates to a spunbonded nonwoven made of thermoplastic material, which exhibits a filament diameter of less than 1.0 μm. The filaments are made from bursted fibers, whereby the filaments exhibit a length of at least five centimeters and are connected to one another at discrete points. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention presented below concerns a stable structure consisting of tubular components of any shape, size or material, and post-tensioned cables or other tensory elements, and, more specifically, to a structure of this nature which may be used as a roof-covering or sheltering element in the most varied of ways and in the most varied of conditions.
More specifically, the structure constituting the basis of this invention was conceived by the purpose of covering spaces of any kind, with areas/spans of practically any dimension, in a simple, quick and economical manner, with the possibility of full recouperation of all materials involved when the said roof-covering is used on a temporary basis.
The principle upon which this invention is based is fundamentally the creation of a structure which includes, at the same time and within the same sole structure, both the covering elements themselves and the respective supporting elements, this being the opposite of all other usual roof-covers, where these two components always have to be considered separately in the application of the structure as a whole. According to the principle of this invention, it is possible to create such a structure using, as the supporting element, post-tensioned cables or other tensory elements, and, as the covering or sheltering element, tubular components of any shape, size or material, will perforations at the ends through which the supporting cables run in a perpendicular direction in relation to the longitudinal direction of the tubular components.
2. Description of the Background Art
The simplest way to achieve such a structure would be to use tubular components that were, let us say, circular, where the perforations through which the cables or other tensory elements pass were situated at the respective ends of an identical diameter of the cross-section of the tubular component. However, this solution has to be rejected, since the structure thus obtained would be unstable, which is not suitable to the objective we are aiming to achieve where complete stability is preferable and, indeed, in some cases, indispensible. In fact, the use of a single cable or other tensory element in the afore-mentioned manner, and as illustrated in FIG. 2, would yield a structure where any modification to the given form with the radius (R), would correspond to a form which would always maintain the same perimeter (P).
The use of a single cable or other tensory element passing through the tubular components via excentrically positioned perforations would also fail to yield a satisfactory result, since the post-tensioning of the cable or other tensory element would lead to the deformation of the given form in one direction only, and the structure would not be self-supporting. The use of two interacting cables or other tensory elements, which run through the tubular components via perforations positioned at either end of two chords of the cross-section of the tubular components, situated on opposite sides of an identical diameter, yields a structure where the post-tensioning of the cables or other tensory elements produces opposite effects and where, given the equilibrium between these effects, structures are obtained with completely stable and self-supporting forms, without the necessity for any kind of horizontal forces at the resting points, since all these forces are absorbed by the structure itself.
This fact is schematically illustrated in FIG. 1, which shows how the deformation of a set of two cables with the given radii (R 1 ) and (R 2 ), which correspond to the given perimeters (P 1 ) and (P 2 ), leads to transformations with the radii (R 3 ) and (R 4 ), with the perimeters (P 3 ) and (P 4 ), which are different, respectively.
An object of this invention is therefore to obtain a stable structure consisting of tubular components of any shape, size or material, and post-tensioned cables or other tensory elements, where the tubular components have, at strategic intervals along their length depending upon their resistence and strength, two pairs of perforations with adequate diameters so as to allow the passage of the supporting post-tensioned cables or other tensory elements, each pair of perforations being situated at the respective ends of a chord of the cross-section of the tubular component, where the chord corresponding to the two pairs of perforations are situated on opposite sides of an identical diameter of the cross-section of the tubular component, and where the structure in question is a stable, self-supporting structure, whose static form is determined by the relative lengths of the two post-tensioned cables or other tensory elements constituting each pair.
The tubular components should, by preference, be all the same, made from any kind of material, but which is duly appropriate to the desired function of the structure in each individual case (roof-coverings or other functions), and which, given the supporting cables or other tensory elements which run through the respective perforations and which are post-tensioned accordingly, may be joined together to obtain forms that are initially unstable, but which become completely stabilized after the post-tensioning of the cables.
The number of pairs of cables or other tensory elements, the distance between them along the respective length of the tubular components and the dimensions of the tubular components themselves will, in each individual case, depend upon conclusions drawn from a stability calculus,
The tubular components need not necessarily be circular. For instance, they may be elliptic, or even non-spherical in form, so long as the given shape permits the perfect, constant and even contact of the individual elements against one another in the formation of the structure.
A roof-covering of a given desired area is obtained, in the direction in which the cables or other tensory elements are extended, via the "threading" of a given number of tubular components with a given diameter onto cables or other tensory elements of the appropriate dimension and, in the perpendicular direction, by joining together the necessary number of tubular components which are interconnecting, and by introducing the respective supporting cables or other tensory elements at each junction point.
One very important characteristic of this invention is the fact that the type of stable structures hitherto described, used either individually or appropriately joined together, can have the most varied of applications for the most varied of purposes.
Thus, for example, if, following the principle of this invention, tubular components are utilized which are all made of a given transparent material with perforations in these tubular components for the passage of the cables or other tensory elements, they can assume the form of a greenhouse used in agriculture, and which is simple, long-lasting, easy to erect and dismantle and completely recouperable.
It is equally possible to build roof-coverings and shelters for areas which must be completely protected from the rain or snow, including, for example, bus shelters. In this case, the supporting cables or other tensory elements would not run through the tubular components themselves, as this would cause impermeability problems due to the perforations. Here, it would be necessary to introduce special tubular components containing the perforations for the passage of the supporting cables or other tensory elements, which would be inserted, in a completely watertight manner, into the ends of the actual covering tubular components running between the respective rows of supporting cables and special tubular components of the structure. The functioning of this version of the roof-covering structure according to this invention is based upon the balanced tensioning of the supporting cables or other tensory elements in order to obtain the required form, which, in this case, is the one described above. It is important to point out the following advantage of roof-covering or sheltering elements conceived using the structure described herein, and which concerns the erection of same.
For instance, the erection of the structure requires no scaffolding or similar type of framework and the tubular components constituting the structure are appropriately positioned and assembled on the ground. The cables or other tensory elements are then threaded, and the erection of the structure is achieved via the tensioning of the cables. If it should prove necessary, the impermeability of the structure can be improved upon by treating the joints of the tubular components accordingly.
In a more perfected version, the tubular components used may be adapted for the captivation of solar energy, which may then be used in buildings.
A further application of the structure described herein is as a bridge, which can be erected without the slightest need for scaffolding, simply by extending the supporting cables or other tensory elements, which are threaded through the tubular components, between the two points to be connected, and then tensioning them. Using the same principle, we can also erect pedestrian walk-overs and bridges such as that shown in FIG. 8.
The structure described herein can also be used suspended in a vertical position, where special tubular components, housing the pairs of perforations, are used in constant succession, and through which the supporting cables or other tensory elements are threaded, but where the tubular components, which are connected onto the special components may or may not be alternate, depending on its application, thereby allowing, or not, for spaces between them (See FIG. 9). This version may be applied in a number of different situations where its characteristics are extremely advantageous. These are, among others:
(i) As an emergency fire-escape or ladder; the supporting cables or other tensory elements are suspended from two consoles, placed a given distance apart, and run through special tubular support elements, and the tubular components which constitute the steps are inserted alternately onto the special tubular support components at distances corresponding to the depth of one step.
(ii) As a protective covering for facades and gable-end walls of buildings under constructions. In this case, the structure is identical to the one above, but the tubular components are connected onto all of the special tubular support elements.
(iii) As a blind, where the structure is identical to the one above.
(iv) Similar structures, but on a horizontal level, may be used for covering swimming-pools when not in use, where the structure does not come into contact with the water, and allowing for free and secure passage over it.
(v) Finally, the use of structures described herein may also be considered for the construction of houses and other enclosed spaces of various shapes and sizes. (See FIG. 7).
Another important characteristic of this invention is the fact that it consists of only a small number of different types of elements, which are simple and can easily be manufactured en masse, and therefore economically.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better illustrate this invention, below is a series of descriptions of its various forms and possible applications, which are to be interpreted merely as examples which are by no means limitative, since the field of application of this structure is virtually inexhaustible, with references to drawings included in the annexes:
FIG. 1 and FIG. 2 show diagrams illustrating the principle upon which this invention is based;
FIG. 3 illustrates schematically a structure according to this invention used in the construction of a greenhouse;
FIG. 4 shows a structure according to this invention used in the construction of a roof-covering or shelter where absolute impermeability is of the essence;
FIG. 4a shows the structure of a special tubular support component utilized in the present invention;
FIG. 4b shows a special intermediary tubular support component utilized in the present invention;
FIG. 5 shows a two-fold structure according to this invention which may be used for the covering of very large areas;
FIG. 6 shows a combination of structures according to this invention used for the construction of a bridge;
FIG. 7 shows a combination of structures according to this invention used for the construction of an enclosed space;
FIG. 7(a) shows a special support component utilized in the present invention in the construction of an enclosed space;
FIG. 8 shows a structure according to this invention used for the construction of a walkway or simple bridge between two given points;
FIG. 9 shows a suspended stairway built using a structure according to this invention;
FIG. 9(a) shows an alternate tubular support component for use in exposed ends of tubular components;
FIG. 10 and FIG. 11 are examples of other types of constructions according to the present invention, where the tubular components have, for example, a circular form;
FIG. 12 shows a structure according to this invention where the tubular components have a triangular cross-section;
FIG. 13 shows a structure according to this invention where the tubular components are of a rectangular cross-section;
FIG. 14 shows a structure according to this invention used for the construction of flat concrete slabs, with no girders or beams, supported by the cables or other tensory elements inherent to the structure; and
FIG. 14(a) shows a flat slab structure for use in the present invention.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative to the present invention, and wherein:
Let us now look in closer detail at each of the drawings.
FIG. 3 is a structure according to the present invention used for the covering of a cultivated area or for a greenhouse, consisting of tubular components 1, with pairs of perforations 3, 3', through which run the supporting cables or other tensory elements 2, 2'. As indicated by the arrows, these cables are tensioned and, according to the degree of tension applied to each of the cables 2 and 2', they take on the forms with radii R 1 and R 2 respectively, from which we obtain a determined stable form of the structure. The tubular components 1 are, in this particular case, transparent.
FIGS. 4-4B, the covering structure is to be an impermeable one, and therefore the tubular components 1 must not be perforated. The supporting cables or other tensory elements 2, 2' are therefore introduced via special tubular support components which may be either terminal 4 or intermediary 5, and which, in this case, contain the pairs of perforations 6 and 6'. The covering tubular components 1, which contain no perforations, are connected onto the said special support components 4 and 5, and are supported by these components.
The special terminal tubular support component 4 is a cylindrical unit with an outer terminal end section 7 that has a larger diameter than the tubular component, this being the section housing the pairs of perforations 6, 6' for the passage of the cables or other tensory elements 2, 2', its inner diameter being equal to that of the outer surface of the tubular components 1, and an inner section 8, which has a narrower diameter than the tubular component 1, and which slots into the tubular components 1, its outer diameter being approximately the same as that of the inner surface of these components 1.
FIG. 5 shows the application of a structure according to this invention for the covering of large areas/wide spans, which may require the use of two three, four, five etc. -fold structures as is represented in the drawing.
FIG. 6 shows the application of the structure according to this invention to the construction of a special bridge between two given points 9 and 10. The flat bridge portion is shown as E 1 , and two angularly oriented stablization portions E 2 and E 3 are connected to the underside of flat portion E 1 and descend toward two anchor points (not shown).
FIG. 7 illustrates schematically a combination of structures according to this invention for the construction of an enclosed space. The walls are composed of the tubular components 1 of the structures, which are connected onto the special support components 11, which are similar in shape and composition to the support components 4 shown in FIG. 4.
FIG. 8 illustrates the application of a structure according to this invention for the construction of a walkway or simple bridge between two given points. This structure is extremely simple. It is assembled on the ground on one of the two sides to be connected, and the cables or other tensory elements are temporarily anchored on this side. Then the structure is placed in position between this and the other side to be connected by pulling the cables over to the other side, and lastly, the cables or other tensory elements are tensioned and fixed in place.
FIG. 9 represents a structure according to this invention which incorporates tubular support components 12, similar to the terminal tubular components 4 illustrated in FIG. 4, which are suspended from a console 13. In this version, the structure may be used as a vertical escape ladder, where the steps/rungs are the tubular components 1 connected onto alternate support components 12, to allow for space between steps, or as a type of blind or protective cover for facades and exposed gable-end walls of buildings during works on, or adjacent to these, for example. In this case, the tubular components 1 are connected onto all the support components 12.
In FIG. 10 and FIG. 11, the tubular components 1 are, for example, circular and, stabilized using post-tensioned cables or other tensory elements, and supported according to the principle of this invention, they permit the construction of enclosed areas of various shapes and with a vast number of different applications.
FIG. 12 schematically illustrates a structure according to this invention where the tubular components 1 have a triangular section, and where, as is obvious, the structure can be given either a rectilinear or a curved directional axis.
FIG. 13 shows an example of a structure according to this invention where the tubular components have a rectangular section.
FIG. 14 represents the specific application of a structure of the type illustrated here, where the tubular components are covered with concrete 14 and are used in the construction of a flat slab with no girders or beams, and where the supporting elements are the post-tensioned supporting cables 2, 2' of the structure described according to this invention. This flat slab structure is first assembled as an encasement with a horizontal form, and the concrete is then poured over it.
Simply to exemplify a little further, below is a list of possible applications of structures according to this invention:
(i) As a roof-covering or shelter for wide spans or large areas of various dimensions in two directions (playing-fields, swimming pools, stadiums, exhibition centres, esplanades, service stations, protective covers for building sites during excavation works, protective covers for areas where demolition or implosion works are being carried out etc.)
(ii) As a vertical protective element for facades and gable-ends of buildings etc.
(iii) As pedestrian walk-overs, walk-ways, bridges etc.
(iv) As a supporting encasement for reinforced concrete slabs.
(v) As a vertical stairway or ladder.
(vi) As a false ceiling or roof.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A stable structure consisting of tubular components and supporting cables or other tensory elements, where the supporting cables, used in pairs, are introduced via pairs of perforations which are positioned excentrically at the respective ends of two predefined chords of a section of the tubular component, so that the tensioning of the cables transforms what is initially an unstable structure into a completely stable one whose form is dependent upon the relative lengths of the two cables in each pair of cables. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for enabling connection among devices in a network.
2. Description of the Related Art
In a Fibre Channel Arbitrated Loop networks, devices are connected to one another to form a “loop” architecture, where all devices may communicate with any device in the loop. The connections are made with optical fibers or copper lines, which provide high bandwidth communication between the devices. Devices may be connected to the loop through two ports, where one port is used as a receiver and another as a transmitter. In such implementations, each fiber cable is attached to a transmitter of a port at one end and a receiver of another port at the other end. Alternatively, a single cable may be used for both receiving and transmitting data. In such case, the device need only have a single connection to another device in the loop. Devices connected in a Fibre Channel arbitrated loop may form a Storage Area Network (SAN), which may include numerous interconnected Fibre Channel Arbitrated Loops.
In one known architecture, a storage device drawer may include multiple hard disk drives and have two adaptor cards. Each adaptor card on the drawer may connect to an adaptor on a separate host system, where the fibre cable between each host and the drawer is bi-directional. Further, drawers may be daisy chained together, such that one host is connected to one storage drawer adaptor, and the other storage drawer adaptor is connected to an additional drawer. Any number of additional drawers may be daisy chained together, with the second host attached to the second adaptor of the last drawer in the daisy chain.
To add a drawer to the loop, if a drawer is connected to two separate hosts, then an administrator has to disconnect one host from one drawer adaptor, connect a cable between the new drawer and the drawer adaptor from which the host was disconnected, and then reconnect the host to the second adaptor on the new drawer. When the host is disconnected from the drawer, the Fibre Channel performs a loop initialization routine to configure the new arrangement. While the host remains disconnected, users can access data to the host remaining connected, but any users that accessed the loop through the disconnected host remain off-line and unable to access the data stored in the storage drawers. This downtime can be problematic, especially if the administrator takes a significant amount of time to connect the disconnected host to the new drawer.
Accordingly, there is a need in the art for improved techniques for adding devices to a loop.
SUMMARY OF THE DESCRIBED IMPLEMENTATIONS
Provided are a method, system, and program for adding a fourth device to a network including a first, second, and third devices, wherein the first and second devices are directly connected to the third device. The fourth device is directly connected to the third device while the first and second devices remain connected to the third device, and wherein the first and second devices continue to have access to the third device while the fourth device is connected to the third device.
In further implementations, the first and second devices access to the third device is only interrupted during an initialization procedure executed when the fourth device is connected to the third adaptor to recognize the fourth device.
In still further implementations, the first and second devices comprise host systems and wherein the third and fourth devices comprise storage devices.
Yet further, the third device may include three adaptor cards, wherein the first and second devices are each connected to one separate adaptor card in the third device, and wherein connecting the fourth device to the third device comprises connecting an adaptor card on the third device to one of the available adaptor cards in the third device.
Described implementations provide apparatus and techniques for connecting one additional device to another device in a manner that allows other devices to remain connected to the device to which the additional device is being connected.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIGS. 1 , 2 , and 3 illustrate network devices connected in accordance with implementations of the invention; and
FIG. 4 illustrates an architecture of computing components in the network environment, such as the hosts and storage devices, and any other computing devices.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, reference is made to the accompanying drawings which form a part hereof and which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized and structural and operational changes may be made without departing from the scope of the present invention.
FIG. 1 illustrates a loop network architecture 2 in accordance with implementations of the invention. Two hosts 4 a , 4 b each having host bus adaptors (HBAs) 6 a , 6 b connect to a separate device adaptor (DA) 8 a and 8 b on storage device 10 , which has an additional device adaptor 8 c comprising a bypass circuit. Each of the adaptors 8 a , 8 b , and 8 c may comprise device adaptors known in the art for connecting a device to a network, such as a Fibre Channel Arbitrated Loop. The cables 12 and 14 connecting the hosts 4 a and 4 b to adaptors 8 a and 8 b may enable bidirectional communication therebetween. The hosts 4 a , 4 b may comprise any type of computer system known in the art, including a server capable of managing data access requests from attached clients to any storage devices in the loop 2 . The storage device 10 may comprise a “drawer”, having numerous interconnected hard disk drives. The hard disk drives 10 in the storage device 10 may be configured as a Redundant Array of Independent Disks (RAID), Just a Bunch of Disks (JBOD), a Direct Access Storage Device (DASD), etc.
FIG. 2 illustrates the state of the network after a storage device 20 having at least two adaptors 28 a , 28 b , 28 c , three are shown, is added to the network 2 . To add the storage device 20 , the administrator would connect a cable from the third bypass adaptor 8 c in storage device 10 to one of the adaptors 28 a , 28 b , or 28 c . Upon connecting storage device 20 to the bypass adaptor 8 c , a loop initialization routine, such as the Fibre Channel Arbitrated Loop initialization routine, would be performed to recognize the added storage device 20 and make the storage device 20 available to all other devices in the loop network 2 , including hosts 4 a , 4 b . Because the loop initialization time is very fast, the hosts 4 a , 4 b appear to have continued access to the storage device 10 while storage device 20 is added to the loop 2 . The host 4 a , 4 b access is only briefly disrupted during the initialization operation. There are no interruptions due to physically disconnecting one host 4 a , 4 b from the storage device 10 to add another storage device 20 , because the new storage device 20 is connected to the bypass adaptor 8 c.
Moreover, interruptions would further be minimized when removing the storage device 20 that was added to the third bypass adaptor 8 c of the storage device 10 connected to the two hosts 4 a , 4 b . With the described implementations, the storage device 20 is removed by disconnecting the storage device 20 from the bypass adaptor 8 c which does not require any physical disruption to the connection with the hosts 4 a , 4 b through device adaptors 8 a , 8 b.
With the described implementation, when adding the new storage device, the cables connecting to the hosts remain undisturbed and continue to be used, thereby avoiding any disruption in host access to the storage device 10 . In the prior art, when disconnecting a host from a storage device to add a new storage device, and then reconnecting the disconnected host to the added storage device, a cable of different length may be needed because the host is being connected to a new storage device, which may be located at a different distance from the host than the storage device to which the host was previously connected. In the prior art, the duration of the disconnection may be extended if the administrator has to locate a cable of appropriate length to connect the host to the new storage device. With the described implementations, there are no such delays because the hosts remain connected to the storage device while the new storage device is added to the loop.
FIG. 4 illustrates one implementation of a computer architecture 200 of the network components, such as the hosts and storage devices shown in FIGS. 1 , 2 , and 3 . The architecture 200 may include a processor 202 (e.g., a microprocessor), a memory 204 (e.g., a volatile memory device), and storage 206 (e.g., a non-volatile storage, such as magnetic disk drives, optical disk drives, a tape drive, etc.). The storage 206 may comprise an internal storage device or an attached or network accessible storage. Programs in the storage 206 are loaded into the memory 204 and executed by the processor 202 in a manner known in the art. The architecture further includes a network card 208 to enable communication with a network, such as a Fibre Channel Arbitrated Loop. As discussed, certain of the network devices may have multiple network cards. An input device 210 is used to provide user input to the processor 202 , and may include a keyboard, mouse, pen-stylus, microphone, touch sensitive display screen, or any other activation or input mechanism known in the art. An output device 212 is capable of rendering information transmitted from the processor 202 , or other component, such as a display monitor, printer, storage, etc.
In the described implementations, the hosts included one host bus adaptor and the storage devices had three adaptors. In alternative implementations, the hosts may have multiple host bus adaptors or multiple ports on one HBA. Further, devices other than storage devices may be designed to have three adaptors capable of providing separate bidirectional connection with other network devices. Still further, if the cables only allow for unidirectional communication, then each adaptor would need two ports to connect to each device, one for transmitting and one for receiving.
In further implementations, the hosts may connect to different ports on the same adaptor in the storage device, thereby requiring fewer adaptors to enable the storage drawer to separately connect to three other devices.
The foregoing description of various implementations of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | Provided are a method, system, and program for adding a fourth device to a network including a first, second, and third devices, wherein the first and second devices are directly connected to the third device. The fourth device is directly connected to the third device while the first and second devices remain connected to the third device, and wherein the first and second devices continue to have access to the third device while the fourth device is connected to the third device. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a catalytic converter element having a plurality of essentially parallel channels through which gas flows during operation of the catalytic converter element.
BACKGROUND OF THE INVENTION
[0002] In a fuel cell system, a combustible gas or synthesis gas containing hydrogen is generated by partial oxidation in a reformer, and this gas is then supplied to the anode of a fuel cell for conversion to electricity. The gases entering the catalytic converter in the reformer in partial catalytic oxidation include essentially hydrocarbons, air, water vapor, carbon monoxide and carbon dioxide. To avoid unnecessary monitoring of the incoming gas with regard to its composition, i.e., to be able to operate the process in the broadest possible lambda window, the anode exhaust gas of the fuel cell or the exhaust of one of the residual gas burners downstream from the fuel cell may be recycled to combine the anode gas and the cathode gas. This increases the water content in the gas, which contributes toward preventing the formation of soot.
[0003] In principle, a catalytic converter element operates at very high temperatures, often near the decomposition limit of the support material forming the catalytic converter element and the coating arranged thereon. On admission of the gas mixture consisting of the aforementioned components, an exothermic oxidation reaction takes place in the first few millimeters of the substrate, i.e., the support material, which has been coated with a catalytically active coating, the so-called “wash coat”; in this reaction, the hydrocarbons react with the oxygen to form carbon dioxide and water. In the remaining course, i.e., as the gas continues to flow through the catalytic converter element, an endothermic steam reforming process takes place, in which carbon dioxide and hydrogen are formed from carbon monoxide and water vapor. The highly exothermic reaction at the point of admission of the catalytic converter element, however, reduces the lifetime of the catalytic converter element and in particular the coating because the dissipation of heat toward the outside is very minimal at the center of the catalytic converter element, for example, and therefore the high temperatures that occur due to the exothermic reaction can in the long run have an effect on the coating, i.e., the wash coat.
SUMMARY OF THE INVENTION
[0004] The present invention relates to the problem of finding a method for a catalytic converter element that will allow a longer lifetime of the catalytic converter element in particular.
[0005] The invention is based on the general idea of providing the substrate, i.e., the support material forming the channel walls with a catalytically active coating, but not completely and uniformly, and instead having it begin with an axial offset at the admission end when there are a few channels running essentially in parallel through the catalytic converter element. This means that in the first few millimeters, some of the channels have the catalytically active coating while some of the other channels do not have this coating. In the channels in which the coating begins at the start of the channel, the heat released by the exothermic oxidation reaction can be transferred through the channel wall to the gas stream of a neighboring channel, whereby the gas flowing there will be much colder than the gas heated by the exothermic oxidation reaction. The heat released in the oxidation reaction can support a shift reaction in the channels with the coating which begins immediately at the admission to the channels with the axially offset coating. This makes it possible to prevent overheating of the catalytic converter element at the admission as well as excessive cooling at the channel ends combined with increased emissions due to unconverted hydrocarbons.
[0006] A plurality of channels is expediently combined to form channel elements, in particular monolithic channel elements. Such monolithic channel elements can be manufactured much more economically and thus less expensively in comparison with individual channels, whereby the effect described in the general idea of the present invention is comparable inasmuch as a plurality of such channel elements are joined together in the case of a worked catalytic converter element and whereby some of the channel elements have the coating beginning at the admission end, while others, preferably the neighboring channel elements, have a coating that is offset axially in the direction of flow.
[0007] In an exemplary embodiment, the channels that are combined to form one channel element have a coating that begins at the same axial position. This allows an economical and thus inexpensive production of the channel elements because the channels combined to form the channel elements all have a similar design.
[0008] The channel walls are expediently formed by a substrate of silicon carbide. Silicon carbide has a high thermal conductivity and therefore ensures a good transfer of heat at the admission end of the catalytic converter element from channels with coatings beginning directly at the admission end to surrounding channels where the catalytically active coating begins only with an axial offset in the direction of flow.
[0009] It is self-evident that the features mentioned above and those yet to be explained below may be used not only in the particular combination given but also in other combinations or alone without going beyond the scope of the invention.
[0010] Exemplary embodiments of the invention are illustrated in the drawings and explained in greater detail in the following description, where the same reference numerals refer to the same or similar or functionally similar components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The schematic diagram in:
[0012] FIG. 1 shows a longitudinal section through an inventive catalytic converter element having a plurality of channels,
[0013] FIG. 2 shows a cross section through a catalytic converter element in the area of its admission end,
[0014] FIG. 3 shows a diagram like that in FIG. 2 , but with a plurality of channel elements, each comprising a plurality of parallel channels.
DETAILED DESCRIPTION OF THE INVENTION
[0015] According to FIG. 1 , a catalytic converter element 1 has essentially a plurality of channels 2 which run parallel to one another and through which gas flows during operation of the catalytic converter element 1 . The gas flowing through the catalytic converter element 1 may be a mixture of hydrocarbon, air, water vapor, carbon monoxide and carbon dioxide. In order for the widest possible range of gas mixtures to be processable by the catalytic converter element 1 , i.e., in order for the catalytic oxidation process to be operable in the widest possible lambda window, an anode exhaust gas or an exhaust gas from a residual gas burner is additionally supplied to the gas mixture, thus increasing the water content in the gas mixture and thereby at least reducing the formation of soot.
[0016] The channels 2 running through the catalytic converter element 1 are bordered by channel walls 3 according to FIG. 1 , having a catalytically active coating 4 that is arranged on the channel walls in at least some areas and is exposed to the gas. During operation of the catalytic converter element 1 , it operates at very high temperatures close to the limit of destruction of the channel walls 3 , which are formed from a substrate, e.g., made of silicon carbide, and the catalytically active coating 4 . The extremely high temperatures come about due to a highly exothermic oxidation reaction in which hydrocarbons react with oxygen to form carbon dioxide and water. This highly exothermic oxidation reaction takes place in the first millimeters of the channels 2 , whereby this oxidation reaction takes place only inasmuch as the channels 2 have a catalytically active coating 4 . Further downstream from the admission end 6 , i.e., in the direction of flow 5 , an endothermic steam reforming process takes place in which carbon dioxide and hydrogen are formed from carbon monoxide and water vapor. However, the highly exothermic reaction at the admission end 6 of the channels 2 in particular threatens the lifetime of the catalytic converter element 1 and the coating 4 because the required dissipation of heat to the outside, in particular at the center of the catalytic converter element 1 , does not occur.
[0017] With the inventive catalytic converter element 1 , the catalytically active coating 4 with some channels 2 therefore begins with an axial offset in the direction of flow 5 with respect to the admission end 6 . As a result, the heat Q released by the exothermic oxidation reaction can be transferred through the channel wall 3 into the gas stream of the neighboring channels 2 ′. The gas flowing there is definitely cooler (approximately 500° C.) so that the heat Q released in the oxidation reaction can support the shift reaction in the channels 2 with an axially offset coating 4 . The term “shift reaction” used here is understood to refer to the conversion of carbon monoxide and water to carbon dioxide and hydrogen. This thus corresponds to the steam reforming mentioned above. Due to the fact that coating 4 is partially offset axially in some channels 2 , overheating of the catalytic converter element 1 at the admission end 6 due to the highly exothermic oxidation reaction can be prevented on the one hand, while on the other hand, excessive cooling at one channel end, which is associated with increased emissions of unconverted hydrocarbons, can also be prevented.
[0018] According to FIG. 2 , channels 2 with an axially offset coating 4 and channels 2 ′ with a coating 4 beginning directly at the admission end 6 may be arranged adjacent to one another, e.g., in a checkerboard pattern. It is also conceivable for multiple channels 2 or 2 ′ to be combined to form channel elements 7 , in particular monolithic channel elements, where the channels 2 or 2 ′ that are combined to form a channel element 7 each have a coating 4 beginning at the same axial position.
[0019] The catalytically active coating 4 is applied to the channel wall 3 , which is formed by a substrate of silicon carbide, for example.
[0020] Use of the inventive catalytic converter element 1 in a reformer, for example, is conceivable, where the reformer generates a combustible gas containing hydrogen from a hydrocarbon fuel and an oxidizer containing oxygen. In such a reformer, either a single catalytic converter element 1 or a plurality of catalytic converter elements 1 may be used.
[0021] Thus, there is presented a catalytic converter element 1 having a plurality of essentially parallel channels 2 , 2 ′, where a catalytically active coating 4 arranged on the channel walls 3 is arranged in some channels 2 so that it is offset axially from the admission end 6 in the direction of flow, so that the highly exothermic oxidation reaction induced by the coating begins only at a later point in time in these channels. The coating 4 , which begins at the admission end 6 in the channels 2 ′, causes the immediate exothermic oxidation reaction, so that the heat Q generated thereby can flow into the neighboring channels 2 in which the coating 4 begins only farther downstream. In this way, overheating of the catalytic converter element 1 on the one hand is prevented so that its long life is promoted, and on the other hand, the heat Q released in the oxidation reaction in the neighboring channels 2 ′ with the axially offset coating 4 can thereby support the endothermic reaction. Furthermore, excessive cooling at the end of the channel combined with increased emissions of unconverted hydrocarbons can be prevented or at least reduced. | The present invention relates to a catalytic converter element having a plurality of essentially parallel channels through which gas flows during operation of the catalytic converter element. The channels are bordered by channel walls which have a catalytically active coating arranged thereon in at least some areas where it is exposed to the gas. In some channels the coating thus begins with an axial offset from the admission end. This allows an improved temperature management within the catalytic converter element. | 1 |
[0001] Chip sockets for personal computers are composed of numerous tiny preformed current-carrying springs mounted in close proximity to one another. These sockets are typically made by forming the individual springs from metal strip, then assembling the springs into a large grid array in a non-conducting base plate.
[0002] In order to function properly, such springs should be made from a metal which exhibits a particular combination of properties, specifically (1) high yield strength, (2) an electrical conductivity of at least 45% IACS and (3) bend formability of no more than about 2 R/t to about 3 R/t in the transverse and longitudinal directions. Bend formability is the ability of a metal sample to bend without cracking and is normally described in terms of the minimum radius R to which a metal sample of thickness t can bent 90 degrees without cracking. A transverse bend (traditionally termed a “Bad Way” bend in the connector industry) has its bend axis parallel to the rolling direction of the strip. A longitudinal bend (traditionally termed a “Good Way” bend) has its bend axis perpendicular to the rolling direction of the strip. Bend formability is another measure of alloy ductility. These combined chip socket performance requirements are sufficiently severe that existing commercial current-carrying spring alloys, whether the “high strength” copper-beryllium alloys such as C17200; or the “high conductivity” copper-beryllium alloys such as C17460, C17410, C17510 or C17500; or various non-beryllium-containing copper alloys, are inadequate in one or more individual properties and are hence marginal, if not unsuited, for present and next generation large grid array chip socket applications.
[0003] Miniaturization is a constant objective in the design evolution of electronic components. In the context of chip socket manufacture, this translates into increasingly denser spacing and/or larger area grid arrays of individual small springs. This, in turn, requires that the metal forming these springs be even stronger, without sacrificing electrical conductivity or bendability, to accommodate variable spring deflections from lack of co-planarity over the large array area and/or misalignments when mating components are inserted into the large array. If the material is incapable of such accommodation, some portion of the springs in a grid array will become permanently deformed and cease to function, resulting in loss or interruption of signal transmission. Unfortunately, the maximum 0.2% yield strength that can be obtained in the “high conductivity” copper-beryllium alloys used today, when manufactured to exhibit the desired electrical conductivity of at least 45% IACS and bend formability of 1.5 to 5 R/t, is 125 ksi.
[0004] Accordingly, it is desirable to provide a new copper-beryllium alloy which can be made to exhibit an even greater 0.2% yield strength, for example as high as 130 ksi or more or even 140 ksi or more, while at the same time still exhibiting the necessary electrical conductivities and bend formabilities indicated above, i.e., an electrical conductivity of at least 45% IACS, with bend formability in both the transverse and longitudinal directions of no more than about 3 R/t.
[0005] Another field of electronic interconnects relates to insulation displacement connectors (IDC's) which comprise relatively flat spring blades with a knife-edged slot to cut through the insulation of an inserted wire. Evolving designs of IDC's have also created a need for higher strength materials with conductivity in excess of the existing commercial “high strength” copper-beryllium alloys such as C17200. Desirable properties for such new IDC applications include 0.2% yield strength of at least about 130 ksi to about 140 ksi, with electrical conductivity of at least about 45% IACS. Because these IDC's are essentially flat, excellent bendability is not a significant performance requirement. Hence, “Good Way” bendability of no more than about 5 R/t and “Bad Way” bend formability of no more than about 9 R/t are adequate for the task.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, it has been discovered that alloys UNS C17410 and C17460 can be made to exhibit these improved yield strengths, without sacrificing electrical conductivity or bendability, by age hardening the alloys with two separate heat treatment steps, with cold working being carried out between these heat treatments rather than before heat treatment begins as in current technology.
[0007] Thus, the present invention provides a new copper-beryllium alloy comprising about 0.15 to 0.5 wt. % Be, about 0.35 to 1.40 wt. % Ni and/or Co, up to about 0.5 wt. % Zr, with the balance being copper and incidental impurities, wherein the alloy exhibits an electrical conductivity of at least about 45% IACS, a bend formability of less than about 3 R/t in the “Good Way” or longitudinal direction and less than about 9 R/t in the “Bad Way” or transverse direction, and a 0.2% yield strength of at least about 130 ksi.
[0008] In addition, the present invention provides a new process for manufacturing a copper-beryllium alloy having an improved combination of electrical conductivity, bend formability and yield strength, the alloy mass containing 0.15 to 0.5 wt. % Be, about 0.35 to 1.40 wt. % Ni and/or Co and up to about 0.5 wt. % Zr, with the balance being copper and incidental impurities, the process comprising age hardening the alloy by heat treating the alloy in a first age hardening heat treatment step carried out directly after final solution annealing, cold rolling the mass before age hardening is completed, and finalizing age hardening by subjecting the mass to at least a second age hardening heat treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention may be more readily understood by reference to the following drawings wherein:
[0010] [0010]FIG. 1 is a schematic representation illustrating the combination of properties exhibited by the alloys of the present invention in relation to the properties of prior art alloys;
[0011] [0011]FIG. 2 is a schematic representation illustrating the thermal and mechanical processing profile experienced by a BeCu alloy which is manufactured into strip by conventional technology, FIG. 2 also illustrating the effect on properties of the different processing steps in this manufacturing method; and
[0012] [0012]FIG. 3 is a schematic representation similar to FIG. 2 illustrating the thermal and mechanical processing profile and effect on properties of the manufacturing method of the present invention.
DETAILED DESCRIPTION
[0013] Improved Combination of Properties
[0014] As indicated above, the present invention provides alloy strip products having a unique combination of properties unavailable in conventional technology. This is illustrated in FIG. 1, which is a schematic representation of the alloys of the present invention in relation to alloys of the prior art in terms of electrical conductivity, bendability and yield strength. As shown in this figure, prior art alloys having electrical conductivities of 45% IACS or higher and good bend formability, when made by conventional technology, exhibit 0.2% yield strengths less than 125 ksi Other prior art alloys, such as C17200, can be made to exhibit good bend formability and 0.2% yield strengths greater than 125 ksi. Such alloys, however, exhibit poor electrical conductivities, i.e., values of 25% IACS or less. The inventive alloys, however, because of the way they are made, exhibit all three excellent properties, i.e. electrical conductivities of at least 45% IACS, bend formabilities of 1 to 8 R/t in both the longitudinal and transverse directions, and 0.2% yield strengths of at least about 130 ksi, preferably at least about 140 ksi.
[0015] Alloy Strip and Wire
[0016] The present invention is directed to making copper-beryllium alloy strip and wire. By “strip” and “wire” is meant metal products which are produced by subjecting an ingot to a series of hot and cold working steps, usually with one or more intermediate solution anneals, to reduce the thickness of the metal mass by a factor of at least about 200 between ingot and finished product. Strip products are typically rectangular in configuration and are worked by hot and cold rolling steps. Wire products are normally circular in cross-section and are worked, at least in later stages of reduction, by drawing through a die one or more times. Wire products of the invention will normally have thicknesses (diameters) of no more than about 0.5 inch, more typically no more than about 0.38 inch, with thicknesses on the order of about 0.25 to 0.001 inch being more typical. Strip products of the invention will normally have thicknesses of and no more than about 0.02 inch. Thickness of about 0.01 inch or less, and especially about 0.003 to about 0.008 inch, are more typical, with 0.002 inch or even less anticipated in future chip socket designs.
[0017] Alloy Chemistry
[0018] The present invention is applicable to BeCu alloys comprising
[0019] about 0.15 to 0.5 wt. % Be,
[0020] about 0.35 to 1.40 wt. % Ni and/or Co, with the proviso that
[0021] if the alloy contains no Co, the Ni content is at least 1.0 wt %,
[0022] if the alloy contains no Ni, the Co content is no more than 0.60 wt %, and
[0023] if the alloy contains both Ni and Co, their combined total not exceed 1.4 wt % and the Co content not exceed 0.35 wt %,
[0024] up to 0.5 (and preferably 0.05 to 0.5 wt. %) Zr,
[0025] with the balance being copper and incidental impurities.
[0026] Preferred alloys are C17460, which contains about 0.15 to 0.5 wt. % Be, about 1.0 to 1.40 wt. % Ni, up to 0.5 wt. % Zr and the balance Cu plus incidental impurities, as well as C17410, which contains about 0.15 to 0.5 wt. % Be, about 0.35- to 0.60 wt. % Co and the balance Cu plus incidental impurities.
[0027] These alloys may contain additional ingredients, provided that the properties of the alloys are not adversely affected to any significant degree. Examples of such additional ingredients are Fe, Al, Si, Sn, Zn, Cr, V, Mo, Mn, W, Ag, Au, Ta, Nb, Ti, Hf, P, Mg, Ca, Se, Te, S and Pb. The total amount of such additional ingredients should not exceed 0.5 wt. %.
[0028] Manufacturing Method
[0029] [0029]FIG. 2 illustrates conventional technology for manufacturing strip products from C17410, C17460, C17510 and other “high conductivity” copper-beryllium alloys such as C17500, etc. As shown in this figure, a melt of the alloy is cast into an ingot, allowed to cool to low temperature, typically room temperature, and then reheated to a temperature above its solvus temperature where it is hot rolled for thickness reduction. Cooling to a low temperature can be omitted if desired. After hot rolling, the ingot is cooled to a low temperature, then cold rolled to further reduce its thickness. One or more optional intermediate anneals may be imparted to soften the cold worked alloy and enable greater total cold reduction. Such cold reduction is carried out to reach a desired ready-to-finish thickness at which the strip is given a final solution anneal at a temperature above its solvus temperature, followed by rapid quenching. Pickling or other surface treating can be used to clean and smooth the strip surfaces.
[0030] Once the cold roll/solution anneal regime is complete, the alloy is age hardened to increase its strength. Like most precipitation hardenable alloys, copper-beryllium alloys also exhibit enhanced response to age hardening if they are cold worked first. Therefore, as illustrated in FIG. 2, the alloy after the final solution anneal at the ready-to-finish thickness is conventionally subjected to a final cold rolling step, typically in the amount of about 10% to as much as about 90% in thickness reduction to achieve the final product thickness and to prepare the metal for the subsequent age hardening heat treatment step. Thereafter, the alloy is heated to an age hardening temperature below the solvus temperature where it is held long enough for the alloy to develop a significant increase in yield strength. See, U.S. Pat. No. 6,387,195, the disclosure of which is incorporated herein by reference, for a further discussion of age hardening.
[0031] [0031]FIG. 2 also illustrates the effect of the various metallurgical treatments described above on the properties of the alloy. In particular, FIG. 2 shows that this age hardening procedure, including the final cold rolling step, increases the 0.2% yield strength of the alloy essentially to its maximum attainable value, which in the case of alloys C17410, C17460 and C17510 is about 120 to 125 ksi. In addition, FIG. 2 also shows that, although age hardening reduces ductility (elongation), the final product is still quite ductile. This is particularly desirable in alloy strip to be used for forming chip socket springs, since bendability and ductility are closely related properties.
[0032] In accordance with the present invention, a modified procedure is used to age harden the alloy. This is illustrated in FIG. 3, which shows that after final solution anneal the alloy is directly subjected to age hardening heat treatment rather than being cold rolled first. In this context, “directly” means that there is no intermediate cold rolling step. The desired intermediate strength after the first age hardening treatment is preferably the “peak”, or essentially maximum, strength attainable in the solution annealed and directly age hardened state; or may range into the slightly “overaged” heat treatment regime. “Peak” aging attends thermal treatment in a narrow range of aging temperature and soak time at this temperature, resulting in highest achievable strength and a particular level of electrical conductivity. “Underaging” refers to thermal treatment at temperatures less than and/or at times shorter than “peak” aging conditions for a given solution annealed alloy, and results in lower strength with lower conductivity. “Overaging” refers to aging at higher temperatures and/or longer times than “peak” aging conditions and generates lower strength with higher conductivity. Then, after the first age hardening has produced the desired intermediate strength, the alloy is cold rolled in an amount of 10 to 70%, preferably, 15 to 60%, more preferably 25 to 40%, in terms of thickness reduction to further enhance its age hardening response. Thereafter, the alloy is again heated under age hardening conditions to complete the age hardening process and produce the final product alloy.
[0033] In accordance with the present invention, it has been found that this modified procedure results in a still further increase in yield strength of the product alloys over and above that obtainable with current technology, without sacrificing ductility (elongation). This is also illustrated in FIG. 3 which shows that, while the ductility of the product alloy is essentially the same as that of the alloy of FIG. 2, the 0.2% yield strength of the product alloy has been increased to as much as 130 ksi or more in two embodiments of the invention (Embodiment II and III) and to as much as 140 ksi or more in another embodiment of the invention (Embodiment I).
[0034] The particular conditions used for the modified age hardening procedure of the present invention are essentially the same as those used in the conventional process and can easily be determined by routine experimentation. In this connection, it is well known that age hardening of strip products can be carried out in batch operation, in which a coil or other bulk arrangement of the strip is heat heated in an age hardening furnace for a suitable period of time, typically about 3 to about 20 hours. Alternatively, the strip can be age hardened continuously by passing a continuous length of the strip through an age hardening furnace, from a pay-off coil on the input side of the furnace to a take-up coil on the output side of the furnace, for a much shorter period of time, normally no more than 10 minutes, more typically no more than 5 minutes.
[0035] Age hardening in batch operation occurs as a practical matter in a fairly narrow temperature range roughly midway between the solvus temperature and room temperature. See, U.S. Pat. No. 6,387,195, mentioned above. For the alloys of the present invention, this temperature range is generally about 500° F. to 1000° F., more typically 500° F. to 900° F. Age hardening in continuous operation normally occurs at higher temperatures, which for the inventive alloys is generally at 750° F. to 1200° F., more typically 750° F. to 1000° F.
[0036] As indicated above, the first age hardening is preferably carried out to achieve the “peak” or a slightly “overaged” strength level of which the solution annealed and directly age hardened alloy is capable. The thermal treatment conditions producing this first age hardened strength level in the inventive alloy are most conducive to bulk age hardening conditions. Strength superior to the maximum strength attainable from conventionally processed “high conductivity” copper-beryllium alloys is then achieved by cold working the material after the first age hardening, resulting is an increase in strength from work hardening, with attendant loss of ductility. This cold working is then followed by a second thermal treatment. One aim of the second thermal treatment is to at least stress relieve the first age hardened and cold worked strip in order to restore ductility to provide satisfactory bendability, yet retain much or all of the first age hardened plus work hardened strength. A continuous-type second thermal treatment step is particularly suited to this objective, although batch-type thermal cycles can also be selected to achieve a similar end. Preferably, the second thermal treatment step is carried out to superimpose a further aging response atop the first age hardened plus cold worked strength level, resulting in very high final strength, coupled with quite useful ductility and bendability. Batch-type second thermal treatment conditions are well-suited to this task, but appropriate continuous-type thermal treatment cycles can also be selected for this purpose.
[0037] Preferred Embodiments
[0038] In accordance with a first preferred embodiment of the invention (Embodiment I), alloy strip having a 0.2% yield strength of at least about 140 ksi, an electrical conductivity of at least about 45% IACS and a bend formability of about 3 R/t or less, preferably about 2.5 R/t or less, in both longitudinal and transverse directions can be produced. This can be accomplished by carrying out
[0039] final solution anneal at about 25 to 50° F. higher than the normal solution anneal temperatures, i.e., at temperatures of about 1700 to 1750° F., more preferably about 1725° F. (with anneal times concomitantly shorter so as to achieve a small to moderate average [Is average correct?] grain size, e.g., on the order of 0.015 mm-0.030 mm, preferably 0.015 mm-0.025 mm),
[0040] the first age hardening heat treatment step at about 700 to 800° F., more preferably about 750° F., for at least about 3 and preferably at least about 5 hours, preferably to achieve approximate peak or slight overaging,
[0041] cold working by an amount of about 15 to 30%, more preferably about 20 to 25%, in thickness reduction, and
[0042] the second age hardening step in bulk at about 450° F. to 700° F., more typically about 500 to 600° F., for at least about 3 hours and preferably at least about 5 hours.
[0043] In accordance with a second preferred embodiment of the invention (Embodiment II), alloy strip having a 0.2% yield strength of at least about 130 ksi, an electrical conductivity of at least about 45% IACS and a bend formability of 3 R/t or less, preferably about 2.5 R/t or less, in both longitudinal and transverse directions can be produced. This is accomplished by carrying out
[0044] final solution anneal at normal solution anneal temperatures, i.e. about 1650 to 1725° F., more preferably about 1675 to 1700° F. (with anneal times chosen to achieve a small to moderate average grain size, e.g., on the order of 0.015 mm-0.030 mm, preferably 0.015 mm-0.025 mm),
[0045] the first age hardening heat treatment step at about 850 to 950° F., more preferably about 900° F., for at least about 5 hours, preferably to achieve slight overaging,
[0046] cold working by an amount of about 15 to 50%, more preferably about 20 to 40% in thickness reduction, and
[0047] the second age hardening step in continuous fashion at about 725° F. to 825° F., more typically about 750 to 800° F. for no more than about 5 minutes, preferably no more than about 3 minutes.
[0048] In accordance with a third preferred embodiment of the invention (Embodiment III), alloy strip having a 0.2% yield strength of at least about 130 ksi, an electrical conductivity of at least about 45% IACS and a bend formability in the transverse direction of about 2 to 2.5 R/t and a bend formability in the longitudinal direction of about 5 to 8 R/t can be produced. This is accomplished by carrying out
[0049] final solution anneal at normal solution anneal temperatures, i.e. about 1650 to 1725° F., more preferably about 1675 to 1700° F. (with anneal times chosen to achieve a small to moderate average grain size, e.g., on the order of 0.015 mm-0.030 mm, preferably 0.015 mm-0.025 mm),
[0050] the first age hardening heat treatment step at about 725 to 825° F., more preferably about 750 to 800° F., preferably for at least about 3 hours and preferably at least about 5 hours, preferably to achieve approximate peak aging,
[0051] cold working by an amount of about 45 to 65%, more preferably about 50 to 60% in thickness reduction, and
[0052] the second age hardening step
[0053] in bulk at about 550° F. to 800° F. for at least about 3 hours and preferably at least about 5 hours, or
[0054] in continuous fashion at about 750° F. to 900° F., for no more than 5 minutes, preferably no more than 3 minutes.
WORKING EXAMPLES
[0055] In order to further describe the present invention, a series of 26 alloy strips were made in accordance with the present invention. Alloys of slightly different chemical compositions, but all meeting the specifications of UNS C17460, were used to form the strip products made in accordance with the present invention. In addition, Comparative Examples A and B represent an alloy outside the composition range of the alloys of the present invention, i.e., commercial C17510, subjected to processing consistent with Embodiment II of the present invention. Furthermore, Comparative Examples C to F show manufacturers' published properties for commercial “high conductivity” copper-beryllium alloys of the prior art. See, “Guide to Copper Beryllium”, Brush Wellman Inc., 2002. Comparative Example F also used an alloy conforming to C17460. Comparative Examples C and D employed alloys conforming to UNS C17510. Comparative Example E employed an alloy conforming to UNS C17410. The compositions of each of these alloys is set forth in the following Table 1:
TABLE 1 Alloy Composition, wt. % Ni [unless noted Alloy Be otherwise] Zr Cu* A 0.32 1.23 0.13 Balance B 0.33 1.28 0.07 Balance C 0.32 1.24 0.08 Balance D 0.37 1.54 0.02 Balance UNS C17460 0.15-0.50 1.00-1.40 0.5 max Balance UNS C17410 0.15-0.50 [0.35-0.60 Co] Not specified Balance UNS C17510 0.2-0.6 1.4-2.2 Not specified Balance
[0056] The finish thicknesses of alloy strip products produced in these examples was as follows
Example 1 0.004 inch Examples 2-19 0.00787 inch Examples 20-26 0.00394 inch Comp. Ex. A-B 0.00394 inch Comp. Ex. C-F Thickness not specified (commercial strip)
[0057] The strip products made in accordance with the present invention were age hardened using a two-step heating process in which the first heating step began directly after final solution anneal, i.e., without cold rolling first. After the first heating step, these strip products were cold rolled by amounts ranging from 20 to 60% in thickness reduction and then subjected to a second age hardening heating step. In Examples 1 to 11 and 22 to 26 the second age hardening step was carried out in batch operation by placing the alloy in bulk in an aging furnace for 5 hours. In Examples 12 to 19 the second stage age hardening step was carried out by a simulated continuous process in which the strip was placed in a molten salt bath for 2 minutes. In Examples 20 and 21 as well as Comparative Examples A and B, second stage age hardening was carried out by passing a continuous length of the strip, from one end to the other, through a 45 foot long aging furnace at a speed which resulted in a dwell time of about 2.25 minutes. In Comparative Examples C to E the alloys were commercially mill hardened in a conventional manner by solution annealing, then cold rolling by an amount of 10 to about 90% in terms of thickness reduction prior to age hardening, and finally heat treated at proprietary batch-type age hardening conditions in the “peak” aging regime for each alloy.
[0058] The conditions used in the various metallurgical treatment steps applied in each example are set forth in the following Table 2, while the results obtained are set forth in the following Table 3:
TABLE 2 Metallurgical Processing Conditions Ready- to-Finish 2 nd Anneal 1 st Cold Work Aging No. Alloy (F.) Embodiment Aging Step (%) Step 1 A 1700 III 800 F./5 hr 50 650 F./5 hr 2 B 1675 III 750 F./5 hr 60 700 F./5 hr 3 B 1675 III 800 F./5 hr 60 650 F./5 hr 4 B 1675 III 750 F./5 hr 50 650 F./5 hr 5 B 1675 III 800 F./5 hr 50 550 F./5 hr 6 B 1675 III 750 F./5 hr 50 800 F./5 hr 7 B 1700 III 750 F./5 hr 60 700 F./5 hr 8 B 1700 III 800 F./5 hr 60 650 F./5 hr 9 B 1700 III 800 F./5 hr 60 800 F./5 hr 10 B 1700 III 750 F./5 hr 50 700 F./5 hr 11 B 1700 III 800 F./5 hr 50 800 F./5 hr 12 B 1675 III 800 F./5 hr 60 800 F./2 min 13 B 1675 III 800 F./5 hr 60 900 F./2 min 14 B 1700 III 800 F./5 hr 60 900 F./2 min 15 B 1675 III 800 F./5 hr 50 750 F./2 min 16 B 1675 III 800 F./5 hr 50 900 F./2 min 17 B 1700 III 800 F./5 hr 50 900 F./2 min 18 B 1675 II 900 F./5 hr 20 800 F./2 min 19 B 1700 II 900 F./5 hr 20 800 F./2 min 20 B 1700 II 900 F./5 hr 40 750 F./2.25 min 21 B 1700 II 900 F./5 hr 25 750 F./2.25 min 22 C 1725 I 750 F./5 hr 25 500 F./5 hr 23 C 1725 I 750 F./5 hr 25 550 F./5 hr 24 C 1725 I 750 F./5 hr 25 600 F./5 hr 25 C 1725 I 750 F./5 hr 25 700 F./5 hr 26 C 1725 I 750 F./5 hr 25 800 F./5 hr A D 1700 II 900 F./5 hr 25 750 F./2.25 min B D 1700 II 900 F./5 hr 40 750 F./2.25 min C C17510 Yes Prior art No Yes Final “peak” age D C17410 Yes Prior art No Yes Final “peak” age E C17460 Yes Prior art No Yes Final “peak” age
[0059] [0059] TABLE 3 Alloy Properties Longitudinal Transverse Ultimate (Good Way) (Bad Way) 0.2% Yield Tensile Electrical Bend Bend Strength Strength Elongation Conductivity Formability Formability No. (ksi) (ksi) (%) (% IACS) (R/t) (R/t) 1 140.9 147.9 2.0 52.0 1.5 7.5 2 144.2 148.8 1.4 48.3 2.5 8 3 145.6 150.5 1.2 47.0 2.5 8 4 141.6 147.3 1.6 45.7 2.3 >7.5 5 142.5 147.3 1.2 45.9 2.3 <7.5 6 132.5 135.7 2.2 51.1 2 5 7 144.3 150.1 1.3 45.6 2.5 8 8 146.5 151.9 1.9 46.4 2.5 8 9 130.5 134.8 1.0 52.3 1.8 >6.3 10 144.7 150.8 1.3 46.3 2.3 8 11 133.1 138.3 1.9 51.9 2.1 <6.3 12 139.7 144.6 1.9 45.4 1.5 8 13 130.4 135.8 2.8 45.5 1.5 6 14 133.0 138.6 2.3 45.2 1.5 6 15 138.6 142.9 1.7 45.7 1.5 6 16 130.7 135.9 3.0 47.1 1.5 5.3 17 132.8 138.3 2.6 46.5 1.5 5.3 18 129.9 133.0 3.8 49.9 2.2 2 19 131.0 131.5 5.0 49.2 1.9 2 20 129.7 130.2 2.0 No data No data No data 21 128.0 132.0 2.0 No data 0.5 0.5 22 149.0 155.7 3.0 47.9 1 1.5 23 147.7 154.6 1.0 48.6 2 3 24 142.8 150.6 1.0 47.3 3 2 25 134.4 141.0 1.5 46.8 1.5 1.5 26 131.8 137.5 2.0 46.8 1.5 2 A 124.8 128.6 2.0 No data 0.25 0.25 B 127.2 132.3 2.0 No data No data No data C 95-120 110-135 8-20 48-60 2.0 2.0 C17510 HT D 100-120 110-130 7-17 45-60 1.2 5.0 C17410 HT E 105-125 120-140 10 min 50 min 1.5 1.5 C17460 HT
[0060] The foregoing data show that the present invention can reliably and consistently produce alloys exhibiting electrical conductivities of at least 45% IACS, bend formabilities of 1 to 2.5 R/t in the longitudinal direction and no more than about 8 R/t in the transverse direction, and a 0.2% yield strengths of about 130 ksi or more. In addition, the foregoing data further show that preferred embodiments of the present invention can produce such alloys which exhibit bend formabilities of about 3 R/t or less in both the longitudinal and transverse directions as well as 0.2% yield strengths of as high as 140 ksi and even higher. Finally, these data further show that alloys outside the scope of the present invention, whether because of being made by conventional technology (Comparative Examples C to E), or because of having a different chemical composition (Comparative Examples A and B), do not exhibit these properties.
[0061] Although only a few embodiments of the present invention have been described above, it should be appreciated that many modifications can be made without departing from the spirit and scope of the invention. For example, although FIGS. 2 and 3 suggest that the different metallurgical treatments illustrated therein are carried out immediately after one another, significant time delays can be accommodated between successive steps without affecting the invention in any significant way. For example, hot rolling can be delayed indefinitely after casting, if desired. Similarly, the various cold rolling and solution anneal and steps shown in these figures can also be delayed for any length of time relative to preceding steps. Furthermore, although the above description indicates that age hardening is done with only two heat treatment steps, three, four or more heat treatment steps could be used, so long as the first heat treatment step is carried out directly after final solution anneal, as indicated above. All such modifications are intended to be included within the scope of the present invention, which is to be limited only by the following claims: | The yield strength of UNS C17460 BeCu alloy can be significantly enhanced without compromising electrical conductivity or bend formability by age hardening the alloy during manufacture using two separate heat treatment steps and cold rolling the alloy for enhancing age hardening response between these two heat treatment steps rather than before age hardening begins as in current technology. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
Referenced-Applications
This application claims the benefit of U.S. Provisional Application Serial No. 60/256,435, filed Dec. 18, 2000.
BACKGROUND OF INVENTION
Tunnel junctions with ferromagnetic electrodes are known to exhibit a large magnetoresistance. This makes magnetic tunnel junctions a strong candidate for applications requiring magnetic sensors, such as high areal density magnetic recording heads, magnetic random access memory (MRAM), and field sensors. However, these applications require junctions with low resistance.
To date, oxidized aluminum is the most widely used material from which the thin insulating tunnel barrier necessary for making low-resistance junctions can be formed. In this case, the aluminum thin film is deposited on the hard layer of the tunnel junction and then oxidized to form the insulating barrier. While many groups have successfully fabricated low-resistance junctions using this method, there are several challenges involved when scaling this technique into a production-level process.
First, tunnel junction performance is strongly dependent upon aluminum thickness when the insulating barriers are very thin. Thus, thin film deposition tools must be able to deposit ˜7 Å of aluminum with sub-angstrom accuracy and precision over an entire wafer. Second, there is evidence that aluminum interdiffuses into conventional electrode materials, such as CoFe and NiFe, which makes the fabrication of monolayer thick barriers difficult. Third, oxidation of the bottom junction electrode must be minimized. Lastly, the oxidized aluminum barriers intermix with CoFe and NiFe, causing irreversible damage, when exposed to temperatures above 250-300° C. This can be a problem because wafer processing can expose on-wafer devices to temperatures of 250° C. and above.
Magnetic tunnel junction performance is strongly dependent upon the thickness and quality of the insulating barrier and its interaction with the ferromagnetic electrodes. Current state-of-the-art junctions have resistance-area products (a measure of the intrinsic barrier resistance) of R*A=˜10 Ω-μm 2 , which is consistent with an alumina barrier between one and two monolayers thick. However, even this low of a resistance is potentially too high for magnetic recording heads. Attempts to push the oxidized aluminum tunnel barrier technology to monolayer thickness have yielded junctions with pinholes or gaps across the barrier. The end result is that the junctions exhibit near zero magnetoresistance and extremely poor magnetic properties.
It is known in the art that small ferromagnetic nanocrystals can be formed out of materials such as Co and FePt. The size of these nanocrystals can, in principle, be tuned by varying preparation conditions, but are typically on the order of ˜10 nm in diameter. Furthermore, they have a nearly monodisperse distribution in size (δ˜5%). The nanocrystals can be applied to wafers by dissolving the particles in a solvent, spreading the solvent/nanocrystal solution on a wafer surface, and inducing a controlled evaporation of the solvent. Using this technique, nanocrystal superlattices one to three monolayers thick have been achieved.
It is desirable to develop a more robust process for fabricating low resistance ferromagnetic tunnel junctions for use in magnetic sensor application to eliminate or reduce the above described difficulties. Further, it would be desirable to replace the oxidized aluminum monolayer with a monolayer composed of ferromagnetic nanoparticles.
SUMMARY OF INVENTION
Disclosed is a magnetic sensor utilizing a tunnel junction which is an improvement over prior art tunnel junctions. The improved tunnel junction ideally consists of a monolayer of ferromagnetic nanoparticles, such as FePt. Surrounding the nanoparticles is an insulating layer composed of oleic acid or other carbonaceous coating. Non-magnetic electrical leads deposited to the top and bottom of the tunnel junction are used to pass current through the device in a perpendicular-to-the-plane (CPP) configuration.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a cross section of a magnetic tunnel junction incorporating a monolayer of monodisperse ferromagnetic nanoparticles.
FIG. 2 ( a ) illustrates a non-uniform nanoparticle superlattice varying in depth from one to three monolayers across the wafer surface.
FIG. 2 ( b ) illustrates incomplete coverage of a wafer surface by nanoparticles.
FIG. 2 ( c ) illustrates a possible solution for the incomplete monolayer coverage shown in FIG. 2 ( b ) by “filling in” gaps in the nanocrystal monolayer through the absorption of long-chain hydrocarbon molecules.
FIG. 3 is a schematic illustration of the magnetics and electrical response of the nanoparticle-based tunnel junction.
FIG. 3 ( a ) illustrates that the collective effect of the nanoparticle monolayer is to act as a single hard magnetic layer, which in the figure has a remnant magnetization along the positive y-direction.
FIG. 3 ( b ) shows M-H loops and transfer curves for the device.
FIG. 4 ( a ) shows the use of the tunnel junction in a magnetic read head;
FIG. 4 ( b ) shows its use as a memory cell.
DETAILED DESCRIPTION
The basic device according to the invention is shown schematically in cross-section in FIG. 1 . Monolayer 10 acts as a solid layer of a hard magnetic material and ideally consists of single layer of monodisperse nanoparticles 12 . Nanoparticles 12 are composed of a ferromagnetic material. As mentioned before, monolayers have been successfully constructed of Co and FePt, however, it is possible that other ferromagnetic materials may be used, as long as the materials exhibit certain characteristics, such as:
A large magnetic anisotropy that ensures the particles remain ferromagnetic at the device operation temperature (i.e. they are not in the superparamagnetic regime).
A large electron spin polarization so that the device will exhibit a large magnetoresistance.
A large coercivity to ensure good stability of the hard layer.
Compatibility with some sort of self-assembly process that produces densely packed monolayers.
Nanometer scale size and a nearly monodisperse size distribution to minimize surface roughness and any concomitant magnetostatic coupling across the tunnel barrier.
Nanoparticles 12 are suspended in a coating of carbon-based molecules 16 , such as oleic acid or another carbonaceous coating, which serves as the insulating barrier between nanoparticles 12 and free layer 14 . The carbon-based nature of the insulating barrier means there will be no paramagnetic spin-flip scattering defects in the insulator that will corrupt the junction magnetoresistance.
Free layer 14 is placed either above or below monolayer 10 . Freelayer 14 is composed of a soft magnetic material, and could be deposited by conventional sputter deposition, or any other deposition process well known in the art, along with the non-magnetic electrical contacts 18 . Non-magnetic electrical contacts 18 are connected to the top and bottom of the device and are used to pass electrical current through the device in a perpendicular-to-the-plane (CPP) geometry.
As previously stated, nanoparticles 12 can be composed of Co of FePt. However, neither Co nor FePt nanocrystals are ferromagnetic in their as-prepared state, due to a combination of crystal structure and superparamagnetism. It has been found, upon annealing at temperatures of ˜500 C. for approximately 30 minutes, that FePt orders into the L 1 0 structural phase.
This crystallographic phase has a very large magnetic anisotropy that overcomes superparamagnetism and yields nanocrystals that are ferromagnetic at room temperature. In addition to producing the ferromagnetic crystal phase of FePt, the high temperature anneal of the nanoparticles promotes mechanical robustness of the self-assembled nanoparticle film. This is an improvement over previous attempts as using self-assembled monolayers as tunnel barriers, which can be damaged during tunnel junction fabrication.
Further, the preparation, self-assembly, and annealing of the nanocrystal monolayer can be done without the presence of oxygen, thereby avoiding the oxidation of the ferromagnetic electrodes and the concomitant degradation in magnetoresistance seen with prior art oxidized aluminum tunnel junctions.
It is also possible that annealing nanoparticles 12 in the presence of a magnetic field will induce crystallographic ordering such that the magnetic anisotropy is aligned along the field direction. For the case of this tunnel junction device, the aligning field should be applied within the plane of the wafer.
After the thermal anneal, carbon-based molecules surrounding each particle decompose into a carbonaceous coating 16 that is thin enough to allow electron tunneling between nanocrystals. The carbon-based molecules (or decomposed carbonaceous coating) 16 therefore acts as a tunnel barrier for current-carrying electrons moving perpendicular to the plane of the film. The thickness of the barrier is set by the lengths of identical carbon-based molecules 16 chemically bonded to nanoparticles 12 . Because the molecule size is set by the lengths of the chemical bonds and number of atoms, the overall length is quantized, resulting in superior thickness uniformity over oxidized aluminum tunnel barriers. Potential thickness variations in the barrier induced by decomposition will be strictly local and still likely to be more uniform than oxidized aluminum. Further, because nanoparticles 12 are nearly monodisperse in size, the roughness of the device should be on the order of a few A, which is comparable to, if not better than, a device fabricated with an oxidized aluminum barrier. This simply follows from the tight size distribution, typically with a standard deviation of 5% to 7%, and small particle size (nanoparticles of ˜6 nm are known in the prior art). The end result is minimization of undesirable effects like ferromagnetic Ne é I coupling across the tunnel barrier.
It is unknown at this time if true single molecule monolayers can be achieved, or achieved in an economical manner. It is known in the prior art to construct superlattices between one and three monolayers thick, as shown in FIG. 2 ( a ). Even if this technology cannot be refined to yield true monolayer films, the monolayers shown in FIG. 2 ( a ) could still be used to construct a tunnel junction for use as a magnetoresistive sensor for application such as a magnetic memory cell (MRAM), where the constraints on device resistance are less stringent than for recording heads. For the situation in FIG. 2 ( a ), it would be best to deposit the free layer first and then apply the nanoparticle film in such a way as to prevent any oxidation of the bottom electrode. Then, the free layer/insulator/nanoparticle structure will be smooth to promote good magnetics. The extra layers in the nanoparticle superlattice will simply add field-independent resistance.
An alternative to using lattices one to three monolayers thick, which would increase resistance and limit the applications of the device, is to form a nanoparticle film which is never locally more than one monolayer thick (i.e., virtually uniform in thickness over the entire surface of the monoayer). This is shown in cross-section schematically in FIG. 2 ( b ). This results in holes or gaps 20 in the monolayer. As illustrated in FIG. 2 ( c ), a second monolayer film with the appropriate chemistry can be used to “fill in” holes 20 of nanoparticle monolayer 10 by bonding to the exposed patches of the underlying wafer surface. The filling-in of holes 20 could be done with at least one, but possibly more, layers of hydrocarbon-based molecules 22 that makes a tunnel barrier much thicker than that around the nanoparticles. Hydrocarbon-based molecules 22 are ideally long chains of hydrocarbons with a molecule 24 on one or both ends that will chemically bond with electrical contact 18 , such as to anchor the hydrocarbon chain to the electrical contact. Such bonding will provide mechanical stability to the entire monolayer 10 . The choice of material for molecule 24 would therefore be a function of the material used for electrical contact 18 . For example, if a gold electrical contact is used, a thiol (SH—sodium and hydrogen) molecule may be used to anchor the hydrocarbon chain. The sharp exponential increase in tunneling resistance with barrier thickness will force the vast majority of the tunneling current to go through nanoparticles 12 , with the end result being a reduction in the “active area” of the tunnel junction device.
FIGS. 2 ( a-c ) show various implementations of monolayers which deviate from the ideal situation in which the monolayer, over its entire surface, is only one nanoparticle thick. Because a mass manufacturing process is likely to produce monolayers which are either more than one nanoparticle thick and non-uniform, as in FIG. 2 ( a ), or which are one nanoparticle thick, but which exhibit pinholes or gaps, as in FIGS. 2 ( b & c ), it is to be understood that the term “monolayer” as used herein and in the claims is meant to refer to an ideal monolayer, or a monolayer which conforms to FIG. 2 ( a ) or 2 ( b-c ).
The basic device structure disclosed herein is very similar in function to current spin valve technology and can be easily incorporated into present or proposed biasing and stabilization schemes for the free layer. However, due to the nature of the tunneling magnetoresistance, the hard layer and free layer only need be thick enough to exhibit bulk spin polarization. Typically, ˜20 Å is sufficient for sheet films. As long as the nanoparticles remain ferromagnetic and maintain a high spin polarization, they can be made arbitrarily small. Therefore, the tunnel junction can be significantly thinner than current state-of-the-art spin valves, and the shield-to-shield spacing in a recording head can be significantly reduced.
In operation, the disclosed device is similar in functionality to present spin valve type devices or GMR devices. FIG. 3 ( a ) shows examples of the magnetic characteristics of the device and FIG. 3 ( b ) shows the magnetoresistive transfer curves. Device 40 in FIG. 3 ( a ), according to this invention, is the functional equivalent to prior art device 50 , where the free layer 42 of device 40 is functionally equivalent to free layer 42 of device 50 , and monolayer 10 is functionally equivalent to insulating tunnel barrier 44 and hard layer 46 of the prior art device. In this case coating 16 acts as the insulating tunnel barrier while nanoparticles 12 act as the magnetic hard layer.
As can be seen in FIG. 3 ( a ), the hard layer has a large uniaxial anisotropy in the wafer plane while the anisotropy and biasing of the free layer depends upon the application. For recording heads, the quiescent state of the device has the free layer magnetization biased 90° with respect to the hard layer and in the plane of the film. Fringe fields from the media rotate the free layer magnetization towards parallel or anti-parallel, thereby varying the resistance between low (parallel) and high (antiparallel).
The relative orientation of the magnetization of the free layer is measured by applying a CPP bias current and monitoring the junction voltage. The resistance of the device is dependent on the relative orientation of the free layer and hard layer magnetizations and can be expressed as R(θ)=R 0 −(ΔR/2)cos(θ), where θ is the relative angle between the free layer and hard layer magnetizations, R 0 is the resistance when θ=π/2, and ΔR is the difference in resistance between the antiparallel (θ=π) and parallel (θ=0) configurations.
Because this device intrinsically has two effective tunnel barriers (one between the free layer 14 and hard layer (nanoparticles) 12 , and one between hard layer 12 and non-magnetic lead 18 ), there is also a resistance contribution from the tunnel barrier between hard layer 12 and non-magnetic lead 18 . Given the quantized nature of the molecular-based insulator, this barrier will have the same resistance as the barrier between free layer 14 and hard layer 12 . While a double barrier tunnel junction has twice the resistance of a single barrier junction, this is potentially outweighed by the benefits of being able to molecularly engineer the barrier and possibly reduce the resistance-area product (R*A) by another order of magnitude. Magnetoresistance, on the other hand, only occurs as the result of tunneling processes between free layer 14 and hard layer 12 . Electrons tunneling from non-magnetic lead 18 have no net spin polarization and, hence, no magnetoresistance will occur. Additionally, there will be no resistance changes due to electrons tunneling between nanoparticles because the magnetization of each nanoparticle is fixed.
The magnetization curves in FIG. 3 ( b ) show the behavior for a device with the hard layer anisotropy along the y-direction, the free layer anisotropy and/or bias along the x-direction, and an external magnetic field applied along the y-direction. The transfer curve evolves according to the relative orientation of the two magnetic moments, exhibiting low resistance for parallel alignment and high resistance for anti-parallel alignment.
In application, this tunnel junction can be applied to any device that requires a magnetoresistive transducer. The device as used in a magnetic read head is shown schematically in FIG. 4 ( a ), and its use in an individual memory cell in an array of MRAM cells as shown schematically in FIG. 4 ( b ). Finally, there is also the potential use of magnetic tunnel junctions as field sensors.
In FIG. 4 ( a ), an exemplary magnetic read head is shown which comprises monolayer 10 , free layer 14 , electrical contacts 84 and 86 , shields 66 and 68 and insulator 90 . Free layer 14 of the tunnel junction is biased into the appropriate operating region by permanent magnet 64 , and the sensing current flows in a current-perpendicular-to-the-plane (CPP) manner, through bottom and top shields 66 and 68 respectively. In all other ways, this read head operates as a standard prior art spin valve based read head.
FIG. 4 ( b ) shows an MRAM memory array using tunnel junction devices as individual memory cells. In this case, the magnetization of the free layer will be flipped between parallel and anti-parallel configurations with respect to the hard layer to represent binary “0” or binary “1” states. The flipping of the magnetization of the free layer can be accomplished by any means well known in the art.
I have disclosed herein a novel tunnel junction using a monolayer of coated nanoparticles as the hard layer and insulating barrier, which can be used as a magnetoresistive sensor. Several applications of the device have also been identified. The invention is delineated by the scope of the following claims and any examples of materials, processes or applications in the specification should not be taken as limiting the invention in any manner. | A fundamentally new magnetic tunnel junction technology based on the use of magnetic nanoparticles is disclosed. The hard layer of the device is composed of the nanoparticles, while the junction insulating barrier is composed of a carbon-based coating on the nanoparticles. This device offers a markedly different approach of tunnel junction fabrication and offers many advantages over the prior art technology, which is based on the use of oxidized aluminum as the insulating barrier. | 8 |
TECHNICAL FIELD
The present invention relates to an arrangement for combustion of waste liquors which are obtained in connection with cellulose production starting from wood chips or similar material containing lignin.
PRIOR ART
Recovery boilers for combustion of waste liquors have been known for several decades now. They generally consist of a shaft-shaped furnace whose walls to a large extent consist of pipes through which water flows and which in its upper part is also provided with pipe systems for water through-flow and cooling of the flue gases. The concentrated waste liquor, which is also called black liquor, is sprayed in through one or more nozzles in the lower part of the furnace. Air for the combustion of the black liquor is blown in at different levels, as primary air, secondary air, tertiary air or also at a later stage as quaternary air.
In addition to gases such as carbon dioxide, various nitrogen oxides, carbon monoxide, sulphur compounds and water, the combustion also generates molten, inorganic material consisting essentially of sodium salts. This molten matter is collected at the base of the boiler, from which it is allowed to run out in a container and is then re-used. The temperature in the combustion zone in the shaft runs to 1000°-1200° C., and the smelt which is removed has a temperature of 700°-900° C. The flue gases are cooled down to 100-200 degrees before they are discharged from the recovery boiler. The heat which is generated and which is removed from the flue gases is transferred to the water in the pipe systems, whereupon steam is produced which is removed in a steam dome at the top of the boiler, and thereafter the boiler is given a superheater for further raising the steam temperature. The generated steam usually has a pressure of 40-100 bar and a temperature of 400°-500° depending on the construction of the boiler.
The water in the pipes flows upwards by virtue of the steam which is formed by the heat transferred from the flue gases. The water that remains after the steam generation is separated from the steam in the steam dome and is returned to the lower end of the pipes.
The height of recovery boilers usually runs to several tens of meters, for example 30-60 meters, and has a circumference of 10-50 meters, for which reason there is room for a very large number of pipes with a substantial overall length around the shaft and along the base part. For reasons relating to production technology, the recovery boilers have been designed in such a way that walls for roof and base consist of pipes joined together to form plane surfaces. Since these pipes will be joined to each other at a certain distance, it is easier to do this in an automatic manner if they are to form plane surfaces. The recovery boilers therefore consist for the most part of a shaft which is square in cross-section. The shaft is usually suspended in a steel or concrete structure and thus hangs down over the collection container for the molten inorganic chemicals.
TECHNICAL PROBLEM
As has been said, recovery boilers of the abovementioned type have existed for a long time, and they function satisfactorily per se, but they can be improved further, both as regards the operation and the production methods. Thus, among other things, there is an uneven heating of the pipes on the inside along the shaft wall since the pipes which are situated in the corners or near to these are at a greater distance from the central furnace and are not accessible to the same heat radiation as are the pipes which are placed more centrally on the wall. The water which is situated in the corner pipes is therefore converted to steam to a lesser extent than is the water which is situated in the other pipes. Certain pipes have a continuation along the base surface. The pipes which constitute the continuation of the corner pipes along the base part will have a slower through-flow or water since the water in the corner pipes circulates more slowly than in the other pipes, and burn damage, so-called burn-outs, therefore occurs sometimes in these base pipes.
Another problem with the conventional recovery boilers is also that it is easy for small drops of molten, inorganic chemicals to fly upwards in the flue gases on account of the great speed of the flue gases. It can happen that they are then deposited on the upper heating surfaces and impair the cooling of the gas and increase the gas flow resistance.
SOLUTION
It has therefore long been an objective to be able to remedy the abovementioned drawbacks of recovery boilers while at the same time maintaining production methods which include automatic welding, and for this reason a recovery boiler for combustion of waste liquors from cellulose production has been proposed, according to the invention, comprising a furnace whose base and walls include a multiplicity of liquid-cooled tubes and whose base constitutes a collection point for inorganic matter in molten form, with air and waste liquor being introduced into the furnace and the combustion gases being conveyed upwards in the boiler, which recovery boiler is characterized in that the cross-sectional area of the furnace at a first lower level exceeds the cross-sectional area of the furnace at a second level higher up in the furnace, so that the average gas flow speed upwards can be kept lower at the first level than would have been the case if the cross-sectional area had been identical at the first and second levels.
According to the invention, it is expedient for the number of wall tubes at the said first level to be essentially the same as, and preferably identical to, the number of tubes at the said second level.
According to the invention, the recovery boiler is also characterized in that the circumference of the cross-section at the two levels is essentially the same.
The recovery boiler according to the invention can expediently have a cross-section at the second level which exhibits an essentially rectangular, preferably square, shape, and a cross-section at the first level which is polygonal, having more than four sides, preferably six or eight.
In the recovery boiler according to the present invention, the pipes along the walls which run vertically and which are placed in the corners of the wall at the second level will, at the first level, be situated along an unbroken surface and at a shorter distance from a centre line extending vertically in the recovery boiler than at the second level.
The recovery boiler according to the invention can expediently be designed such that the first lower level represents about 1/4 of the total height.
The invention is further characterized in that the collection base for the inorganic substances in molten form has the shape of an open, upwardly directed V.
According to the invention, it is expedient for outlets from the base to be arranged at both ends of the V-shaped base.
The recovery boiler according to the present invention is also characterized in that the final part of the cooling of the flue gases is designed in two stages, with the flue gases in the penultimate stage being made to flow downwards along the pipes in a heat exchanger having vertical, water-filled pipes, while in the final stage they are made to flow downwards across the pipes in a heat exchanger having horizontally positioned pipes.
According to the invention, it is expedient for the final stage to have an inlet directly connected to the outlet of the penultimate stage.
According to the invention, it is expedient for the final stage to be designed as several pipe assemblies, preferably three or more, arranged one after the other in the direction of the flue gases.
According to the invention, one of the final stages in the cooling of the flue gases can be supported from below instead of being suspended.
DESCRIPTION OF THE FIGURES
The invention will be described in greater detail hereinbelow with reference to a preferred embodiment which is shown in the attached figures, in which:
FIG. 1 shows, diagrammatically and in partial cross-section, a recovery boiler according to the invention,
FIG. 2 shows, again diagrammatically and in cross-section, the lower part of the recovery boiler according to FIG. 1 in an enlarged representation,
FIG. 3 shows a section along the line B--B in FIG. 2,
FIG. 4 shows a section through the boiler at the level where the black liquor is sprayed in, and
FIG. 5 shows a section higher up in the boiler where the latter is square and where the lowermost part of the channels for the outgoing combustion gas is shown.
DETAILED DESCRIPTION
FIG. 1 shows, in section, the main parts of a preferred recovery boiler according to the invention. The boiler consists of a shaft-shaped furnace having a first lower level 1 and a second upper level 2. The second level 2 is of conventional type and has, at its upper end, a constriction, a so-called nose 3. A final set of air injection nozzles 4 for quaternary air is present at this level but is not necessary for the invention. The upper shaft-shaped part 2 of the boiler has been made square in the present case. Pipes for through-flow of water and for heat absorption are arranged on the inside of the whole boiler, but for reasons of simplicity they are not shown in the drawing.
As is evident from the Figure, the lower level 1 is widened in relation to the upper part 2. This level 1 has been made octagonal in the present case, although a hexagon can also be used, or a polygon with more then eight corners, in which respect the lower part approaches a circular shape the more edges there are. What is important is that the lower part 1 has more edges than the upper part 2. The number of edges can be chosen freely. However, an expedient number is eight, since in this way excessively small, plane surfaces need not be formed by the walls. The cross-sectional area of this lower part 1 is consequently greater than the cross-sectional area of the upper part 2, while the circumference of the latter remains the same. Due to the fact that the cross-sectional area is greater than in the upper part 2, the gas speed will be lower in this part, which has, inter alia, the advantage that drops of liquid, particles etc are not so easily drawn upwards by the gas flows. A set of nozzles 5 for secondary air and 6 for primary air have also been arranged in the lower part. The molten chemicals are collected at the base 7 and are allowed to flow out into one or more collection tanks 8 under the boiler.
The black liquor which is to be combusted is introduced into the lower part 1 via nozzles at a level 17 above the secondary air set 5.
Situated above the upper part 2 of the furnace is a cooling system 9 for the flue gases which is of conventional type. This system 9 consists, on the one hand, of suspended pipes through which steam from the so-called steam dome 10 flows, and, on the other hand, of suspended pipes through which water or a mixture of water and steam flows. Steam from the pipes in the furnace is collected in the steam dome 10. Water to the pipes intended to form steam (food water) is also fed into the steam dome 10. The pipes in the cooling system 9 are suspended in a normal manner and are divided up into several assemblies with dust blowers arranged between the assemblies.
As the flue gases pass through the cooling system 9, the gases are cooled. The cooling system 9 ends with an elongate cooling arrangement 11 in which the flue gases can flow along the pipes. The cooling arrangement 11 which will cool the flue gases from about 450° C. constitutes a penultimate stage of the whole cooling system in the boiler. Directly connected to the penultimate stage 11 is a further and final stage 12 which consists of in principle the same heat exchanger as above, but with the pipes placed horizontally in several assemblies in which the gases are made to flow across the pipes. This crosswise flow is more effective than lengthwise flow in respect of the heat transition between the flue gas and the water in the tubes, and in this final stage 12 the gas can be cooled to 100°-200° C. In the drawing, the final stage 12 is made up of three pipe assemblies, but a larger number can also be provided. The reason why the pipes are arranged in different assemblies is that it will be possible for dust blowers to be arranged between the assemblies. It is inevitable that some dust will be carried from the furnace, which dust settles on the pipes and must be removed at regular intervals in order to avoid impaired heat transfer. The dust from dust blowing can either fall directly down in the furnace or can be collected in funnels 13, 14 and 15 and then fall down into a container 16, from which this material is returned to the furnace 1.
It is expedient for the inlet of the final stage 12 of the cooling system to be directly connected to the penultimate stage 11. Cooling medium in the stages 11 and 12 consists of water, so-called feed water, which, when it has been heated, is supplied to the steam dome.
The final stage 12 can also be supported from below and does not therefore have to be suspended.
The whole boiler system is otherwise suspended and is supported by the columns 18 or another suitable structure.
FIG. 2 shows the lower level 1 of the boiler according to the invention. In the present preferred case this is octagonal. At the upper part and at the base part the cooling pipes 19 are indicated by dashes. These pipes, which are vertical along the walls, execute, at opposite sides in the lower part, a turn to an almost horizontal position along the base. Not all the pipes can be turned in this way and accommodated in one and the same plane, for which reason some of the pipes pass down into a distribution pipe 20.
As is shown in cross-section, the base 21 is V-shaped upwards and has the form of a very open V. The molten inorganic material will therefore be collected in the channel which is formed by this V. This molten material is drained off on both sides of the V through openings 22, which in the present case are three in number on each side. The openings 22 lie slightly above the V base, for which reason a pool of molten material is intentionally left in the base. The injection of primary and secondary air and in addition liquor sprayers are indicated by the same references as in FIG. 1, while the injection of tertiary air takes place at the level 23.
The pipes which are situated in the corners in the upper part 2 of the furnace come not to be situated in any corner in the lower part of the furnace in accordance with the invention. This is shown clearly by FIG. 3 which represents a section along the line b--b in FIG. 2. In this Figure, a corner in the upper part is marked by the reference 24, and the corners in the lower part by the references 25. As is evident from the Figure, the pipes from the corner 24 turn inwards and reach the lower edge 26. There, they are not situated in any corner, but instead approximately centrally on the side However, the octagon is not equilateral, for which reason the pipes do not turn to the same extent. The pipes from the corners 24 of the square thus come to be situated nearer the centre of the furnace in the lower octagonal part than in the upper square part, while, in a corresponding manner, the pipes in the corners 25 in the lower octagonal part come to be situated nearer the centre of the furnace in the upper square part. The corner pipes therefore come to be warmer than if they had remained corner pipes, and the continuation of these pipes horizontally along the base therefore comes to have water flowing through it at a greater speed than if the square cross-sectional form had been kept all the way down. This counteracts the risk of burn damages in the base pipes, so-called burn-outs.
The left part of FIG. 3 shows how the base pipes are arranged. The vertical pipes along the sides 27 and 28 are bent in parallel inwards along the base. Since the side 27 has a certain angle with the base pipes, these base pipes, if they have the same external diameters, come to be situated nearer each other from this side than at the side 28 where the pipes are bent straight outwards.
FIG. 4 shows a section at the level for liquor injection in the upper part of the first lower level of the recovery boiler. As can be seen, the cross-section is octagonal, with eight sets of injection nozzles 17, one at the middle of each side. The sides of the octagon need not be of identical length, and in the Figure the sides 26 and 27 are slightly longer than the sides 28. There is therefore no right angle in the octagon where the vertical pipes would be able to "hide", and instead all the pipes are virtually equal as regards the heat transfer from the furnace to the water in the pipes.
FIG. 5 shows a section in the upper part 2 at the level lying immediately above the point where the upper part 2 begins to merge with the lower part 1. As can be seen, the section through the furnace is square.
The lower part 29 of the flue gas channels in the final cooling stage 12 is indicated on the right side of the Figure. The channel 29 for the flue gases can divide in two or more parts from the funnel-shaped part 15. Situated horizontally in this funnel-shaped part 15 is a discharge screw 30 for discharging dust and other substances which have been separated from the flue gas and have collected in the funnel 15.
The present invention has thus provided a recovery boiler which has better properties than the former conventional recovery boilers. The widened lower part of the furnace allows for a lower gas speed, with a resultant favourable separation and precipitation of molten drops, and in addition the pipes are not shadowed in a corner and as a result permit a more uniform and quicker through-flow of water. Furthermore, the economic aspects of the recovery boiler have been improved as a result of the more efficient cooling of the flue gases leaving the boiler. The combustion air can also be added more evenly since the boiler has a rounder shape than the conventional boilers. The rounder shape is especially advantageous if it is wished to rotate the combustion air and gases in the lower part of the furnace, so-called rotation firing.
The V-shaped design or the base, with distribution box or channel in the middle, means that each individual pipe has a shorter distance associated with the base. This too leads to a safer construction with less risk of so-called burnout.
The base is cooled by a greater flow of water than in conventional cases, which also improves the safety. This is due to the fact that a greater proportion of wall pipes are connected to the base compared to an entirely square boiler.
The invention is not limited to the embodiment shown, but instead can be varied in different ways within the scope of the patent claims. Thus, one advantageous embodiment may have a completely circular cross-section in the lower part 1. | The invention relates to a recovery boiler for combustion of waste liquors. It comprises a furnace whose base and walls include a multiplicity of liquid-cooled tubes and whose base (21) constitutes a collection point for inorganic substances in molten form, with air and waste liquor being introduced into the furnace and the combustion gases being conveyed upwards in the boiler. The invention is characterized essentially in that the cross-sectional area of the furnace at a first lower level (1) exceeds the cross-sectional area of the furnace at a second level (2) higher up in the furnace. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application Ser. No. 14/032,722, filed Sep. 20, 2013, entitled Manufacture and Method For Forming Structures and the Structures Resulting Therefrom, which application is incorporated by reference herein in its entirety.
FIELD
The present invention relates to joinery methods and manufactures for assembling structures and more particularly, to such methods and manufactures applied to the task of assembling structures, such as doors, windows and frames, from members conjoined at an angle, e.g., perpendicular to one another.
BACKGROUND
Various manufactures and methods are known for joining adjacent members, such as welding, mortise and tenon joints, the use of threaded fasteners extending through the adjacent ends of the members, etc. As applied to metal structures, such as metal doors, traditional welding methods of the stiles to the rails is labor and skill intensive, costly, and often causes discoloration and distortion of pre-finished members. The use of full-width tie rods in conjunction with corner fittings requires multiple fittings and assembly is time consuming and costly. Improved and/or alternative methods and devices for joinery therefore remain desirable.
SUMMARY
The disclosed subject matter relates to a structure having a first member with an open end and an interior hollow, the open end communicating with the interior hollow thereof, a first wall, a second wall and a third wall conjoining with the first wall on opposite sides thereof defining an interior shape of the first member proximate the first wall; a second member having an interior hollow and an open end, the open end communicating with the interior hollow thereof; a clip attaching the first member to the second member, the clip having a first leg and a second leg, conjoined at a first angle forming a first conjunction, a third leg attached to the second leg at an end thereof distal to the first leg forming a second conjunction, the third leg extending along the second leg proximate and substantially parallel to a surface thereof in a direction from the second conjunction toward the first leg and a fourth leg extending from a third conjunction with the third leg distal to the second conjunction, the fourth leg extending parallel to the first leg along a portion of the length of the first leg with a spacing between the fourth leg and the first leg accommodating the first wall of the first member there between, the first leg inserted into the hollow in the first member and positioned against the first wall of the first member, the first leg of the clip abutting against the first wall of the first member, mating with the interior shape of the first member proximate the first wall, and being fastened to the first member, the fourth leg being fastened to the first wall of the first member, the second leg extending outside the interior hollow of the first member, inserting into the open end of the second member and being fastened to the second member.
In another embodiment, a fifth leg is attached to the fourth leg at an end thereof distal to the third leg forming a third conjunction, the fifth leg extending distal to the first leg and substantially parallel to the direction of extension of the third leg, the third leg, fourth leg and fifth leg forming a U-shape, the second leg, third leg and fifth leg extending into the open end of the second member.
In another embodiment, the first, second, third, fourth and fifth legs are each formed from a continuous metal strip.
In another embodiment, the second member has first and second substantially parallel walls bridged by a connecting wall, the first wall of the second member fastened to the second leg of the clip and the second wall of the second member fastened to the fifth leg.
In another embodiment, the first leg and the fourth leg of the clip have fastener apertures therein that align with an aperture in the first wall of the first member, wherein the second and third legs have apertures that align with an aperture in the first wall of the second member, and wherein the fifth leg has an aperture therein which aligns with an aperture in the second wall of the second member and further comprising a plurality of fasteners extending through the aligned apertures of the clip and the first and second members securing the clip to the first member and the second member.
In another embodiment, the fasteners are blind rivets.
In another embodiment, a pair of support wings extend from opposite sides of the first leg, the support wings mating with the interior shape of the first member.
In another embodiment, each of the support wings include a connector portion that extends at an angle from the first leg and a lip that extends at an angle from the connector portion.
In another embodiment, the connector portion extends at about 90° from the first leg and the lip extends at about 90° from the connector portion.
In another embodiment, the first wall of the first member has a slot accommodating the clip at a position spaced above an end of the first member.
In another embodiment, the first wall of the first member has a shallow U-shaped cross-sectional shape having a bottom portion and a pair of short end portions and wherein opposing outer edges of the first conjunction are relieved and the widths of the first leg and the first conjunction approximate the width of the bottom portion of the shallow U-shape allowing the first leg to be accommodated between the end portions of the shallow U-shape.
In another embodiment, the second wall of the second member has a shallow U-shaped cross-sectional shape having a bottom portion and a pair of short end portions and wherein opposing outer edges of the third conjunction are relieved and the width of the fifth leg and the third conjunction approximate the width of the bottom portion of the shallow U-shape of the second wall of the second member, allowing the fifth leg to be accommodated between the end portions of the shallow U-shape.
In another embodiment, the second member has a fourth wall parallel to and spaced from the connecting wall and bridging between the first wall and the second wall of the second member to define a tubular structure, the second leg and third leg of the clip being fastened to the first wall of the second member and the fifth leg of the clip being fastened to the second wall of the second member, the width of the second leg and the third leg approximating the distance between the fourth wall and the connecting wall of the second member.
In another embodiment, a structure has a first member with an interior hollow and an aperture in a first wall thereof communicating with the interior hollow, a second wall and a third wall of the first member conjoining with the first wall on opposite sides thereof defining an interior shape of the first member proximate the first wall, the first wall of the first member having a shallow U-shaped cross-sectional shape having a bottom portion of the U-shape and a pair of short end portions of the U-shape;
a second member having an interior hollow and an open end, the open end communicating with the interior hollow thereof; a clip attaching the first member to the second member, the clip having a first leg and a second leg, conjoined at a first angle forming a first conjunction, the first leg inserted into the hollow in the first member and positioned against the first wall of the first member proximate the aperture of the first wall of the first member, the first leg of the clip abutting against the first wall of the first member and being fastened to the first member, the first leg mating with the interior shape of the first member proximate the first side wall, the widths of the first leg and the first conjunction approximating the width of the bottom portion of the U-shape allowing the first leg to be accommodated between the end portions of the U-shape, a pair of support wings extending from opposite sides of the first leg, the support wings mating with the interior shape of the first member and overlapping the short end portions of the U-shape, the second leg extending outside the interior hollow of the first member, inserting into the open end of the second member and being fastened to the second member.
In another embodiment, each of the support wings include a connector portion that extends at an angle from the first leg and a lip that extends at an angle from the connector portion.
In another embodiment, the clip has a plurality of fastener apertures formed therein and the first member and the second member each have at least one fastener aperture therein, the plurality of fastener apertures of the clip and the apertures in the first member and the second member being aligned in an assembly orientation, and further including a plurality of fasteners inserted through the aligned fastener apertures of the clip and the first and second members to fasten the first and second members to the clip.
In another embodiment, the first and second members are tubular extrusions of aluminum alloy.
In another embodiment, the structure is a portion of a door.
In another embodiment, a structure includes a first tubular member having an interior hollow and an open end communicating with the interior hollow, a first wall, a second wall and a third wall conjoining with the first wall on opposite sides thereof defining an interior shape of the first member proximate the first wall; a second tubular member having an interior hollow and an open end, the open end communicating with the interior hollow thereof; a clip attaching the first member to the second member, the clip having a first leg and a second leg, conjoined at a first angle forming a first conjunction, the first leg inserted into the hollow in the first member and positioned against the first wall of the first member, the first leg of the clip abutting against the first wall of the first member and being fastened to the first member, the first leg mating with the interior shape of the first member proximate the first wall,
the second leg extending outside the interior hollow, inserting into the open end of the second member and being fastened to the second member, a third leg attached to the second leg at an end thereof distal to the first leg forming a second conjunction, the third leg extending along the second leg proximate and substantially parallel to a surface thereof in a direction from the second conjunction toward the first leg and a fourth leg extending from a third conjunction with the third leg distal to the second conjunction, the fourth leg extending parallel to the first leg along a portion of the length of the first leg with a spacing between the fourth leg and the first leg accommodating the first wall of the first member there between, the fourth leg being fastened to the first wall of the first member, a fifth leg attached to the fourth leg at an end thereof distal to the third leg forming a third conjunction, the fifth leg extending distal to the first leg and substantially parallel to the direction of extension of the third leg, the third leg, fourth leg and fifth leg forming a U-shape, the second leg, third leg and fifth leg extending into the open end of the second member and attaching thereto.
In another embodiment, the first wall of the first member has a shallow U-shaped cross-sectional shape having a bottom portion of the U-shape and a pair of short end portions of the U-shape and wherein opposing outer edges of the first conjunction are relieved, and the widths of the first leg and the first conjunction approximate the width of the bottom portion of the U-shape allowing the first leg to be accommodated between the end portions of the U-shape and wherein the second wall of the second member has a shallow U-shaped cross-sectional shape having a bottom portion of the U-shape and a pair of short end portions of the U-shape and wherein opposing outer edges of the third conjunction are relieved and the width of the fifth leg and the third conjunction approximate the width of the bottom portion of the U-shape of the second wall of the second member, allowing the fifth leg to be accommodated between the end portions of the U-shape.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.
FIG. 1 is perspective view of a clip for assembling members in accordance with an embodiment of the present disclosure.
FIG. 2 is a perspective view of the clip of FIG. 1 looking from another direction.
FIG. 3 is a perspective view of the clip of FIGS. 1 and 2 in position for insertion into a first hollow member.
FIG. 4 is a partially phantom perspective view of the clip of FIG. 3 positioned within the first hollow member.
FIG. 5 is a perspective view of the clip and hollow member of FIGS. 3 and 4 coupled to an adjacent member to form an assembly.
FIG. 6 is a cross-sectional view of the assembly of FIG. 5 .
FIG. 7 is a perspective view of the cross-section of the assembly of FIG. 6 .
FIG. 8 is a perspective view of the assembly of FIGS. 5-7 viewed from another direction.
FIG. 9 is perspective view of a clip for assembling members in accordance with another embodiment of the present disclosure.
FIG. 10 is a perspective view of the clip of FIG. 9 looking from another direction.
FIG. 11 is a partially phantom, perspective view of the clip of FIGS. 9 and 10 in a first insertion position into a slot in a first hollow member.
FIG. 12 is a partially phantom, perspective view of the clip of FIG. 11 as it is rotated into a second insertion position within the first hollow member.
FIG. 13 is a partially phantom perspective view of the clip of FIGS. 11 and 12 in the second insertion position within the first hollow member.
FIG. 14 is a perspective view of the clip and hollow member of FIG. 13 coupled to an adjacent member to form an assembly.
FIG. 15 is a cross-sectional view of the assembly of FIG. 14 .
FIG. 16 is a perspective view of the cross-section of the assembly of FIG. 15 .
FIG. 17 is perspective view of a clip for assembling members in accordance with another embodiment of the present disclosure.
FIG. 18 is a perspective view of the clip of FIG. 17 looking from another direction.
FIG. 19 is a perspective view of the clip of FIGS. 17 and 18 in position for insertion into a first hollow member.
FIG. 20 is a partially phantom, perspective view of the clip of FIG. 19 positioned within the first hollow member.
FIG. 21 is a perspective view of the clip and hollow member of FIG. 20 coupled to an adjacent member to form an assembly.
FIG. 22 is a cross-sectional view of the assembly of FIG. 21 .
FIG. 23 is a perspective view of the cross-section of the assembly of FIG. 22 .
FIG. 24 is perspective view of a clip for assembling members in accordance with another embodiment of the present disclosure.
FIG. 25 is a perspective view of the clip of FIG. 24 looking from another direction.
FIG. 26 is a partially phantom, perspective view of a pair of clips shown in FIGS. 24 and 25 in a first insertion position into a pair of slots in a first hollow member.
FIG. 27 is a partially phantom, perspective view of the clips of FIG. 26 as they are rotated into a second insertion position within the first hollow member.
FIG. 28 is a partially phantom perspective view of the clips of FIGS. 26 and 27 in the second insertion position within the first hollow member.
FIG. 29 is a perspective view of the clips and hollow member of FIG. 28 coupled to an adjacent member to form an assembly.
FIG. 30 is a cross-sectional view of the assembly of FIG. 29 .
FIG. 31 is a perspective view of the cross-section of the assembly of FIG. 30 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The present disclosure describes a clip and clip installation process that may be used in conjunction with fasteners to assemble a frame joint from component members. In one embodiment, the dip may be used to join a stile and rail of a door or window frame, e.g., made from hollow members, such as extrusions made from aluminum alloy. The clip may be used to align vertical and horizontal components relative to each other, allowing them to be joined at the proper angle. The clip may be used to join members of various lengths, such as tall/short top and bottom rails, allowing a variety of structures to be assembled using a common clip, e.g., to produce a variety of frames of different dimensions. The clip may be made from plastic, aluminum or steel depending on the strength needed for the joint connection. In those applications where high strength, low cost and formability are required, steel can be used. Progressive, one-piece steel stamping designs are presented herein, but fabricated steel, machined aluminum, machined plastic, extruded or cast aluminum and extruded or cast plastics could also be used for forming the clip. The present disclosure includes clip installation methods that could be categorized as: inside mounting, outside mounting or slide-in mounting. In one embodiment, the clip may be attached to the members to be joined through the use of blind fasteners. The fastener dimensions may be selected to provide the required strength for the application and may be set using a hydraulic or pneumatic gun, eliminating welding and the inherent heat related problems that it creates. Other types of fasteners can be used for attachment, such as screws, bolts, rivets, spot welds, etc. Typically, the use of the clip and methods of the present disclosure allow a reduction in the number of parts required to join members into a frame structure over conventional approaches. The avoidance of welding may also lead to reductions in labor costs and required skill levels, assembly time, number of parts to assemble and stock, manufacturing costs, rework and scrap. The ease of assembly provided by the clip may also allow assembly to take place in the field versus in the factory.
FIGS. 1 and 2 show a clip 10 for assembling members 11 , 13 (see FIG. 5 ) in accordance with an embodiment of the present disclosure. The clip 10 could be described as having a stacked or double L configuration with a first leg 12 having a first panel 14 , an offset 16 and a second panel 18 . A second leg 20 extends at an angle, e.g., 90 degrees from the first panel 14 , defining the bottom portion of a first L shape and a third panel 22 depends from a reverse curve 24 , such that the third panel 22 extends parallel to the second panel 18 and in line with the first panel 14 . The offset 16 has dimensions approximating the thickness of the third panel 22 and permits the third panel 22 to be in line with the first panel 14 . A third leg 26 extends from the third panel 22 at an angle, e.g., 90 degrees, forming in conjunction with the third panel 22 , another L shape that nests (with a space between second leg 20 and third leg 26 ) with the L shape formed by the first leg 12 and the second leg 20 . The second leg 20 has a flattened U shaped cross-section with a central area 20 C, bends 20 B and flat portions 20 F that overall provide a stiffening function and may mate in complementary fashion with interior surfaces of the member 13 . A pair of support wings 28 extend from opposite sides of the first panel 14 with a connected portion 28 C extending at an angle, e.g., 90 degrees relative to the first panel 14 to a bend 28 B of, e.g., 90 degrees from which extends a lip 28 L. A similar pair of support wings 30 with portions 30 C, 30 B and 30 L extend in a similar manner from third panel 22 . Holes 32 A 1 - 32 E permit the passage of fasteners (not shown) like rivets, screws, bolts, etc. through the clip 10 .
FIGS. 3 and 4 show the installation of the clip 10 into a hollow structural member 11 that may be made, e.g., from extruded aluminum or plastic. The member 11 has a wall 11 W with a shallow U cross sectional shape. Slots S 1 , S 2 in the wall 11 W receive the second leg 20 and the third leg 26 , respectively, there through and apertures A 1 , A 2 align with apertures 32 A 1 / 32 A 2 and, 32 B of the clip 10 . Because the clip 10 is inserted into the hollow member 11 and then the second leg 20 and third leg 26 are extended through the slots S 1 , S 2 , the arrangement can be designated an “inside mount” of the clip 10 . When fully inserted into the slots S 1 , S 2 , the support wings 28 , 30 , being complementarily shaped relative to the shallow U shaped wall 11 W, bear against the wall 11 W and/or the interior 11 I of the member 11 to resist torsional forces F 1 , F 2 (clockwise or counterclockwise, see FIG. 5 also) that may be exerted on the clip 10 and members 11 , 13 . The slots S 1 , S 2 and apertures A 1 , A 2 may be punched, drilled or machined into the wall 11 W.
FIGS. 5-8 show an assembly 34 formed from members 11 , 13 conjoined by clip 10 and fasteners 36 A- 36 E. The fasteners 36 A- 36 E may be “blind fasteners,” such as pop rivets that can be applied from one side of an assembly and have a head portion H, which is larger than the apertures A 1 , A 2 in member 11 (member 13 having similar apertures) and an expandable portion M, which is inserted through aligned apertures, e.g., A 1 and 32 A 1 , 32 A 2 and then expanded (by pulling on a central, breakable core pin with a swage tip) to enlarge the expandable portion M to a dimension larger than the apertures A 1 , 32 A 1 , 32 A 2 , clamping the member 11 to the clip 10 . Blind fasteners do not require access to the side of the assembly 34 opposite to the head portion H. The member 13 is similarly held to the clip 10 by the action of fasteners 36 C, 36 D and 36 E. Other types of fasteners 36 may be used, such as machine or self-threading screws or bolts with mating nuts.
FIGS. 9 and 10 show a clip 110 for assembling members 111 , 113 (see FIG. 14 ) in accordance with an embodiment of the present disclosure. The clip 110 could be described as having a stacked or double L configuration with a first leg 112 having a first panel 114 , an offset 116 and a second panel 118 . A second leg 120 extends at an angle, e.g., 90 degrees from the first panel 114 , defining the bottom portion of a first L shape and a third panel 122 depends from a reverse curve 124 , such that the third panel 122 extends parallel to the second panel 118 offset from the plane occupied by the first panel 114 . The offset 116 has dimensions approximating the thickness of the third panel 122 plus the thickness of the member 111 (wall 111 W) and permits the third panel 122 to abut against the interior surface of the wall 111 W while the first panel 114 abuts the exterior surface of the wall 111 W, when the clip 110 is installed on member 111 (See FIG. 13 ). A third leg 126 extends from the third panel 122 at an angle, e.g., 90 degrees, forming in conjunction with the third panel 122 , another L shape that nests (with a space between second leg 120 and third leg 126 ) with the L shape formed by the first leg 112 and the second leg 120 . The second leg 120 has a flattened U shaped cross-section like second leg 20 of FIG. 1 . A pair of support wings 129 extend from opposite sides of the first panel 114 extending at an angle, e.g., 90 degrees relative to the first panel 114 . Holes 132 A 1 - 132 E permit the passage of fasteners like rivets, screws, bolts, etc. through the clip 10 . Additional holes, like 132 F (only shown in FIGS. 9 and 10 ) may be made to accommodate additional fasteners.
FIGS. 11, 12 and 13 show the installation of the clip 110 into a hollow structural member 111 that may be made, e.g., from extruded aluminum or plastic. The member 111 has a wall 111 W with a shallow U cross sectional shape. Slot S 1 in the wall 111 W receives the second and third panels 118 , 122 . When the clip 110 is rotated (counterclockwise in these views), the support wings 129 extend into slots S 2 A and S 2 B and the aperture 132 D aligns with aperture A 1 in 111 W and apertures 132 A 1 , 132 A 2 align with aperture A 2 in wall 111 W. Because the clip 110 is partially inserted into the hollow member 111 from the outside and second leg 120 , first panel 114 and third leg 126 remain on the outside of the member 111 , the arrangement can be designated an “outside mount” of the clip 110 . When fully inserted into the slots S 2 A, S 2 B, the support wings 129 bear against the slots S 2 A, S 2 B and/or the interior 1111 of member 111 to resist torsional forces F 1 , F 2 (See FIG. 4 ) that may be exerted on the clip 110 .
FIGS. 14-16 show an assembly 134 formed from members 111 , 113 and conjoined by clip 110 and fasteners 136 A- 136 E. The fasteners 136 A- 136 E may be “blind fasteners,” such as pop rivets that can be applied from one side of an assembly and have a head portion H and an expandable portion M, which is inserted through the aligned apertures, e.g., A 1 , 132 A 1 , 132 A 2 and then expanded to enlarge the expandable portion M to a dimension larger than the apertures A 1 , 132 A 1 , 132 A 2 , clamping the member 111 to the clip 110 . The member 113 is similarly held to the clip 110 by the action of fasteners 136 C, 136 D and 136 E. Other types of fasteners 136 may be used, such as machine or self-threading screws or bolts with mating nuts.
FIGS. 17 and 18 show a clip 210 for assembling members 211 , 213 (see FIG. 21 ) in accordance with an embodiment of the present disclosure. The clip 210 could be described as having an L configuration with a first leg 212 having a flattened U shaped cross section. A second leg 220 extends at an angle, e.g., 90 degrees from the first leg 212 , defining the bottom portion of the L shape. A third panel 221 extends back from a reverse curve 223 , such that the third panel 221 extends parallel to the second leg 220 . An upright panel 225 extends from curve 227 parallel to and spaced from first leg 212 by a spacing approximating the thickness of wall 211 W and ends in curve 229 . A forth panel 226 extends from curve 229 parallel to panels 220 and 221 . The clip 210 could be described as L shaped with a U shaped element composed of panels 221 , 225 and 226 attached to the bottom leg 220 , such that the bottom portion of the L is bifurcated.
A pair of support wings 228 extend from opposite sides of the first leg 212 with a connected portion 228 C extending at an angle, e.g., 90 degrees relative to the first leg 212 to a bend 228 B of, e.g., 90 degrees from which a lip 228 L extends. Holes 232 A- 232 E 2 permit the passage of fasteners like rivets, screws, bolts, etc. through the clip 210 .
FIGS. 19 and 20 show the installation of the clip 210 into a hollow structural member 211 that may be made, e.g., from extruded aluminum or plastic. The member 211 has a wall 211 W with a shallow U cross sectional shape. A slot S 1 in the wall 211 W accommodates the clip 210 allowing the leg 220 to project from a level above that of the edge 211 E of the member 211 and allowing the apertures A 1 and A 2 to align with holes 232 A and 232 B 1 / 232 B 2 ( 232 B 2 is not visible in this view). The slot S 1 may extend up the wall 211 W to any selected extent, so long as the apertures A 1 , A 2 , which may occupy any selected position, are positioned to align with the apertures 232 A, 232 B 1 / 232 B 2 for given slot S 1 dimensions. Because the clip 210 is slipped into the hollow member 211 via the slot and the spacing between panel 225 and leg 212 , the arrangement can be designated a “slide mount” of the clip 210 . When fully inserted into the slot S 1 and fastened by fasteners, as shown in FIG. 21 , the support wings 228 , being complementarily shaped relative to the shallow U shaped wall 211 W, bear against the wall 211 W and/or the interior 2111 of the member 211 to resist torsional forces F 1 , F 2 that may be exerted on the clip 210 and/or members 211 , 213 .
FIGS. 21-23 show an assembly 234 formed from members 211 , 213 and conjoined by clip 210 and fasteners 236 A- 236 E. The fasteners 236 A- 236 E may be “blind fasteners,” such as pop rivets that can be applied from one side of an assembly and have a head portion H, which is larger than the apertures A 1 , A 2 in the member 211 (member 213 having similar apertures) and an expandable portion M, which is inserted through the aligned apertures, e.g., A 1 , 232 A and then expanded to enlarge the expandable portion M to a dimension larger than the aperture 232 A and clamping the member 211 to the clip 210 . The member 213 is similarly held to the clip 210 by the action of fasteners 236 C, 236 D and 236 E. Other types of fasteners 236 may be used, such as machine or self-threading screws or bolts with mating nuts.
FIGS. 24 and 25 show a clip 310 for assembling members 311 , 313 (see FIG. 29 ) in accordance with an embodiment of the present disclosure. The clip 310 could be described as having an L configuration with a first leg 312 having a stub 316 extending at an angle, e.g., 90 degrees, from a first panel 318 . A second leg 320 extends at an angle, e.g., 90 degrees from a second panel 322 , defining the bottom portion of the L shape, the second panel 322 depending from a reverse curve 324 extending from the first panel 318 , such that the second panel 322 extends parallel to the first panel 318 . The stub 316 extends from the first panel 318 parallel to the second leg 320 , bracing the position of the second leg relative to the second panel 322 . Holes 332 A 1 - 332 D permit the passage of fasteners like rivets, screws, bolts, etc. through the clip 310 . The clip 310 features two holding tabs 317 A, 317 B that prevent the clip 310 from passing through a given slot in a hollow member when it is partially inserted therein to assemble a structure, as shall be described below. Reliefs 319 A, 319 B, 321 A and 321 B at the reverse curve 324 , stub 316 and bend 323 remove the burr that is produced as a consequence of forming a bend at these locations. A burr could interfere with the insertion and rotation of the clip 310 in a close fitting slot in a member to be joined. The clip 310 is also radiused at 325 A and 325 B to facilitate insertion into a mating slot in a structural member, such as the rail of a door.
FIGS. 26, 27 and 28 show the installation of a pair of clips 310 A, 310 B into a hollow structural member 311 that may be made, e.g., from extruded aluminum or plastic. The member 311 has a wall 311 W with a shallow U cross sectional shape. Slots S 1 , S 2 in the wall 311 W receive the first legs 312 of clips 310 A, 310 B. When the clips 310 A, 310 B are inserted fully, the holding tabs 317 A, 317 B abut against the corresponding slot S 1 , S 2 , preventing the clip 310 from passing entirely through the slots S 1 , S 2 into the interior hollow 3111 of the hollow member 311 . When the clips 310 A, 310 B are rotated (counterclockwise in these views), the apertures 332 A 1 / 332 A 2 and 332 B 1 , 332 B 2 align with apertures A 1 , A 2 , A 3 , A 4 in wall 311 W. Because the clips 310 A, 310 B are partially inserted into the hollow member 311 from the outside and second leg 320 , remains on the outside of the member 311 , the arrangement can be designated an “outside mount” of the clip 310 .
FIGS. 29-31 show an assembly 334 formed from members 311 , 313 and conjoined by clips 310 A, 310 B and fasteners 336 A- 336 H. The fasteners 336 A- 336 H may be “blind fasteners,” such as pop rivets that can be applied from one side of an assembly. The member 313 is similarly held to the clips 310 A, 310 B by the action of fasteners 336 E- 336 H. Other types of fasteners 336 may be used, such as machine or self-threading screws or bolts with mating nuts. The clips 310 A, 310 B may be used in pairs to join two members e.g., 311 , 313 . One of the clips connects the upper part of the horizontal extrusion (rail) with the vertical extrusion, (stile), while the other clip joins the lower part of the horizontal extrusion (rail) with the vertical extrusion. Since a pair of clips 310 A, 310 B can accommodate multiple rails of different dimensions by adjusting the position of the slots S 1 , S 2 and the resultant spacing between the clips 310 A, 310 B, the clips 310 A, 310 B could be described as “universal.” For structures having less demanding requirements of strength and rigidity, a single clip 310 could be used to fasten two members 311 , 313 .
It will be understood that the embodiments described herein are merely exemplary and that a person skilled in the art may make many variations and modifications without departing from the spirit and scope of the claimed subject matter. For example, while 90 degree assemblies are shown above, the clip 10 , 110 , 210 , 310 may have a shape other than a 90 degree L, wherein the lower portion of the L is oriented at an acute or obtuse angle relative to the upper portion of the L, so that members 11 , 13 may be joined at other than 90 degrees. All such variations and modifications are intended to be included within the scope of the appended claims. | A clip for assembling corners of hollow members such as the rails and stiles of an extruded aluminum door. The clip has a double L shape. A portion of the clip inserts into the hollow of a first member and is attached thereto. Another U-shaped portion defining the bottom of the double L extends into the other hollow member for attachment thereto to form a sturdy joint without welding. The first member may have a slot that receives the clip and the clip may be shaped to conform to the internal surfaces of one or both members. Clips may be used at each corner. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an anesthetic evacuation regulator, and more particularly pertains to the use of a device to control the exhaust of an anesthetic administering system into the air. In the field of anesthetic application, there is a hazard to the doctor due to the exhaust of anesthetic gases into the air. One such hazard exists in dentist offices where anesthetic is used to control pain during dental procedures. This is also a problem in veterinary offices where surgical cages are used to hold the animal during surgical procedures.
2. Description of the Prior Art
Various types of anesthetic evacuation regulators are known in the prior art. A typical example of such an anesthetic evacuation regulator is to be found in U.S. Pat. No. 4,180,066 which issued to Milliken et al. The Milliken patent discloses the use of a valve to control the exhausting of anesthesia gases. The device uses a spring loaded valve to control the flow of gases from the pop-off valve to the exhausting system. The device does not show the use of a simple anesthetic equalizer to control the exhaust flow. It also does not show the use of an easily adjustable valve which can be adjusted to help evacuate the waste gases following a procedure.
U.S. Pat. No. 4,219,020, which issued to Czajka, shows the use of another spring loaded circuit which exhausts anesthesia gases from a mask during the use of anesthesia. As with the Milliken device, it does not shown the novel features of applicant's invention.
U.S. Pat. No. 4,109,651, which issued to Steigerwald, shows the use of a waste gas evacuation system which is designed to attach itself to the ventilation bag of an anesthesia device. Owing to the nature of this device, it is neither as accurate or as convenient as the device of the applicant, which easily attaches to the waste gas (pop-off) valve currently in use on many anesthesia machines.
U.S. Pat. No. 4,527,558, which issued to Hoenig, shows the use of an exhaust device which attaches to the exhaust port of a normal anesthesia mask. The system uses a series of valves which control the exhausted gases of the patient. The important feature of this patent is the use of a surge reservoir which can contain a large volume of exhausted gases. The vacuum is then attached to this device to exhaust the gases. The use of the reservoir serves to avoid the need to adjust the vacuum level needed to exhaust the gasses without overcoming the spring loaded exhaust valves in the anesthesia system. The present invention utilizes an easily variable exhaust pressure which eliminates the need for this extra hardware since the vacuum can be adjusted to a low enough level to exhaust the air without opening the pop-off valve in the anesthesia system due to excess vacuum.
While the above mentioned devices are suited for their intended usage, none of these devices show the use of an easily adjustable anesthesia exhausting system. Furthermore none of the above system show the use of a system which is capable of driving multiple units at one time under different conditions. Additionally, none of the prior art devices disclose the use of an atmospheric equalizer valve which provides instant adjustment at the location of use of the amount of vacuum pressure being applied. Inasmuch as the art is relatively crowded with respect to these various types of anesthetic evacuation regulators, it can be appreciated that there is a continuing need for and interest in improvements to such anesthetic evacuation regulators, and in this respect, the present invention addresses this need and interest.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of anesthetic evacuation regulators now present in the prior art, the present invention provides an improved anesthetic evacuation regulator. As such, the general purpose of the present invention, which will be described subsequently in greater detail is to provide a new and improved anesthetic evacuation regulators which has all the advantages of the prior art anesthetic evacuation regulator and none of the disadvantages.
To attain this, representative embodiments of the concepts of the present invention are illustrated in the drawings and make use of an anesthetic evacuation device for use in situations where the anesthetic gasses are exhausted into the room air. More specifically, the invention deals with a device which can be attached to the pop off valve of many of the current anesthesia machines. This contains and exhausts the excess anesthesia gasses to the outside air, preventing any danger to medical personnel who must be in the same room. The system also allows for the rapid exhaust of any leftover gasses following the medical procedure.
The system consists of a small number of simple components. The first component is a base unit which may either be mobile or permanently mounted on an exterior wall of the building in which it is used. The second component is a vacuum producing motor which is contained in the base unit. A series of connecting pipes connect the vacuum producing motor to a remote location where the vacuum is needed. A vacuum control valve or atmospheric equalizer is connected between the exhaust system pipes and the pop-off valve of an anesthetic machine or animal operating cage.
The control valve or atmospheric equalizer determines how much vacuum is applied to the pop-off valve of a conventional anesthesia machine to assist in the exhausting of the anesthetic gases to the outside of the building. This allows the medical personnel to adjust the amount of vacuum in accordance with their needs.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of 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 the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved anesthetic evacuation regulator which has all the advantages of the prior art anesthetic evacuation regulators and none of the disadvantages.
It is another object of the present invention to provide a new and improved anesthetic evacuation regulator which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved anesthetic evacuation regulator which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved anesthetic evacuation regulator which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such anesthetic evacuation regulators economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved anesthetic evacuation regulator which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved anesthetic evacuation regulator which gives the user more complete control over the exhausting of the excess gases.
Yet another object of the present invention is to provide a new and improved anesthetic evacuation regulator which is easily adapted to serve multiple units simultaneously and provides each outlet with a different amount of vacuum according to the needs of the user.
Even still another object of the present invention is to provide a new and improved anesthetic evacuation regulator which can be used to help in the quick dissipation of anesthesia gases in situations where animals are sedated by use of an anesthesia cage.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 illustrates the base vacuum source unit of the anesthetic exhaust system for use in hospitals or clinics.
FIG. 2 is a side view of the device as shown in FIG. 1.
FIG. 3 is a diagram of the air flow through the vacuum source motor.
FIG. 4 is a view of an air control valve used to activate or deactivate an exhaust gas circuit.
FIG. 5 is a view of an air handling system used in an alternative embodiment of the anesthetic evacuation device of the present invention.
FIG. 6 illustrates an atmospheric equalizer used to control exhaust gas air flow.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 1 thereof, a new and improved anesthetic evacuation regulator embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the first embodiment 10 of the invention includes a housing 11 which encloses a motor 32 (not shown) and an atmospheric equalizer to control the amount of vacuum present in the system. The motor drives a fan which produces an exhaust flow through the pipe outlet 24. Pipe outlet 24 is connected to outlet pipe 12 which extends through the exterior wall 20 of the building in which the device is installed. This allows the gasses which are collected to be vented through a hole in wall 20 to the outside of the building. The exhaust gases are collected through hose 14 which is connected during use to the vacuum port 54 located on the side of the housing 11. When the motor 32 is activated by use of switch 26 (FIG. 2) on the front of the housing, the fan driven by motor 32 produces an outlet flow through the exhaust pipe 12 and simultaneously produces a vacuum at the intake port 54. Hose 14 is attached to a hose handler 16 which allows the hose to be extended without dragging on the ground or interfering with the use of the device by medical personnel. During use, the distal end 18 of hose 14 is connected to the scavenger output of a "T" piece breathing, anesthetic dental mask or pop-off valve of an anesthetic machine. This allows the hose 14 to collect the exhaust gases which would normally be passed into the air within the building. This protects the medical personnel in the area from being exposed to the buildup of these gases during medical procedures.
FIG. 2 illustrates a side view of the device shown in FIG. 1. During operation the hose 14 is connected at intake port 54 which is shown on the housing 11.
FIG. 3 is a flow diagram which illustrates the air flow into and out of the fan driven by the motor 32 to produce the vacuum. When the motor 32 is activated it produces a suction at intake 50 which is connected to the intake of the fan. The actual flow through the fan is controlled by the use of valve 60. This valve regulates, the flow of the air from the intake port 54 and also allows ambient air to be collected through ambient air intake 56 to keep the fan from overheating and preventing the collection of moisture in the plumbing. After the gases and cooling air pass through the fan housing, they are exhausted through the exhaust port 24 which is connected to the exterior vent pipe 12 (FIG. 1).
FIG. 4 illustrates a second embodiment of the invention in which the device is arranged so that it may serve multiple users at one time. In this embodiment the housing 11 still contains a fan and motor which produce a vacuum at the intake port 28. In this case, however, the intake is connected to a manifold including a rigid pipe 45 which extends in the space above the ceiling 47 to adjoining treatment rooms in a typical medical environment. In the space above the ceiling, the pipe 45 connects to a set of distributions pipes 46 which terminate in each treatment room at a threaded connector 44. This allows the vacuum produced by the motor 32 to be readily accessible in each of the treatment rooms.
To control the flow of air in each treatment room, a valve 40 (FIG. 5) is connected to the threaded connector 44. This valve has a butterfly type valve 34 which can open or close to connect the room with the vacuum source. This valve is operated by lever 36, which in turn is actuated by rod 38. Rod 38 is designed to be of sufficient length so that a normal sized person could reach up and pull it down to actuate the vacuum system. When the vacuum in no longer needed, the valve is closed by pushing up on rod 38 which in turn will close valve 34 to stop the exhaust flow. The flow, when actuated, is then passed through a flexible hose 42 which is connected to an atmospheric equalizer at its distal end 43.
FIG. 6 illustrates the atmospheric equalizer. The atmospheric equalizer is used to control the amount of vacuum which is applied to the waste gas input 54 and reduce high levels of vacuum to levels of less than 0.25" HG which is applied to the pop-off valve of the anesthetic machine, scavenger hose of a dental mask or "T" piece breathing circuit. The atmospheric equalizer is in the shape of a right circular cylinder with two pipe tees connected to it, one at each of two opposite sides. At the top end 56 there is an opening for ambient air to be drawn in. This allows the ambient air to be mixed with waste gases which are drawn in through waste input 54. The amount of air which is mixed with the waste gases is controlled by a knob 58 which controls a butterfly valve 60. If the valve 60 is fully open, the ambient air is almost 95% of the mixture which is passed through the exhaust port 50. If the valve is fully closed, the waste gasses account for fully 100% of the gases which are exhausted through port 50. This adjustable valve allows the user to control the amount of vacuum which is applied to the pop-off valve of the anesthetic machine. The adjustable nature of the device makes it very useful since it is more versatile. By setting the amount of vacuum low, the device may be used to exhaust the gases from a patient's mask without opening the spring loaded exhaust valve. If excess vacuum is produced, it will overcome the spring force of the anesthetic mask and exhaust gases before the patient can inhale them. This would interfere with the administration of the anesthetic. On the other hand, producing a large vacuum is useful too. In many veterinary offices, the animals are sedated by placing them in an anesthetic box which is then filled with anesthetic gases to produce unconsciousness in the animal patient. This box is usually just opened to the air to allow the gases to dissipate. By connecting the box to a vacuum port of the present invention and adjusting the equalizer 52 to produce a high suction, the gases could be quickly and safely exhausted without risk to the staff. During normal use, the atmospheric equalizer would be attached to a bracket on the anesthetic machine (not shown) to allow the flow to be quickly and easily adjusted according to the needs of the medical personnel involved. The equalizer 52 also allows ambient air to be mixed with the waste anesthetic gas, which, in an undiluted concentration, is corrosive to the plumbing of the exhaust gas system. For those hospitals which have in house suction, such as dental clinics and plastic surgery clinics, a vacuum flow meter (not shown) is inserted between the vacuum source and the exhaust port 50 of the atmospheric equalizer to control the amount of vacuum present in the system which is connected to the pop-off valve of the anesthetic machine or dental mask through intake port 54.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | The present invention is directed to an anesthetic evacuation device for use in situations where the anesthetic gasses are exhausted into the room air. More specifically, the invention discloses a device which can be attached to the popoff valve of many of the current anesthesia machines. The device contains and exhausts the excess anesthesia gases to the outside air, preventing any danger to medical personnel who may be in the same room. The system also allows for the rapid exhaust of any leftover gasses following the medical procedure. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is being filed contemporaneously with application for U.S. Pat. No. ______, entitled TURF AERATOR, which is hereby incorporated by reference herein.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of turf aerators. In another aspect, the invention concerns walk-behind power turf aerators having a unibody construction and a compact configuration.
[0004] 2. Description of the Prior Art
[0005] Walk-behind power aerators have been used for years to maintain healthy lawns by cutting and removing plugs from the turf. Due to the expense and infrequent required use of power aerators, most individual homeowners do not own a power turf aerator. Rather, the bulk of the power aerators in service today are owned by rental companies or professional lawn care providers. As such, power aerators are frequently transported from location to location either by individuals renting the aerator from a rental company or by professional lawn care providers servicing different clients. In the past, however, efficient transportation of power aerators has been encumbered by the high weight and bulky configuration of conventional power aerators. In most cases, a truck and/or trailer has been required to transport conventional power aerators because they would not fit in the trunk of a car.
[0006] Another disadvantage of conventional power aerators is the lack of structural rigidity of the aerator body. Power aerators are necessarily subjected to conditions of high mechanical vibration and repeated mechanical stress. Over time, conventional aerators which have been manufactured by bolting various body parts to a structural frame can require frequent maintenance and/or replacement of body parts which have been damaged or loosened during normal operation of the aerator. This problem can be especially pronounced when the power aerator is employed in a high-use situation, such as for power aerators owned by rental companies or professional lawn care providers. In addition, it has been discovered that many owners of conventional aerators fail to properly maintain their power aerators due to the difficulty of gaining access to the components needing routine maintenance (e.g., moving parts equipped with grease fittings/zerks). For example, many conventional aerators require a body panel to be unbolted in order to gain access to grease fittings that should be frequently used to properly lubricate the aerator.
[0007] Many conventional power aerators in use today employ a rotating rear “spoon” assembly equipped with a plurality (e.g., 20-50) individual spoons/tines extending radially from a common rotating shaft. When the spoon assembly is rotated by the motor, the spoons/tines penetrate into the turf and remove plugs therefrom. This traditional configuration has a number of disadvantages. For example, such a configuration causes the aerator to be very difficult to maneuver and typically requires additional “add-on” weights for effective operation. Further, such a configuration can only remove relatively shallow plugs and causes compaction of the soil and root exposure around the location where the plug is removed. In addition, the high number of relatively weak spoons/tines can necessitate frequent tine replacement, which is a time consuming and expensive activity.
SUMMARY OF INVENTION
[0008] It is, therefore, an object of the present invention to provide a power aerator that can be shifted into a highly compact configuration to facilitate transportation and/or storage of the power aerator.
[0009] A further object of the present invention is to provide a power aerator having a body with increased structural rigidity to thereby better resist the vibrational and load forces experienced during normal operation.
[0010] Another object of the present invention is to provide a power aerator that provides easy access to components which require regular maintenance.
[0011] Still another object of the present invention is to provide a power aerator that employs a minimal number of plug-removing tines, but creates a relatively dense plug removal pattern.
[0012] Yet another object of the present invention is to provide a power aerator utilizing high-strength tines that are easily replaceable.
[0013] A still further object of the present invention is to provide a power aerator which removes plugs from turf in a manner which causes minimal soil compaction and root exposure.
[0014] It should be understood that the above-listed objects are only exemplary, and not all the objects listed above need be accomplished by the invention described and claimed herein.
[0015] Accordingly, in one embodiment of the present invention, there is provided a turf aerator comprising a body having a unibody and a plurality of wheels rotatably coupled to the body and supporting the body for movement on the turf.
[0016] In another embodiment of the present invention, there is provided a turf aerator comprising a crank shaft assembly and a plurality of generally upright tines. The crank shaft assembly includes a rotatable crank shaft comprising a plurality of axially spaced plates and a plurality of eccentric bars. Each of the eccentric bars is rigidly coupled to and extends between a respective pair of adjacent plates. Each of the tines includes a connection portion rotatably coupled to a respective eccentric bar and a tip portion configured to cut and remove plugs from the turf.
[0017] In still another embodiment of the present invention, there is provided a highly transportable turf aerator that is shiftable between an operating configuration wherein the aerator can be used to remove plugs from the turf and a compact configuration wherein the dimensions of the aerator are minimized to facilitate transportation and storage of the aerator. turf aerator comprises a substantially rigid body, a motor supported by the body, a plurality of tines shiftable relative to the body and powered by the motor, a plurality of wheels coupled to the body and providing for movement of the body on the turf, and a handle hingedly coupled to the body. The handle is shiftable between an extended position where it extends outwardly from the body and a folded position where it is over the body. The handle is in the extended position when the aerator is in the operating configuration, and the handle is in the folded position when the aerator is in the compact configuration.
BRIEF DESCRIPTION OF DRAWINGS
[0018] A preferred embodiment of the present invention is described in detail below with reference to the attached drawing figures, wherein:
[0019] FIG. 1 is a front isometric view of a power aerator constructed in accordance with the principles of the present invention;
[0020] FIG. 2 is a rear isometric view of the power aerator;
[0021] FIG. 3 is an enlarged cut-away front isometric view of the power aerator, particularly illustrating the unibody construction of the aerator body and the manner in which the crank shaft assembly is supported by the body;
[0022] FIG. 4 is an isometric assembly view of the crank shaft assembly and swingable tine guide positioned within and supported by the body of the power aerator;
[0023] FIG. 5 is an isometric assembly view of a tine of the power aerator, particularly illustrating the manner in which the tine connects to an eccentric bar of the crank shaft;
[0024] FIG. 6 is a sectional side view of the power aerator, particularly illustrating the swingable tine guide in an aeration position where the tines are positioned for cutting and removing plugs from the turf;
[0025] FIG. 7 is a sectional side view of the power aerator, particularly illustrating the swingable guide tine in a transportation position where the tines are positioned out of contact with the turf;
[0026] FIG. 8 is an enlarged side view of the base of a handle used to manipulate the aerator during operation, particularly illustrating the handle in an extended and locked position with a handle bar being locked in a handle base with a collar;
[0027] FIG. 9 is an enlarged side view similar to that of FIG. 8 , particularly illustrating the handle being shifted out of the extended and locked position by sliding the collar off of the handle base and pivoting the handle bar in the handle base;
[0028] FIG. 10 is a side view of the power aerator in a compact configuration with the handle bar being positioned towards the front of the aerator to thereby minimize the height and length of the aerator; and
[0029] FIG. 11 is a top view of a preferred plug pattern which can be created by the inventive aerator.
DETAILED DESCRIPTION
[0030] Referring initially to FIG. 1 , aerator 10 generally includes a body 12 , a plurality of wheels 14 , a motor 16 , a handle assembly 18 , and a guard bar 20 . Wheels 14 are rotatably coupled to body 12 and provide for movement of aerator 10 on a surface, such as the turf being plugged by aerator 10 . Wheels 14 can be any suitably strong conventional wheel assembly known in the art such as, for example, Gleason Corporation Model #99059450, available from Gleason Corporation of Milwaukee, Wis. Motor 16 is rigidly coupled to and supported by body 12 near the front of body 12 . Motor 16 is preferably a 5 horse power Briggs and Stratton Intekâ gasoline engine with a 6:1 gear ratio; however, motor 16 can be any suitable engine of similar horse power and gear ratio such as, for example, commercially available Honda OHV engines. Handle assembly 18 is hingedly coupled to the rear of body 12 and can be pivoted relative to body 12 between an operating position where handle assembly 18 extends upwardly and rearwardly from body 12 (as shown in FIG. 1 ) and a transport/storage position where the handle is folded generally over body 12 (as shown in FIG. 10 , which is discussed in detail below). Guard bar 20 is rigidly coupled to body 12 and extends generally upwardly and forwardly from the front of body 12 . Guard bar 20 includes a generally horizontally extending portion that is positioned in front of motor 16 and protects motor 16 from frontal impact. The horizontal portion of guard bar 20 also provides a convenient manual grasping location to facilitate lifting of aerator 10 onto or off of an elevated surface, typically during transportation or storage of aerator 10 .
[0031] Referring now to FIGS. 1 through 3 , body 12 is comprised of a right side member 22 , a left side member 24 , a front member 26 , and a rear member 28 . Preferably, body 12 has a unibody construction. As used herein, the term “unibody construction” shall denote a manner of constructing an apparatus wherein sheet metal body parts are combined with stress-bearing elements to form the body and chassis of the apparatus as a single piece, as opposed to attaching body parts to a frame. It is preferred for members 22 , 24 , 26 , 28 of body 12 to be formed from sheet metal that has been bent to provide enhanced structural rigidity. As perhaps best shown in FIG. 3 , a number of the edges of left and right side members 22 , 24 are bent in a generally U-shaped configuration, although a generally V-shaped or L-shaped configuration would also fBM — 1_BM — 1_unction to enhance the lateral strength of members 22 , 24 . In addition to providing enhanced strength, the bent edges of left and right side members 22 , 24 provide convenient locations for attaching a front cover 30 , a rear cover 32 , and a top cover 34 (shown in FIGS. 1 and 2 ) to body 12 . The sheet metal used to form members 22 , 24 , 26 , 28 of body 12 is preferably a 4 to 16 gauge steel sheet metal, more preferably a 6 to 14 gauge sheet metal, and most preferably an 8 to 12 gauge steel sheet metal. Body 12 also includes a lateral support member 36 (shown in FIG. 3 ) which extends between and is coupled to right and left side members 22 , 24 . Body 12 is preferably manufactured by unibody construction via permanently attaching members 22 , 24 , 26 , 28 , 36 to one another. As used herein, the term “permanently attaching” or “permanently attached” shall denote a manner of attaching two components to one another wherein the components cannot be detached without cutting or breaking the components apart. Preferably, members 22 , 24 , 26 , 28 , 36 are welded to one another. It can be seen from FIGS. 1 through 3 that substantially all of the mechanical components of aerator 10 are supported on/by members 22 , 24 , 26 , 28 , 36 of body 12 .
[0032] As opposed to conventional power aerators which typically employ a non-sheet metal structural frame with sheet metal components bolted thereto, the sheet metal components (i.e., members 22 , 24 , 26 , 28 ) of inventive aerator 10 are actually load-bearing structural members. As perhaps best shown in FIG. 3 , wheels 14 are directly coupled to right and left side members 22 , 24 . As used herein, the term “directly coupled” shall denote a manner of coupling two elements to one another wherein the elements directly contact one another, as opposed to having an intermediate structure disposed between the two elements. Right and left side members 22 , 24 each include a pair of reinforced openings that receive an axle of wheels 14 , thereby allowing wheels 14 to be rotatably coupled to right and left side members 22 , 24 . In this configuration, all of the weight of aerator 10 that is supported by wheels 14 is transferred to side members 22 , 24 . Thus, side members 22 , 24 bear a substantial portion of the weight of aerator 10 . Preferably, side members 22 , 24 bear a majority (i.e., more than 50 percent) of the weight of aerator 10 .
[0033] Referring now to FIGS. 1 through 3 and 6 , front member 26 of body 12 extends between and is permanently attached to right and left side members 22 , 24 . Motor 16 is directly coupled to and entirely supported on front member 26 . As perhaps best shown in FIG. 6 , the front edge of front member 26 is bent in a configuration which provides significant structural reinforcement to front member 26 . The bent configuration of the front edge of front member 26 presents a sloped surface to which guard bar 20 can be rigidly and permanently attached. The rear edge of front member 26 is also bent in a generally L-shaped configuration to provide significant structural reinforcement to front member 26 . As perhaps best shown in FIGS. 2 and 6 , rear member 28 extends between and is permanently attached to right and left side members 22 , 24 . An upper portion of rear member 28 is bent in a generally V-shaped configuration to thereby provide significant structural reinforcement to rear member 28 .
[0034] Referring to FIG. 3 , body 12 of aerator 10 houses and supports the internal mechanical components of aerator 10 . In particular, a crank shaft assembly 38 is directly coupled to, supported by, and extends between right and left side members 22 , 24 . Referring now to FIGS. 3 and 4 , crank shaft assembly 38 generally includes a crank shaft 40 which is rotatably coupled to body 12 via bearings 42 , end plates 44 , and bolts 46 , 48 . Crank shaft 40 includes a plurality of substantially upright axially spaced plates 50 which are aligned along the axis of rotation of crank shaft 40 . Crank shaft 40 also includes a plurality of eccentric bars 52 , each disposed between a respective pair of aligned plates 50 . Eccentric bars 52 are offset from the axis of rotation of crank shaft 40 . Adjacent eccentric bars 52 are staggered relative to one another around the axis of rotation of crank shaft 40 . Crank shaft assembly 38 also includes a drive shieve 54 which is rigidly coupled to crank shaft 40 via bolts 56 . As best shown in FIG. 3 , a motor shieve 58 of motor 16 powers a drive belt 60 which, in turn, rotates drive shieve 54 and crank shaft 40 .
[0035] Referring now to FIGS. 3 through 5 , a plurality of tines 62 are rotatably coupled to eccentric bars 52 of crank shaft 40 . As best shown in FIG. 5 , each tine 62 includes an end piece 64 , an elongated shaft portion 66 , and a connection portion 68 . Connection portion 68 couples each tine 62 to a respective eccentric bar 52 . Connection portion 68 includes a base 70 permanently fixed to shaft portion 66 and a cap 72 which can be removably coupled to base 70 via bolts 74 . Base 70 and cap 72 are configured to cooperatively define an opening through which eccentric bar 52 can extend. A bushing 76 is preferably disposed within the opening cooperatively defined by base 70 and cap 72 and extends around a narrow portion 78 of eccentric bar 52 . Narrow portion 78 of bar 52 and a wide portion 80 of bar 52 define a pair of shoulders 82 between which bushing 76 is disposed to thereby inhibit axial shifting of bushing 76 and tine 62 relative to eccentric bar 52 . Bushing 76 allows eccentric bar 52 to rotate freely within the opening cooperatively defined by base 70 and cap 72 of tine 62 . A grease fitting/zerk 84 is provided in cap 72 to lubricate bushing 76 and reduce wear caused by the rotation of crank shaft 40 . Thus, eccentric bars 52 and connection portion 68 cooperate to allow rotary motion of crank shaft 40 to be converted to reciprocal motion of tines 62 . End piece 64 of tine 62 is adapted to cut and remove plugs from turf when tine 62 is reciprocated into and out of the turf. End piece 64 defines an axially extending opening 86 which receives the cut plug from the turf. End piece 64 is preferably formed of a high-strength heat-treated metal that minimizes damage and wear to end piece 64 . End piece 64 also includes a male threaded portion 88 that cooperates with a female threaded end of shaft portion 66 and a lock nut 90 to thereby allow end piece 64 to be easily attached, removed, or replaced.
[0036] Referring now to FIGS. 3 and 4 , aerator 10 includes a swingable tine guide 92 that generally includes a pair of laterally spaced side supports 94 and a guide plate 96 . The lower ends of side supports 94 are rigidly coupled to opposite ends of guide plate 96 so that guide plate 96 extends between the lower ends of side supports 94 . The upper ends of side supports 94 are pivotally coupled to right and left side members 22 , 24 via bushings 98 . Thus, swingable tine guide 92 is hingedly coupled to and supported by right and left side members 22 , 24 . Guide plate 40 defines a plurality of elongated slots 100 . As perhaps best shown in FIG. 3 , each slot 100 is adapted to receive a respective tine 62 . During reciprocal motion of tines 62 , guide plate 96 maintains tines 62 in a substantially upright position.
[0037] Referring to FIGS. 1 and 2 , handle assembly 18 includes a generally U-shaped handle bar 102 projecting rearwardly and upwardly from body 12 of aerator 10 . The upper end of handle bar 102 presents a generally horizontal portion which can be manually grasped by the user to facilitate manipulation of aerator 10 . Handle assembly 18 also includes a cross bar 104 to which a clutch lever 106 and an aeration/transport lever 108 are pivotally coupled. Clutch lever 106 and aeration/transport lever 108 can be shifted between a down position, wherein levers 106 , 108 are positioned closer to body 12 , and an up position, wherein levers 106 , 108 are positioned further from body 12 . Levers 106 , 108 each include a generally U-shaped handle portion which receives the generally horizontal portion of handle bar 102 when levers 106 , 108 are in the up position. Handle assembly 18 also includes a swingable lock 110 pivotally coupled to the generally horizontal portion of handle bar 102 . Swingable lock 110 is operable to selectively lock either clutch lever 106 or aeration/transport lever 108 in the up position. Clutch lever 106 is coupled to a clutch cable 112 via a spring 114 . Clutch lever 106 is operable to pull on or increase the tension in clutch cable 112 when clutch lever 106 is shifted from the down position to the up position. Aeration/transport lever 108 is operable to pull on an aeration/transport cable 116 when lever 108 is shifted from the down position to the up position.
[0038] Referring to FIGS. 1 and 3 , when clutch lever 106 (shown in FIG. 1 ) is shifted from the down position to the up position, clutch cable 112 causes a clutch shieve 118 (shown in FIG. 3 ) to shift from a position to an engaged position. When clutch shieve 118 is in the engaged position, clutch shieve 118 provides sufficient tension in drive belt 60 so that the rotation of motor shieve 58 causes rotation of drive shieve 54 via drive belt 60 . When clutch shieve 118 is in the disengaged position, the tension in drive belt 60 is decreased to a level which allows motor shieve 58 to rotate without rotating drive shieve 54 . The shifting of clutch shieve 118 between the engaged and disengaged position is facilitated by a clutch plate 120 which is pivotally coupled to right side member 22 of body 12 . A spring 122 can be coupled between clutch plate 120 and body 12 to thereby bias clutch shieve 118 towards the disengaged position.
[0039] Referring to FIGS. 6 and 7 , when aeration/transport lever 108 is shifted from the down position (shown in FIG. 6 ) to the up position (shown in FIG. 7 ), aeration/transport cable 116 causes tine guide 92 to shift from an aeration position (shown in FIG. 6 ) to a transport position (shown in FIG. 7 ). When tine guide 92 is shifted from the aeration position (shown in FIG. 6 ) to the transport position (shown in FIG. 7 ), tines 62 are pulled from a substantially upright position to a less upright position by guide plate 96 of tine guide 92 . When tine guide 92 is in the aeration position, end pieces 64 of tines 62 can extend below wheels 14 so that plugs can be cut and removed from the ground 124 via the generally upright reciprocal movement of tines 62 . When tine guide 92 is in the transport position, end pieces 64 of tines 62 are swung into a position where they can not extend below wheels 14 , thereby allowing aerator 10 to be rolled across the ground 124 without interference from tines 62 .
[0040] Referring to FIGS. 1, 2 , 6 , and 7 , it can be seen that front, rear, and top covers 30 , 32 , 34 extend between and are releasably coupled to right and left side members 22 , 24 . Covers 30 , 32 , 34 are preferably formed from sheet metal of substantially lighter weight than the sheet metal used to form members 22 , 24 , 26 , 28 of body 12 . Preferably, covers 30 , 32 , 34 are formed from 14 to 24 gauge sheet metal, most preferably 16 to 22 gauge steel sheet metal. Top cover 34 is hingedly coupled to front cover 30 via releasable hinge 126 . Top cover 34 can be shifted between a closed position (shown in FIGS. 1, 2 , and 6 ) and an open position (shown in FIG. 7 ) by simply pivoting top cover 34 relative to front cover 30 at hinge 126 . Latches 128 are provided to hold top cover 34 in the closed position. However, latches 128 can be easily released to allow top cover 34 to be shifted into the open position. When top cover 34 is in the closed position, top cover 34 covers a substantial portion of crank shaft assembly 38 . When top cover 34 is in the open position, crank shaft assembly 38 is substantially uncovered and can be accessed from above to thereby allow for the performance of routine maintenance, such as lubrication of tines 62 via grease fiftings/zerks 84 .
[0041] Referring to FIGS. 1 and 8 through 10 , handle assembly 18 of aerator 10 can be shifted between an operating position (shown in FIG. 1 ) and a transport/storage position (shown in FIG. 10 ). Handle assembly 18 includes a handle base 130 for hingedly coupling handle bar 102 to body 12 . Handle base 130 includes a channel 132 , a collar 134 , and a hinge 136 . Referring now to FIG. 8 , when handle assembly 18 is in the operating position, handle bar 102 is locked in channel 132 by extending collar 134 around handle bar 102 and channel 132 . Referring now to FIG. 9 , to shift handle assembly 18 out of the operating position, collar 134 is slid upwardly off of channel 132 and onto handle bar 102 . Handle bar 102 can then be pivoted upwardly and forwardly via hinge 136 . Channel 132 defines an opening 138 which allows the distal end of handle 102 to extend therethrough when handle assembly 18 is shifted out of the operating position.
[0042] Referring now to FIG. 10 , when handle assembly 18 of aerator 10 is in the storage/transport position, aerator 10 has a very compact configuration. Preferably, the compact configuration of aerator 10 allows aerator 10 to be transported in the trunk of a standard mid-size or full size car. When handle assembly 18 is in the storage/transport position (shown in FIG. 10 ), it is preferred for the maximum height (h) of aerator 10 to be less than about 36 inches, more preferably less than about 30 inches, and most preferably less than 24 inches. When handle assembly 18 is in the storage/transport position (shown in FIG. 10 ), it is preferred for the maximum length (l) of aerator 10 to be less than about 48 inches, more preferably less than about 42 inches, and most preferably less than 39 inches. When handle assembly 18 is in the storage/transport position, it is preferred for the maximum width (w) of aerator 10 to be less than about 36 inches, more preferably less than about 30 inches, and most preferably less than 24 inches. The unibody construction of turf aerator 10 allows aerator 10 to have a significantly more compact configuration than conventional aerators using a frame-type construction. A significant advantage of the compact configuration of turf aerator 10 is the reduced wheel base (i.e., distance between the axes of rotation of the front and rear wheels) of inventive turf aerator 10 . It is preferred for the wheel base of turf aerator 10 to be less than about 36 inches, more preferably less than about 24 inches, and most preferably less than 20 inches.
[0043] Referring to FIG. 11 , it is preferred for aerator 10 to create a relatively dense plug pattern in the turf. Preferably, the maximum distance (A) between plugs aligned along the direction of travel of aerator 10 is less than about 12 inches, more preferably less than about 10 inches, and most preferably less than 8 inches. Preferably, the maximum lateral distance (B) between plugs perpendicular to the direction of travel of aerator 10 is less than about 8 inches, more preferably less than about 6 inches, and most preferably less than 4 inches. Preferably, the density of the plugs in the turf is at least 6 plugs per square foot, more preferably at least 8 plugs per square foot, and most preferably between 10 and 15 plugs per square foot.
[0044] The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Obvious modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0045] The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims. | A walk-behind power turf aerator having a rigid unibody construction and being shiftable into a highly compact configuration to facilitate transportation and storage thereof. The power turf aerator utilizes the reciprocal movement of a plurality of generally upright tines to create a relatively dense plug pattern in the turf. | 0 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to the field of textile structures and more specifically those which are adapted to the manufacture of composite materials. The invention relates more specifically to a textile structure which is capable of deformation and can thus be shaped in an advantageous manner at the time of a molding process for obtaining a final composite material.
(2) State of the Prior Art
It is known that composite materials are constituted by a textile reinforcement and by a resin matrix, this unit being made and shaped at the time of a molding process. It is not necessary to go over in detail the various techniques which can be used in practice for the manufacture of such composite materials because they are now well-known to one skilled in the art.
The manufacturers of composite materials are well aware that the shape of the final pieces to be obtained often raises technical problems which are difficult to solve. In fact, the textile reinforcement consequently has to be shaped either in advance or at the time of positioning in the mold. When it is a matter of manufacturing pieces of developable shape, the textile reinforcement elements can be prepared without major difficulty, except for allowing a good injection of resin into the mold before the polymerization which leads to the final composite material. The technical difficulties are therefore dependent upon the nature of the composite material itself and not upon its shape. In complete contrast, when it is necessary to manufacture non-developable pieces, use has to be made of separate elements of textile reinforcement, which it is therefore appropriate cut, position and to superpose so as to provide a reinforcement corresponding to the final shape desired. Any cut-out in a textile reinforcement introduces a discontinuity in the yarns and fibers thereof, which leads to regions of weakness in the piece made of the composite material. This is completely unacceptable for certain applications, for example in aeronautics. Moreover, the cutting-out operations are lengthy and costly
The Patent FR-1 068 334 relates to a process for obtaining a fibrous material intended for the reinforcement of plastic materials. The aim of this patent is to make a network of a number of fabrics, imbricated with one another by a weaving operation.
The imbrication between the fabrics is obtained by warp yarns which pass periodically from one fabric to another.
The fibrous material obtained by this process makes it possible to limit the risks of cleavage which can exist when two adjacent layers of fabric are not connected to one another by a fibrous link.
However, precisely because of the imbrication between the fabrics, the fibrous material obtained is not deformable and therefore cannot be shaped in an advantageous manner.
Efforts are therefore currently being made to perfect textile structures which can be deformed so as to significantly reduce the implementation time, making it possible to manufacture a piece made of a composite material while avoiding cut-outs, the textile structure then being capable of being preformed in order to be adapted to the shape of the piece to be obtained.
It is this technical problem which provides the basis of the present invention. The invention affords a simple solution and produces very advantageous results in relation to the proposals of the prior art.
It has already been proposed to use, as textile reinforcements, fabrics of a somewhat loose texture, in such a manner that they give at the time of shaping. However, to the knowledge of the applicant, this solution has never led to satisfactory practical results because, if a structure is deformable, it does not, for all that, satisfy the other criteria which are necessary in order that it constitute a good textile reinforcement for composite materials.
By way of a simple example, the mats which are constituted by yarns and fibers distributed in a random manner are easily deformable but have very poor mechanical properties. Similarly, fabrics of the satin type are not suitable either. Despite a certain capacity for deformation, such a fabric forms creases if it is attempted to position it on a complex surface which has particularities. Thus, the presence of creases considerably weakens the mechanical properties of the piece made of the composite material.
It has already been proposed to use fabrics comprising yarns in one direction and, in the other direction, undulating yarns, this undulation being oriented in the plane of the fabric. Such a textile structure has the capacity of being deformed, at least in a direction parallel to the axis of the undulations. However, after deformation, the orientation of the fibers is fundamentally modified. Therefore does not allow the properties of composite materials which have been made and contain such structures as reinforcements to be anticipated. It is also known that fabrics exist which comprise undulating yarns, the undulations of which are perpendicular to the plane of the fabric. These fabrics are deformable, at least in the direction of the undulations, but they too do not provide an optimum orientation of the fibers when they are shaped in order to serve as a reinforcement in composite materials. As in the case of the undulations in the plane, but to a lesser degree, such fabrics are not suitable for high-performance composite materials.
It has further been proposed to use, as textile structures, fabrics obtained by oblique interlacings of yarns, so as to make somewhat loose structures, similar to lattices, of which the intervals separating the yarns have a shape similar to lozenges or parallelograms, having a certain capacity for deformation. However, these structures are very loose, and it is not possible to obtain fiber coverage rates in the textile reinforcement which are adequate in order to obtain good properties in the composite material. By fiber coverage rate is understood, in general, the ratio of the volume occupied by the fibers in relation to the volume of the textile surface.
Textile structures are also known which are obtained by superposing a certain number of fabrics or layers in which the yarns and fibers have a certain capacity for sliding in relation to one another. Thus there exist structures in which the fibers can, at the time of deformation, orient themselves in a direction which is generally parallel to that of the plane of the structure as a whole. This structure of a multi-directional type is also not suitable as a reinforcement for composite materials, because when it is used to make pieces which have sharp angles, the sliding of the fabrics leads to a perforation of the fabric which is, of course, unacceptable.
Lastly, it has already been proposed to use superposed fabrics or layers, generally two in number, or at most three, which are kept in position by very loose tying so as to allow a sliding of the yarns and fibers parallel to the plane of the structure as a whole, so that, at the time of shaping on a curved surface, the yarns essentially follow the contour of the shape. Although the general concept of this solution appears good, it has not given rise, thus far, to a satisfactory practical embodiment, above all because of poor performances obtained upon use as textile reinforcement. Thus, the deformability can be obtained in a satisfactory manner, but the performances of the structure in the dry state, and above all after shaping and impregnation, are not adequate for the requirements of reinforcements for high-performance composite materials.
In order to clarify these ideas, if an arbitrary scale is adopted in order to evaluate performance after impregnation of the structure, and by attributing the value 10 to a mat, as far as mechanical performances are concerned, a value close to 12 can be estimated for the results provided by a structure with fabric comprising undulations in the plane, a value of around 14-15 for fabrics with undulation perpendicular to their plane and likewise for lattice-type fabrics. As far as fabrics are concerned which allow a parallel sliding of the fibers, it is not currently possible to reconcile at the same time a good aptitude for deformation and adequate mechanical performances. Although, by adopting the above-mentioned arbitrary scale, such fabrics make it possible to achieve values of 18-20, they are then no longer sufficiently deformable. Conversely, when, with a sufficiently loose tying, an adequate deformability is obtained, the mechanical performances do not exceed a value of 14-15, as in the case of a lattice-type fabric.
SUMMARY OF THE INVENTION
The present invention starts from the abovementioned prior art in order to create a textile structure which is capable of, at the same time, having a high aptitude for deformation and providing good mechanical performance when used as a textile reinforcement for composite materials. At the same time, the textile structure can be made and obtained at a low cost.
Another object of the invention is a textile structure which can be made while maintaining an essentially constant and uniform fiber content in the textile reinforcement once shaped and in the final piece made of the composite material, inasmuch as the fiber content can be provided for in advance by varying it as required in given regions of the structure, which it is known will correspond to given parts of the final piece to be obtained. In particular, it is possible to provide that the fiber content is relatively higher in those parts of the fabric corresponding to those parts of the piece involving relatively greater deformations in such a manner that the fiber content is essentially homogeneous and constant in the final piece made of a composite material.
The subject of the invention is a textile structure comprising a superposition of unidirectional layers of yarns, the directions of which are crossed in relation to one another and which are tied by tying yarns, the structure being characterized in that the number of superposed layers is at least equal to three, in that the tying rate lies between 2 and 15% approximately and in that each tying yarn ties at least one set of yarns of superposed layers, defined by at least a first yarn of a first layer and at least a second yarn of a second layer, the second yarn being offset in relation to the first, the connection of the layers thus being sufficiently loose in order to keep the structure in position and allow it to deform.
According to the invention, the expression "superposition of layers" means that the layers are placed on top of one another, without shrinking of the warp.
According to the invention, the expression "tying rate" designates the ratio of the mass of tying yarns to the mass of yarns of the structure.
According to the invention, the expression "the tying yarn ties a set of yarns" means that the tying yarn surrounds this set without passing through the latter.
According to a particular embodiment of the invention, the yarns in the same direction are distributed in essentially superposed rows, each tying yarn tying at least certain of the yarns of one row at the same time as at least certain yarns of at least one adjacent row.
According to the invention, the phrase according to which "the tying yarn ties two adjacent rows of yarns" means that the tying yarn partially surrounds these two rows, without passing between them according to an orientation which is substantially orthogonal to the layers of yarns.
According to a preferred embodiment of the invention, the layers are parallel with one another.
According to another preferred embodiment of the invention, the direction of the yarns of one layer forms an angle of 90° approximately with that of the adjacent layers.
For the requirements of the invention, technical yarns and fibers are used which are suitable for the textile reinforcements used in the manufacture of composite materials. The structure can thus comprise layers formed of metal, glass, carbon, silicon carbide, boron, aramid yarns and fibers and other similar technical fibers. The yarns constituting the layers can be of a thermoplastic nature or associated with a thermoplastic resin, in particular by coating, intimate mixing or preimpregnation. Inside one and the same textile structure, it is possible to find layers of different natures as well as one or more layers of a hybrid nature. Optimum results have been achieved with glass fibers.
It has been indicated above that the number of superposed unidirectional layers was at least equal to three. The requirements of the invention are satisfied with structures consisting of relatively thick fabrics, in order to impart good mechanical strength to the whole, while being deformable.
The unit weight of the textile structure in the dry state, that is to say without preimpregnation resin, is comprised, for example, between 300 and 1000 g/m 2 approximately and preferably between 400 and 600 g/m 2 approximately, the lowest surface unit weights being reserved for aeronautical uses, whereas the highest values of the range, which correspond to heavier fabrics, can be used for less costly applications.
One of the essential characteristics of the invention is the presence of tying yarns in a number and in an orientation which are well defined. Thus, for example, known structures which are known as "tridimensional", such as those described in the Patent Application EP-0 056 351, comprise unidirectional layers of yarns, the directions of which are crossed in relation to one another, the yarns of the layers in the same direction being distributed in substantially superposed rows. The layers are tied by tying yarns, the orientation of which is substantially perpendicular to the layers and which are arranged between two adjacent rows of yarn of the superposed layers. In contrast to these structures, in which the tying rate is high, and situated, for example, between 15 and 20%, the value of the tying rate in the structure of the invention is situated between 2 and 15% approximately, so as to constitute a loose structure which is capable of deformation. Apart from this condition with regard to the tying rate, it is also necessary that the tying yarns have certain orientations, so as not to enclose successively all the yarns of the rows of superposed layers, passing from one row to the adjacent row.
In the structure according to the invention, the tying yarns can tie all the yarns of a row but, at the same time, they also tie at least certain yarns of at least one adjacent row. Examples of this will be given below. The orientation of the tying yarns in relation to the superposed layers can be substantially orthogonal to the latter or, on the other hand, the tying yarns can extend obliquely in order to tie successively a certain number of yarns in adjacent rows. Illustrations of this embodiment will also be indicated below.
Use is in general made of tying yarns of finer diameter than the yarns constituting the layers. In fact, the role of the tying yarns is solely to keep the structure in position, constituting a sort of frame. In this regard, the tying yarns can be made in any manner, of natural or artificial fibers. They can be yarns which remain permanently in the final composite material or, on the other hand, they can be heat-meltable yarns which disappear at the time of manufacture of the piece made of composite material. The tying yarns can also be of thermoplastic nature or associated with a thermoplastic resin, in particular by coating, intimate mixing or preimpregnation. In general, however, fine yarns are preferred, which make it possible to satisfy better the requirements of weight and of mechanical characteristics of the final structure.
The advantages provided by the invention are illustrated by a certain number of tests which show that the structures have at the same time a high aptitude for deformation, while imparting good mechanical properties to the textile reinforcement of the composite material, at a low cost, with a distribution of fibers within the piece such that neither perforations at in sharp angles, if the piece to be manufactured has these, nor creases or undulations have been observed, and this distribution of fibers being substantially homogeneous and constant.
The textile structure according to the invention can be used after having been impregnated with resin, in particular thermosetting resin.
From another angle, the subject of the invention is also the final composite pieces comprising at least one textile structure of the type described above.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and other object advantages and characteristics of the latter will appear more clearly from reading the description which follows of embodiments of the invention, which are given non-limitatively, and to which drawings are attached, in which:
FIG. 1 is a schematic view in cross-section according to the warp yarns of a first example of a textile structure according to the invention,
FIG. 2 is a schematic view in cross-section according to the warp yarns of a second example of a textile structure according to the invention,
FIG. 3 is a schematic view in cross-section according to the warp yarns of a third example of a textile structure according to the invention,
FIG. 4 is a schematic view in cross-section according to the warp yarns of a fourth example of a textile structure according to the invention,
FIG. 5 is a schematic view in cross-section according to the warp yarns of a fifth example of a textile structure according to the invention,
FIG. 6 is a schematic view in cross-section according to the warp yarns of a sixth example of a textile structure according to the invention,
FIG. 7 is a schematic view in cross-section according to the warp yarns of a seventh example of a textile structure according to the invention,
FIG. 8 illustrates an example of a known structure known as "tridirectional",
FIG. 9 is a view from above of a fabric according to the invention draped over a first piece of a particular shape,
FIG. 10 is a developed view of the fabric in FIG. 9, and
FIG. 11 is a view from above of a fabric according to the invention draped over a second piece of particular shape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The elements common to the different figures are designated by the same reference characters.
FIG. 1 shows a textile structure comprising four layers 1 to 4 of weft yarns 10 and three layers 5 to 7 of warp yarns 30 arranged alternately, the yarns all having the same direction within one and the same layer.
It can be noted that the yarns have substantially the same direction from one layer to another of the same nature (warp or weft). The layers are arranged in such a manner that the direction of a layer is crossed in relation to that of the adjacent layers. In this case, the directions of two adjacent layers are substantially at 90° to one another.
The layers are furthermore arranged in such a manner that the yarns in the same direction are distributed in rows 8 substantially perpendicular to the plane of the layers.
The stacked layers of the textile structure are tied by tying yarns 20. The method of tying is of the 7/1 twill type. The tying yarns are represented in a different manner in order to distinguish them.
FIG. 2 shows a textile structure comprising a stack of layers of yarns which is substantially identical to that of the textile structure represented in FIG. 1.
The tying yarns 20 which connect the layers of the stack are in this case arranged according to a method of the 8/2 twill type.
FIG. 3 represents a textile structure composed of a stack of layers of yarns which is substantially identical to that of the textile structure in FIG. 1.
The tying yarns 20 are in this case arranged according to a method of the asymmetrical composed twill type: 7/3 on the upper layer 1 of weft yarns and 9/1 on the lower layer 4 of weft yarns.
FIG. 4 shows a textile structure comprising three layers 11 to 13 of weft yarns 10 and two layers 14 and 15 of warp yarns 30 which are arranged alternately and have the same characteristics as those described with reference to FIG. 1.
The layers of the stack are connected by tying yarns 20 arranged according to a method of the symmetrical composed twill type: 8/4 and 5/1.
With reference to FIG. 5, the textile structure is composed of a stack of layers of yarns which is substantially identical to that of the textile structure in FIG. 1.
The tying yarns 20 are in this case oriented so as to have a great angle with the layers of the stack. This angle is in this case close to 90°. The method of tying represented is of the 5/1 twill type.
It can be noted that the tying yarns can have an angle of close to 90° with the layers of the stack inasmuch as they do not tie successively all the yarns of the rows perpendicular to the plane of the layers. Thus, a textile structure of which the tying yarns are arranged according to a method of the 3/2 twill type corresponds to the invention.
The textile structure represented in FIG. 6 comprises a stack of layers of weft yarns 10 and of warp yarns 30 which is substantially identical to that in FIG. 1.
The tying yarns are oriented so as to have a relatively small angle with the layers of the stack. The method of tying represented is of the 10/1 twill type.
It can be noted that it is not necessary that the arrangement of the layers leads to a distribution of the yarns in the same direction according to substantially superposed rows, perpendicular to the plane of the layers. This in fact has no effect on the functions which are fulfilled by the textile structure according to the invention or on its mechanical properties. In any case, when a structure is draped over a piece, the layers of yarns which constitute it slide in relation to one another.
Thus, the invention is not limited to a distribution of the yarns in the same direction according to substantially superposed rows.
For example, FIG. 7 shows a textile structure according to the invention comprising, like that illustrated in FIG. 1, four layers 16 to 19 of weft yarns 10 and three layers 21 to 23 of warp yarns 30, arranged alternately, the yarns all having the same direction within one and the same layer.
It can be noted that the layers are arranged in such a manner that the direction of one layer is crossed in relation to that of the adjacent layers. In this example, the directions of two adjacent layers are essentially at 90° from one another.
The layers are arranged in such a manner that the yarns of the layers of the same nature (warp or weft) are not superposed but offset in relation to one another.
The stacked layers of the textile structure are tied by tying yarns 20. The method of tying is of the 4/1 twill type. It can be noted that each tying yarn ties, between two passages on the lower layer 19, for example, a set of yarns of layers which are parallel to one another. One of these sets is defined by a first yarn of a first layer, for example the yarn 24 of the layer 16, a second yarn of a second layer, for example the yarn 25 of the layer 19, and a third yarn of a third layer, for example the yarn 26 of the layer 19. The second and third yarns 25, 26 are offset in relation to the first yarn 24.
It is necessary, on the other hand, that the textile structure comprises at least three superposed layers of yarns. It is observed in fact that a textile structure composed of only two layers deforms much less well.
In these different examples of textile structure according to the invention, the tying rate is comprised between 2 and 15% approximately. It is a necessary condition in order that the fabric be deformable while being adequately held together by the tying yarns.
The invention and the advantages which it affords in relation to the known textile structures will be demonstrated further by comparisons carried out with regard to the mechanical performances and the drapability of textile structures obtained according to the known techniques and according to the invention.
As far as the mechanical performances are concerned, the comparison will be carried out between three textile structures: the first, designated henceforward as structure (1), corresponds to the invention; the second, designated henceforward as structure (2), is a fabric of the twill type, and the third, designated henceforward as structure (3), is a fabric of the tridirectional type.
Textile structure (1) was made so as to have the following characteristics:
Weave: textile structure made according to the fourth example for making the textile structure according to the invention, described with reference to FIG. 4.
Nature of yarn:
warp: silionne 300 tex
tying yarn: silionne 34 tex
weft: roving 160 tex.
Surface mass: 600 g/m 2 approximately.
Contexture:
warp: 9.6 yarns/cm
tying yarn: 4.8 yarns/cm
weft: 18.5 shots/cm.
Mass distribution:
warp: 48%
tying yarn: 3%
weft: 49%.
Textile structure (2) was woven so as to have the following characteristics:
Weave: 2 ties 2 twill.
Nature of yarn:
warp: 3 parallel yarns of silionne 68 tex
weft: 3 parallel yarns of silionne 68 tex.
Surface mass: 295 g/m 2 approximately.
Contexture:
warp: 7 yarns/cm approximately
weft: 7 shots/cm approximately.
Mass distribution:
warp: 50%
weft: 50%.
Such a structure does not strictly comprise tying yarns. It is the weft and warp yarns which play the role of tying yarns. In order to be able to compare this textile structure to textile structure (1), it can be estimated that the "equivalent tying rate" is approximately 50%.
Lastly, textile structure (3) has the following characteristics:
Weave: textile structure made according to FIG. 8, in which the weft yarns have the reference 40 and the warp yarns the reference 50.
The warp yarns 50 are undulating perpendicularly to the plane of the weft yarns 40.
Nature of yarn:
warp: silionne 300 tex
weft: silionne 300 tex.
Surface mass: 1045 g/m 2 approximately.
Contexture:
warp: 16.2 yarns/cm
weft: 16.2 shots/cm.
Mass distribution:
warp: 50%
weft: 50%.
As for textile structure (2), textile structure (3) does not comprise tying yarns. It is the warp yarns which carry out the tying. It is for this reason that in this case too an "equivalent tying rate" which is 50% can be defined.
The tests were carried out according to IGC standards. These standards correspond globally to ISO standards, the conditions fixed in the ISO standards being within those fixed in the IGC standards. The correspondence which can be established with these reserves will be indicated in each case.
All these tests were carried out, according to the standards below, on flat test-pieces, of a thickness of 3 mm approximately, of textile structures (1), (2) and (3), comprising a fiber volume rate, that is to say the ratio of volume of fibers of the textile structure to volume of composite, of 52% and after use of the epoxy resin LY 564-1/HY 2954 of Ciba Geigy.
The above epoxy resin has the following conditions of use:
polymerization: 1 hour at 110° C. in the mold,
post-curing out of mold: 4 hours at 145° C.
In order to obtain this fiber volume rate of 52% for the textile structures (1), (2) and (3), it was necessary to make the following stacks:
for textile structure (1): stack of 7 plies.
for textile structure (2): stack of 14 plies.
for textile structure (3): stack of 4 plies.
Lastly, all these tests were carried out in the warp direction.
They made it possible to determine:
shear stress at breaking, according to Standard IGC 04 26 235 (ISO 4585),
the modulus in bending and the bending stress at breaking, according to Standard IGC 04 26 245 (ISO 178),
the modulus in tension and the tensile stress at breaking according to Standard IGC 04 26 250 (ISO 3268, 527, 9163).
The results obtained are as follows:
______________________________________TextilestructureTests (1) (2) (3)______________________________________SHEARINGStress 53 MPa 51 MPa 39 MPaBENDINGModulus 22,400 MPa 21,300 MPa 14,800 MPaStress 690 MPa 640 MPa 310 MPaTENSIONModulus 20,500 MPa 17,500 MPa 16,500 MPaStress 520 MPa 420 MPa 400 MPa______________________________________
These results reveal that textile structure (1) according to the invention has mechanical properties which are very considerably superior to those of the tridirectional textile structure (3) and substantially superior to those of textile structure (2), above all as far as tension is concerned.
These tests with regard to mechanical properties were supplemented by tests with regard to drapability, so as to reveal that the textile structure according to the invention, in contrast to known textile structures, has at the same time good mechanical performances and a high aptitude for deformation.
The notion of drapability or even conformability is not defined in a precise manner in the area of composite materials. It will be understood here as the capacity of a fabric to follow a shape which has curvature in more than two directions, on the understanding that a force may possibly be exerted upon the positioning of the fabric.
This test is, conventionally, carried out on a hemispherical shape of a diameter of 100 mm. The measure of the drapability is given by the height of the spherical cap which the fabric can follow without forming creases or undulating.
Tests of this type already carried out have shown that all known fabrics have a drapability which is lower than the height of the spherical half-cap. They have furthermore shown that the drapability capacity of fabrics is, in increasing order, as follows: fabric of taffeta weave, fabric of twill weave, fabric of satin weave, fabric of tridirectional type.
More specifically, the results of such tests have, for example, been reported in the article by M. P. LISSAC, published in the review COMPOSITES, No. 3, May-June 1985. These tests were carried out on fabrics of taffeta weave and of satin weave.
The best result was obtained for a fabric of a satin weave of 8 and of a surface mass equal to 500 g/m 2 . It was possible to confirm that for this fabric the height of the spherical cap which it is possible to drape is comprised between 40 and 50 mm. It is approximately 40 mm for a fabric of the same weave and of a surface mass equal to 600 g/m 2 like textile structure (1).
This test was carried out for a textile structure according to the invention and identical to textile structure (1) described above.
It was observed that textile structure (1) has a drapability which exceeds the limits of this test since it easily follows the hemisphere over its entire height.
It therefore appears that the textile structure according to the invention has a drapability which is superior to that of a fabric of a satin weave of 8, for an identical surface mass.
It therefore seemed of interest to evaluate the limit from which textile structure (1) forms creases. To do this, the hemisphere of a diameter of 100 mm was prolonged by a cylinder of the same diameter. It was observed that the first creases appear at a cylinder height greater than 50 mm.
FIG. 9 represents a view from above of a textile structure, which corresponds to textile structure (1), draped over a shape constituted by a cylinder C of a diameter of 100 mm and a height of 50 mm, surmounted by a hemisphere S of a diameter of 100 mm. The curved lines represent one warp line out of ten and do not have irregularities revealing creases or undulations.
FIG. 10 represents a developed view of the textile structure in FIG. 9. The continuous lines represent 1 warp yarn out of 10, the discontinuous lines represent 1 weft yarn out of 10. This figure makes it possible to represent better the whole of this piece and gives the orientations of the fibers and the relative local variations of their spacing.
This figure reveals that the fiber content is essentially constant over the entire spherical cap as well as in the upper part of the cylinder. The fiber content is no longer homogeneous in the rest of the cylinder.
It must be noted that the homogeneity of the fiber content must be appreciated by comparing that which can be obtained by the textile structure according to the invention and by known textile structures. The test carried out on the shape composed of a hemisphere prolonged by a cylinder makes it possible to demonstrate the limits of the textile structure according to the invention but above all to shows that these limits are situated well beyond those of known textile structures, since the latter form creases and therefore a fortiori do not have a constant fiber content over the spherical cap.
An example of the use of the textile structure according to the invention is illustrated by FIG. 11. The lines represent one warp or weft yarn out of ten. It can be observed that on this piece, of complex shape, no crease appears and the fiber content is essentially constant over the entire piece. The textile structure used is textile structure (1).
In contrast, it is not possible to drape over this piece a fabric such as textile structures (2) or (3), defined above, without creases forming.
It appears that the homogeneity of the fiber content within a fabric draped over a given piece is connected to the depth of this piece. Thus, for example, the fiber content is substantially constant for the piece illustrated in FIG. 11, which is relatively shallow, whereas it is no longer homogeneous in the piece in FIG. 9, which is relatively deep.
The textile structure which has just been described can also be used after having been impregnated with, in particular thermosetting resin.
It can be noted that it is, moreover suitable for making composite articles, in particular on a resin base with textile reinforcement. These articles can be obtained, for example, by means of injection-molding processes. The most commonly used resins in this type of application are in particular epoxy, phenolic, acrylic, bis-maleimide, polyester and other resins. | The invention relates to a textile structure comprising a superposition of unidirectional layers of yarns, the directions of which are crossed in relation to one another and which are tied by tying yarns. According to the invention, the number of superposed layers is at least equal to. The tying rate lies between 2 and 15%, approximately, and each tying yarn (20) ties at least one set of yarns of superposed layers, this set being defined by at least a first yarn (24) of a first layer (16) and at least a second yarn (25) of a second layer (19). The second yarn (25) is offset in relation to the first (24), and the connection of the layers is thus sufficiently loose in order to keep the structure in position and allow it to deform. | 3 |
REFERENCE TO RELATED U.S. APPLICATIONS
[0001] This application claims the benefit of Provisional Patent Application Ser. No. 60/562,404 filed Apr. 15, 2004.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a sports device, and, more particularly, to a ball pitching target which presents to the user the impact speed of the baseball or softball when the ball strikes the target. The target device may be incorporated into a modified ball catching mitt and the catcher of a baseball or softball may immediately read the impact speed when the ball is caught, or the target device may be a unit which may be attached to vertical or near-vertical structures including backstops and baseball rebound nets and users including coaches may immediately read the impact speed of the ball.
[0003] Information as to the speed of a thrown baseball or softball, and of the speed of balls and sports implements in sports other than baseball, is of great interest to both professional and amateur players and coaches, and to spectators. Radar devices are commonly used to measure the speed of pitched baseballs, and the speeds are commonly used in the evaluation and comparison of pitchers, and in written and broadcast reports and commentaries. A radar device designed to measure the speed of a baseball, attached to a catching mitt, is disclosed in U.S. Pat. No. 5,864,061. An acoustic device designed to measure the impact speed of a baseball on a target surface is disclosed in U.S. Pat. No. 5,447,315. A timing device incorporated into a baseball, designed to indirectly measure the speed of the thrown baseball or other projectile over a fixed distance, is disclosed in U.S. Pat. No. 5,806,848 and U.S. Pat. No. 5,946,643. Other devices are disclosed for the measurement of the speed of baseballs and other sports objects by use of capacitive sensor technology (U.S. Pat. No. 6,033,370); measurement of the force of boxing and other blows (U.S. Patent Application No. 2003/0217582); measurement and broadcast of the motion of sporting equipment (U.S. Patent Application No. 2003/0207718 A1) and measurement of the speed of impact of a baseball bat, tennis racquet or other sports implement with a ball or other sports object (U.S. Pat. No. 6,173,610; U.S. Pat. No. 6,565,449; U.S. Pat. No. 6,134,965).
[0004] Radar devices are inherently complex, emit radiation and utilize significant energy, characteristics that are disadvantageous or undesirable to many users.
[0005] There is thus a need for a compact and inexpensive ball speed measuring device that does not utilize radar technology.
[0006] Advances in the design and production of solid state force sensors, including accelerometers and compression sensors, provide capabilities for the measurement of impact forces by the use of smaller and less expensive devices. For example, MEMS (micro-electro-mechanical system) accelerometers incorporate mechanical and electronic components on a single silicon chip (http://weaveserve.egr.duke.edu:8080/weave/Modules/Module1/3dof-tut/node12.html).
[0007] Known prior art devices do not avoid these disadvantages or do not take advantage of the capabilities of solid state force sensors or other advances in impact measurement modes.
BRIEF SUMMARY OF THE INVENTION
[0008] In response to the needs described I have invented a sports device in the form of a ball pitching target having one or more compression sensors which provide one or more impact force signals to a control unit, which in turn provides the ball impact speed to a digital display unit.
[0009] In the preferred embodiment of the invention, the target device is incorporated into a modified ball catching mitt. The modified ball catching mitt has one or more electronic compression sensors in the ball catching area of the mitt. The electronic signal or signals produced by the sensor or sensors as a result of the impact of a baseball or softball are transmitted by one or more signal conductors to a solid state unit, which converts the electronic sensor signal or signals into a digital signal corresponding to the ball's impact speed. The digital signal corresponding to the ball's impact speed is transmitted by a signal conductor to a digital readout display, which the catcher of the ball observes. Optionally, the digital signal corresponding to the ball's impact speed may also be provided to a connector for conduction to an external digital readout display. The device includes an electrical power source, preferably a battery power supply, an on-off switch and optional calibration means by which the accurate conversion of the electronic signals produced by the sensor or sensors can be adjusted to produce the correct ball impact speed.
[0010] In a second embodiment of the invention, the target device is a unit which may be attached to vertical or near-vertical surfaces, including baseball rebound nets, backstops and walls.
[0011] It is therefore a general object of this invention to provide a sports device in the form of a set of components which provide an accurate digital display of the impact speed of a baseball or softball, immediately after the baseball or softball is caught by the user or strikes the target device.
[0012] A further object of the invention is to provide a sports device in the form of a modified ball catching mitt, which displays a digital readout of the impact speed of a baseball or softball immediately after the ball is caught, and which does not interfere with the normal catching of a baseball or softball, in comparison to an unmodified ball catching mitt.
[0013] A further object of the invention is provide a sports device in the form of a modified ball catching mitt, which displays a digital readout of the impact speed of a baseball or softball immediately after the ball is caught, and which can be calibrated to provide an accurate digital display of the impact speed of a baseball or softball.
[0014] A further object of the invention is to provide a sports device in the form of a target unit which may be attached to a vertical or near-vertical surface, which displays a digital readout of the impact speed of a baseball or softball immediately after the ball strikes the target unit.
[0015] A further object of the invention is provide a sports device in the form of a target unit which may be attached to a vertical or near-vertical surface, which displays a digital readout of the impact speed of a baseball or softball immediately after the ball is caught, and which can be calibrated to provide an accurate digital display of the impact speed of a baseball or softball.
[0016] Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view showing a modified ball catching mitt, including a control unit and digital readout display unit;
[0018] FIG. 2 is a partial cutaway view showing a modified ball catching mitt, including a compression sensor and a solid state control unit which converts the sensor signal into a digital signal for transmission to the digital readout display unit, and signal conductors.
[0019] FIG. 3 is a diagram showing elements of the solid state control unit, the compression sensor, the source of electrical power, signal and electrical conductors, and switches and controls.
[0020] FIG. 4 is a perspective view of a baseball rebound net having an attached ball pitching target device.
[0021] FIG. 5 is a partial cutaway view showing the back of the ball pitching target device, including a compression sensor and a solid state control unit which converts the sensor signal into a digital signal for transmission to the digital readout display unit, the source of electrical power, signal and electrical conductors, and switches and controls.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Turning more particularly to the drawings, FIG. 1 shows the mitt 1 modified by attachment of a solid state control unit 2 and a digital readout display unit 3 . FIG. 1 further shows a baseball or softball 4 approaching the mitt 1 to be caught by the user 5 .
[0023] FIG. 2 shows the mitt 1 modified by attachment of a compression sensor 6 , input signal conductor 7 between the compression sensor 6 and control unit 2 , and output signal conductor 8 between control unit 2 and display unit 3 . The solid state control unit 2 has an on/off switch 9 , a reset button 10 and optionally a calibration control 11 . The solid state control unit 2 and digital readout display unit 3 are powered by a source of electrical power, preferably a miniature replaceable battery 14 , via the on/off switch 9 and electrical conductors 15 A and 15 B. Optional connector 3 A provides the digital display output signal for conduction to an optional external display unit.
[0024] FIG. 3 shows elements of the solid state control unit 2 including the signal conversion element 12 , which receives the impact force signal from the compression sensor via input signal conductor 7 and sends a digital speed signal to the display unit 3 via output signal conductor 8 . The optional connector 3 A receives the same output signal via output signal conductor 8 A as the signal sent to display unit 3 via output signal conductor 8 . A reset button 10 is used to instruct the control unit to reset the display unit to a reading of zero, in preparation for receiving a subsequent impact force signal. An optional calibration element 13 of the solid state control unit is used to adjust the accuracy of the force to speed conversion of the signal conversion element, via the calibration control 11 .
[0025] An external digital display unit having self-contained power may receive the digital speed output signal via optional output signal conductor 8 A and optional connector 3 A.
[0026] FIG. 4 shows a baseball rebound net device 16 and the attached ball pitching target device 17 , having a target area 17 A. The target device may be attached to any of a set of vertical or near-vertical surfaces, including baseball rebound nets, backstops and walls.
[0027] FIG. 5 shows a partial cutaway view of the back of the ball pitching target unit including a compression sensor 18 , control unit 19 and display unit 20 . The solid state control unit 19 and digital readout display unit 20 are powered by a source of electrical power, preferably a miniature replaceable battery 21 . Optional connector 22 provides the digital display output signal for conduction to an optional external display unit. The solid state control unit 19 has an on/off switch 9 , a reset button 10 and optionally a calibration control 11 . The control unit circuits include an algorithmic expression for conversion of the impact force signal to the corresponding digital output signal for display of said impact speed in miles per hour or, optionally, kilometers per hour.
[0028] It is understood that the mitt 1 as shown is made to fit on the left hand of a user who is right-handed, and that a mitt made to fit on the right hand of a user who is left-handed is modified in mirror image fashion for this invention.
[0029] The compression sensor 6 and input signal conductor 7 can optionally be replaced by more than one compression sensor, arrayed within the ball catching area of the mitt, and an equal number of input signal conductors; the solid state control unit 2 would select the largest impact force signal received via the input signal conductors for conversion to the corresponding digital output signal.
[0030] The control unit can optionally include a function to turn itself off after a predetermined non-use time.
[0031] Said on/off switch and said reset button can optionally be replaced by a single control button, which functions as an on switch when the device is off, as a reset control when pressed for a short period while the device is on, and as an off switch when pressed for a predetermined longer period while the device is on.
[0032] The digital readout display unit is preferably a liquid crystal display or optionally a light-emitting diode.
[0033] The source of electrical current is preferably a conventional miniature replaceable battery, or optionally can be a solar powered storage battery or mechanical electrical generation device.
[0034] It is also understood that a compression sensor is equivalent to an accelerometer.
[0035] The compression sensor or sensosrs 6 may be of any strong material, but the preferred embodiment is that the material be a metal or high impact plastic.
[0036] It is important that the compression sensor 6 be located at the center of the ball catching area of the mitt 1 or, if more than one sensor is used that the sensors be arrayed within the ball catching area of the mitt, said area being positioned by the user 5 in preparation for catching the ball.
[0037] The compression sensor 6 , or multiple sensors if used, must be minimal in size so as to not to interfere with the catching of the ball 4 , as the user 5 supports the mitt 1 , as shown in FIG. 1 .
[0038] The mitt 1 may be of any strong and flexible material but the preferred embodiment is that the material be of leather.
[0039] It is important that the sensor 18 be located at the center of the target area 17 .
[0040] In use of the mitt 1 , the user presses the on/off switch to activate the display, or if the display is on, the reset button to reset the display to zero; supports the mitt 1 with the left or right hand, according to the mitt design, and positions the catching area of the mitt so that an approaching ball strikes the center of the catching area. After noting the ball impact speed presented in the display, the user presses the reset button and positions the catching area of the mitt to catch the next ball in the catching area. The device may be inactivated by pressing the on/off button, or holding down the optional single on/off/reset button, or optionally by allowing the device to turn itself off after a predetermined time without input from sensors or controls.
[0041] In use of the ball pitching target unit, the user presses the on/off switch to activate the display, or if the display is on, the reset button to reset the display to zero; notes the ball impact speed after the pitch and presses the reset button prior to the next pitch. The device may be inactivated by pressing the on/off button, or holding down the optional single on/off/reset button, or optionally by allowing the device to turn itself off after a predetermined time without input from sensors or controls.
[0042] The solid state control unit may optionally have a calibration element, so that the impact speed presented by the digital readout display unit may be adjusted to a correct value. For example, if the displayed impact speed varies as a result of changes in the compression sensor or sensors, the displayed value may be corrected. The displayed impact speed may also be adjusted according to the mass of the ball used, for example a regulation baseball or a regulation softball. The correct value may be determined by any accepted method, including a properly calibrated radar unit.
[0043] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims and allowable functional equivalents thereof. | A ball speed measuring device comprises a ball pitching target having an electronic compression sensor in the ball target area, and having a digital readout display unit connected to the compression sensor through a solid state unit which converts the compression force, measured when a ball strikes the target area, to the speed of the ball, and displays the impact speed. The ball speed measuring device may be incorporated into a modified ball catching mitt, wherein the ball pitching target is the ball catching area of the mitt, or into a unit which may be attached to vertical supports including backstops and baseball rebound nets. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application No. 60/323,669 filed Sep. 20, 2001, which is incorporated herein by reference in its entirety to the extent not inconsistent herewith.
BACKGROUND
[0002] Garlic ( Allium sativum ) is a popular cooking spice and has been known as a folk remedy for centuries. Its use was described by Virgil in the Second Idyll as a treatment for snake bite and by Hippocrates for treating pneumonia and suppurating wounds. It has also been used for treating gastric catarrh, dysentery, typhoid and cholera. (E. D. Wills (1956) “Enzyme Inhibition by Allicin, the Active Principle of Garlic,” Biochem J. 63:514-519.) It has alterative, stimulant, diaphoretic, expectorant, antiseptic, antibiotic, antispasmodic, cholagogue, vulnerary, vermifuge, antibacterial, and antifungal properties. (“Allium sativum—Garlic (Liliaceae),” The Herbalist, newsletter of the Botanic Medicine Society, 1988) downloaded Dec. 5, 2000 from www.ibiblio.org.) Aqueous extracts (25% w/v) of garlic are bacteriostatic and bactericidal against a number of bacteria on blood agar and at further dilutions (down to {fraction (1/32)}, and in one case {fraction (1/64)}, of the original extract). (I. Elamin et al. (1983), “The Antimicrobial Activity of Garlic and Onion Extracts,” Pharmazic 38:747-748.)
[0003] Other health concerns for which garlic is recommended are atherosclerosis, candidiasis, hypertension and hypoglycemia. It is known as having fibrinolytic properties and inhibits blood platelet aggregation as well as reducing plaque in arteriosclerosis therapy. (“Garlic,” Whole Health Discount Center website, downloaded Dec. 5, 2000 from www.health-pages.com/ga/. Garlic extract has been shown to protect against cardiovascular disease as a result of inhibiting platelet aggregation. (K. Rahman and D. Billington (2000), “Dietary Supplementation with Aged Garlic Extract Inhibits ADP-Induced Platelet Aggregation in Humans,” J. Nutr. 130:2662-2665.) In the People's Republic of China, it is administered orally and intravenously to treat cryptococcal meningitis, and has been shown to possess antiviral activity against influenza B and herpes simplex viruses but not against Coxsackie B1 virus. (Y. Tsai et al. (1985), “Antiviral Properties of Garlic: In vitro Effects on Influenza B Herpes Simplex and Coxsackie Viruses,” Planta Medica 51:460. It has also been used in combination with other herbs for treatment of psoriasis, rheumatism and asthmatic dyspnea. (U.S. Pat. No. 5,165,932 issued Nov. 24, 1992 to Horvath for “Therapeutical Compositions Against Psoriasis.”)
[0004] Fermented with rice bran and Aspergillus, then extracted with ethanol, garlic is said to be useful as a coating agent for treating diseases of trichophytosis. (PCT Publication 88/04933 dated Jul. 14, 1988 for “Specially Processed Garlic Product” (Abstract)). Enzymatically-deactivated and fermented with Aspergillus and/or Monascus, it is known as a prophylactic or therapeutic agent for diabetes, hepatic disease, cancer, immunopathy, and hyperemia. (U.S. Pat. No. 6,146,638 issued Nov. 14, 2000 to Kakimoto et al. for “Fermented Garlic Composition.”) Extracts have been recommended for inhibiting apoptosis. (U.S. Pat. No. 5,635,187 issued Jun. 3, 1997 to Bathurst et al. for “Compositions which Inhibit Apoptosis, Methods of Purifying the Compositions and Uses Thereof.”) A composition made by combining extract of garlic with S-allylcysteine is said to be useful in controlling hepatopathy and oncogenesis. (U.S. Pat. No. 5,093,122 issued Mar. 3, 1992 to Kodera for “Method for Preparing an S-Allylcysteine-containing Composition.” Garlic and extracts have been orally administered for treating and preventing cardiovascular diseases such as myocardial infarction, stroke and multiple arteriosclerosis by reduction of high levels of plasma homocysteine. (U.S. Pat. No. 6,129,918 issued Oct. 10, 2000 to Amagase for “Method and Pharmaceutical Composition for Reducing Serum Homocysteine Concentration.”) U.S. Pat. No. 5,705,152 issued Jan. 6, 1998 to Plummer for “Antimicrobial Composition” discloses the use of dried garlic powder in combination with non-pathogenic microorganisms useful for combating pathogenic microorganisms in animal gastrointestinal tracts.
[0005] The active principles present in garlic have been found to be mainly sulfur-containing compounds. The principal component of a colorless oil obtained from steam distillates of garlic extracts was shown to be a sulfur compound, C 6 H 10 S 2 O, named allicin (thio-2-propene-1-sulfinic acid S-allyl ester, or alternatively, 2-propene-1-sulfinothioic acid S-2-propenyl ester, or diallyl thiosunfinate). (C. J. Cavallito and J. H. Bailey (1944), “Allicin, the antibacterial principle of Allium sativum. I. Isolation, physical properties and antibacterial action. J. Am. Chem. Soc. 66:1944-1952; and C. J. Cavallito et al. (1944) “Allicin, the antibacterial principle of Allium sativum. II. Determination of the chemical structure. J. Am. Chem. Soc. 66:1952-1954.) The structure of allicin is:
[0006] Allicin is a colorless, volatile liquid with a pungent odor, a water solubility of about 2%, moderate solubility in hexane and high solubility in organic solvents more polar than hexane. (“Garlic: The Science and Therapeutic Application of Allium sativum L . and Related Species”(Second Edition, 1996) (H. P. Koch and L. D. Lawson, eds.) pp. 56-57). It is responsible for most of the smell of garlic. A garlic bulb exhibits little or no odor until it is cut or crushed. The intact garlic clove does not contain allicin but rather its odorless precursor alliin ((+)(S)-allyl-L-cysteine sulfoxide) that is converted to allicin, pyruvate and ammonia by a C-S lyase present in the garlic plant termed allicin lyase or alliinase. Alliin and alliinase are found in different compartments of the garlic clove. The cutting or crushing of the clove enables the enzyme to come into contact with the precursor of allicin. (PCT Publication WO 97/39115 dated 23 Oct., 1997, D. Mirelman et al. “Immobilized Alliinase and Continuous Production of Allicin.”) Allicin is an unstable compound, having a half-life of sixteen hours at 23° C., and in water solution at 0.1-2 mg/ml at this temperature of 30-40 days. (“Garlic”, Koch and Lawson eds., supra, p. 58.) Its major biological effects have been attributed to antioxidant activities and to rapid reactions with thiol-containing proteins. (A. Rabinokov et al. (1998), “The mode of action of allicin: trapping of radicals and interaction with thiol containing proteins,” Biochimica et Biophysica Acta 1379:233-244.)
[0007] The synthesis of allicin was described in U.S. Pat. No. 2,508,745 issued May 23,1950 to C. J. Cavallito et al. for “Hydrocarbon Esters of Hydrocarbonylthiosulfinic Acids and Their Process of Preparation.”
[0008] Other components of garlic and their degradation products are described in L. D. Lawson et al. (1991), “Identification and HPLC Quantitation of the Sulfides and Dialk(en)yl Thiosulfinates in Commercial Garlic Products,” Planta Med. 57:363-370.
[0009] C. J. Cavallito and J. H. Bailey (1944) (I., supra) showed in cylinder-plate tests using meat extract broth at pH 6.8 or 0.5% dextrose-veal infusion broth that allicin at dilutions as great as 1:25 prevented growth of a number of bacteria. Allicin has been shown to exhibit a wide spectrum of antibacterial activity against gram negative and gram positive bacteria, including Escherichia coli , antifungal activity against Candida albicans , antiparasitic activity including against Entamoeba hisiolytica and Giardia lamblia , and antiviral activity. (S. Ankri and D. Mirelman (1999), “Antimicrobial properties of allicin from garlic,” Microbes and infection 2:125-129; S. Ankri et al. (1997), “Allicin from Garlic Strongly Inhibits Cysteine Proteinases and Cytopathic Effects of Entamoeba histolytica ” Antimicrobial Agents and Chemotherapy, October:2286-2288. See also D. Mirelman et al., “Pathogenesis of the Parasite Entamoeba histolytica ,” downloaded from http://bioinfo.weizmann.ac.il on Dec. 5, 2000.) However, mammalian cells are protected by the peptide glutathione which acts to restore activity of affected enzymes. (“A Garlic Charm Against Stomach Bugs,” Academic Press Daily Insight, downloaded Dec. 5, 2000 from www.apnet.com/inscight/10141997/graphb.htm.)
[0010] Enzymes of the succinic oxidase system are inhibited by allicin, however, cysteine, glutathione, and 2:3-dimercaptopropanol) are protective agents, and serum has a weak protective action. Allicin is known to inhibit alkaline phosphatase and invertase, urease, succinic dehydrogenase, lactate dehydrogenase, tyrosinase, peroxidase, papain, amylase, xanthine oxidase, choline oxidase, levokinase, cholinesterase, glyoxylase, triose phosphate dehydrogenase. Some of this inhibition occurs in a pH-dependent manner. (E. D. Wills (1956), “Enzyme Inhibition by Allicin, the Active Principle of Garlic,” Biochem J. 63:514-520; Chem. Abstr. 50 (1956) 15612.)
[0011] Allicin was shown to have a minimum inhibitory concentration against Helicobacter pylori of 4.0 μg/ml in medium. (E. A. O'Gara et al. (2000), “Activities of Garlic Oil, Garlic Powder, and Their Diallyl Constituents against Helicobacter pylori ,” Applied and Environmental Microbiology, May:2269-2273). U.S. Pat. No. 5,321,045 issued Jun. 14, 1994 to Dorsch et al. for “Method and Composition for the Treatment of Inflammatory Conditions using Thiosulphinic Acid Derivatives” reports that intravenous administration of compounds including allicin at 0.5-500 mg/kg provides anti-inflammatory activity. R. S. Feldberg et al. (1988), “In Vitro Mechanism of Inhibition of Bacterial Cell Growth by Allicin,” Antimicrobial Agents and Chemotherapy, 32:1763-1768) discloses bacteriostatic concentrations of allicin (0.2 to 0.5 mM) in Luria broth for Salmonella typhimurium . A. D. Kaye et al. (July, 2000), “Analysis of responses of garlic derivatives in the pulmonary vascular bed of the rat,” J. Appl. Physiol. 89:353-358) report that allicin and related compounds are vasodilators.
[0012] U.S. Pat. No. 4,917,921 issued Apr. 17, 1990 to Hermes for “Antithrombogenic and Antibiotic Composition and Methods of Preparation Thereof” discloses antithrombogenic and antibiotic polymeric coatings made from copolymerization of 2-vinyl-4H-1,3-dithiin (a component of garlic) and N-vinyl pyrrolidone. U.S. Pat. No. 4,665,088 issued May 12,1987 to Apitz-Castro et al. for “(E-Z)-4,5,9-Trithiadodeca-1,6,11-triene-9-oxides” discloses the use of compounds such as (E,Z)-ajoene as antithrombotic agents. H. Yoshida et al. (1999), “An Organosulfur Compound Isolated from Oil-Macerated Garlic Extract,” Biosci. Biotechnol. Biochem. 63:588-590 discloses anitmicrobial effect of E-4,5,9-trithiadeca-1,7-diene-9-oxide isolated from garlic. H. Yoshida et al. (999), “Antimicrobial Activity of the Thiosulfinates Isolated form Oil-Macerated Garlic Extract,” Biosci. Biotechnol. Biochem. 63:591-594, disclose antimicrobial activities of 2-propene-1-sulfinothioic acid S-(Z,E)-1-propenyl ester, 2-propenesulfinothioic acid S-methyl ester, and methanesulfinothioic acid S-(Z,E)-1-propenyl ester.
[0013] J. C. Harris et al. (December, 2000), “The microaerophilic flagellate Giardia intestinalis: Allium sativum (garlic) is an effective antigiardial,” Microbiology 146:3119-3127, suggest that the antimicrobial properties of garlic are due to metabolic breakdown products of allicin (diallyl disulphide and diallyl sulphide) rather than allicin itself.
[0014] Ajoene is another compound formed as garlic is crushed. Alliin in the garlic comes into contact with allinase in the cell wall to form allicin. Then in the presence of a polar molecule such as a lower alcohol or even water, allicin forms ajoene, which can be administered, e.g. interarterially, for treatment of inflammation. (See U.S. Pat. No. 6,177,475 issued Jan. 23, 2001 to Tatarintsev et al. for “Methods of Using Integrin Modulators for Treatment of Inflammation.” Tatarintsev et al. have also disclosed that ajoene can be administered to a patient for inhibiting integrin-mediate cell-cell fusion (U.S. Pat. No. 5,981,602 issued Nov. 9, 1999), for treatment of shock (U.S. Pat. No. 5,968,988 issued Oct. 19, 1999), for treatment of tumors (U.S. Pat. No. 5,932,621 issued Aug. 3, 1999), for inhibiting immune response (U.S. Pat. No. 5,863,955 issued Jan. 26, 1999), and for inhibiting the progression of infection and other pathologies produced by a viral infection (U.S. Pat. No. 5,948,821).
[0015] Isoalloxazine and related compounds have been used as antimicrobials as described in: U.S. Pat. No. 6,258,577 issued Jul. 10, 2001; U.S. Pat. No. 6,277,377 issued Aug. 21, 2001; PCT Publications WO 0194349A1 published Dec. 13, 2001 and WO 0196340A1 published Dec. 20, 2001; U.S. Pat. No. 6,268,120 issued Jul. 31, 2001; PCT Publication WO 0243485A1 published Jun. 6, 2002; and/or U.S. Patent Publication No. 2001/0024781A1 published Sep. 27, 2001, which concern methods and apparatuses for blood and blood product decontamination using isalloxazine and related compounds.
[0016] While the antimicrobial effects of allicin and the foregoing related compounds have been described in the literature, these compounds do not appear to have been used as additives to blood, blood products or blood storage solutions to delay growth of microorganisms or kill them.
[0017] All publications referred to herein are incorporated herein by reference to the extent not inconsistent herewith.
SUMMARY
[0018] Blood products are typically removed from a donor, separated into components (platelets, plasma, and red blood cells), stored, and used for therapeutic purposes by administration back to the donor or to another recipient. Due to the growth of microorganisms in stored platelets over time, they cannot typically be stored under normal storage conditions for periods longer than about five days. Normal storage conditions for platelets include storage at a temperature of about 22° C. with agitation (preferably on a shaker table at about 72 cycles per minute). In the 1970s, government regulation allowed platelet storage for up to seven days, but occurrence of bacterial infection/contamination caused this period to be reduced to no more than five days.
[0019] Other blood products have varying safe storage periods. For example, red blood cells can be stored for up to 42 days at 4° C. in additive solutions compliant with government regulations, but bacteria such as Yersinia entercolitica will still grow. Table 1, taken from the American Association of Blood Banks (AABB) Technical Manual, 13 th Edition, 2000, provides storage conditions and expiration dates for a number of blood products.
TABLE 1 Category Expiration Whole Blood ACD 1 /CPD 2 /CP2D 3 - 21 days Whole Blood Modified ACD/CPD/CP2D - 21 days CPDA-1 4 - 35 days Whole Blood Irradiated Original outdate (see outdates above per anticoagulant) or 28 days from date of irradiation, whichever is sooner Red Blood Cells (RBCs) ACD/CPD/CP2D - 21 days CPDA-1 - 35 days RBCs, Additive Solutions 42 days RBCs, Washed Time approved by FDA RBCs, Leukocytes Reduced ACD/CPD/CP2D - 21 days CPDA-1 - 35 days Open system - 24 hours Additive solutions - 42 days RBCs, Rejuvenated 24 hours RBCs, Rejuvenated, Washed 24 hours RBCs, Irradiated Original outdate above or 28 days from date of irradiation, whichever is sooner RBCs, Frozen 40% Glycerol 10 years RBCs, Frozen 20% Glycerol 10 years RBCs, Open System 24 hours RBCs, Open System - Frozen 10 years, 24 hours after thaw RBCs, Frozen - Liquid Nitrogen 10 years Platelets 24 hours to 5 days, depend- ing on collection system Platelets, Pheresis 5 days Platelets Pooled or in Open System 4 hours, unless otherwise specified Platelets, Leukocytes Reduced 4 hours open system 5 days closed system Platelets, Pheresis, Leukocytes Reduced 5 days Platelets, Irradiated 4 hours open system 5 days closed system Granulocytes 24 hours Fresh Frozen Plasma (FFP) 12 months (−18° C.) 7 years (−65° C.) FFP, Thawed 24 hours FFP, Open System - thawed 24 hours Pooled Plasma, Solvent/detergent-treated 12 months Pooled Plasma, Solvent/detergent-treated - 24 hours Thawed Plasma (frozen within 24 hours) 12 months Plasma (frozen within 24 hours) Thawed 24 hours Plasma Thawed >24 hours, <5 days Plasma Liquid 5 days after expiration of RBCs FFP - Donor Retested Thawed 24 hours FFP - Donor Retested 12 months Plasma, Cryoprecipitate-Reduced, Thawed 24 hours Cryoprecipitated Anti-hemophilic Factor 12 months (AHF) Cryoprecipitated AHF, Thawed ASAP or within 4 hours if open system or pooled, 6 hours if single unit or pooled
[0020] Growth of microorganisms in stored blood products renders the products less safe than fresh blood products for administration to patients. Further, short storage periods give rise to problems in matching supply to demand and cause inefficiencies and extra expense in providing patients with required treatments. To increase the safety of stored blood products and allow a longer storage life for blood products, this invention teaches adding to stored blood products compositions which kill microorganisms, or slow the growth thereof. In one embodiment, the storage life of platelets is increased to more than five days, up to at least about six days, preferably up to about seven days.
[0021] This invention also provides an aqueous additive solution (also referred to herein as a “storage solution”) for storage of blood products selected from the group consisting of whole blood, red blood cells, white blood cells, platelets, serum and plasma, said additive solution comprising a composition selected from the group consisting of garlic extract, allicin, other microorganism-growth-inhibiting compounds derived from garlic, and analogs and derivatives of allicin and said other compounds, in amounts effective to inhibit growth of at least one selected microorganism.
[0022] The term “derived from garlic” means removal of naturally-occurring microorganism-growth-inhibiting compounds from garlic by extraction or other means known to the art. Such compounds need not be isolated in pure form (but may be isolated in pure form) to be useful in this invention.
[0023] This invention also provides a composition comprising a mixture of anticoagulant and a storage-life increasing amount (an amount effective to inhibit growth of at least one selected microorganism) of garlic extract, allicin, other microorganism-growth-inhibiting compounds from garlic, or analogs and derivatives of allicin and said other compounds. Such compositions also comprising a blood product are provided as well. Anticoagulants are known to the art and include acid citrate dexytrose (ACD), citrate phosphate dextrose (CPD), citrate phosphate dextrose dextrose (CP2D), and citrate phosphate dextrose adenine (CPDA-1). Such solutions generally have a pH of around 6.4.
[0024] Garlic extract or allicin and derivative compositions of this invention may be added to platelet additive solutions known to the art. Such known platelet additive solutions include those disclosed in U.S. Pat. Nos. 5,908,742; 5,482,828; 5,569,579; 5,236,716; 5,089,146; and 5,459,030. Platelet additive solutions may contain physiological saline solution, buffer, preferably sodium phosphate, and other components including magnesium chloride and sodium gluconate. The pH of such solutions is preferably between about 7.0 and 7.4. These solutions are designed as carriers for platelet concentrates to allow maintenance of cell quality and metabolism during storage, reduce plasma content and extend storage life. A preferred platelet additive solution comprises monobasic sodium phosphate, riboflavin, dibasic sodium phosphate, sodium chloride, sodium ascorbate, potassium chloride, and magnesium chloride.
[0025] Compositions of this invention containing garlic extract or allicin and derivative compositions preferably have a pH between about 6.4 and about 7.4.
[0026] The allicin and related compositions of this invention may be present in the storage solutions at concentrations sufficient to inhibit the growth of at least a selected microorganism, e.g., from about 10 μg/ml to the solubility of the compounds in the solution, and preferably up to about 3000 μg/ml, more preferably at least about 30 μg/ml. It is preferred that the concentration be minimized when odorous compounds such as allicin are used.
[0027] Concentrations of allicin and related compounds sufficient to inhibit growth of selected microorganisms in selected blood products may easily be determined as known to the art and in accordance with the teachings hereof. Preferably such compounds are present in the blood product at a concentration of between about 5 volume percent and about 35 volume percent, preferably about 5 to about 10 volume percent. Blood product is preferably present at a concentration between about 65 and about 95 volume percent. “Growth inhibition” as used herein is measurable growth inhibition as determined by assays known to the art.
[0028] Sulfur-containing compounds such a glutathione in the blood product or solution may compete with reactions of compositions of this invention and affect their growth-inhibitory action on microorganisms. The concentration of allicin and related compounds present in blood product should be adjusted to take account of such competing reactions.
[0029] Selected microorganisms whose growth it is desired to inhibit when storing blood products include gram negative and gram positive bacteria such as Staphylococcus epidermidis, Yersinia enterocolitica, Esherichia coli, Pseudomonas aeruginosa, Staphylococcus aureus, Klebsiella pneumoniae, Treponema pallidum, Bacillus cereus, Clostridium perfringes, Enterobacter cloacae, Proteus mirabilis, Salmonella cholerasuis, Serratia liquefactions, Serratia marscesens, Francisella tularensis, Streptococcus pyogenes , and Streptococcus mitis ; viruses such as Human Immunodeficiency Virus (HIV), Influenza A and B, Hepatitis viruses such as hepatitis B and C, Epstein-Barr virus (EBV), Herpes simplex, pneumonia virus, cytomegalovirus (CMV), and parvovirus; fungi such as Candida albicans, Trichophyton cerebriforme, Trychophyton granulosum and Microsporum canis ; protozoa such as Paramecium caudatum, Lamblia intestinalis, Grandia lamblia, Trypanosoma cruzi and Entamoeba histolytica ; parasites such as Ascaris strongyloides, Oxyuris, Ancyclostoma caninum , and Necator americanus , Trypanosome spp., Plasmodium spp., and Wucheria bancrofti . Preferred microorganisms are blood-borne pathogens such as HIV, CMV, Hepatitis viruses, plasmodium, trypanosome, Francisella tularensis , and Wucheria bancrofti.
[0030] Without wishing to be bound to any particular mechanism of action of allicin and related compounds, applicants believe that the enzyme-inhibiting effects of these compounds may interfere with the ability of microorganisms to metabolize, reproduce, or respirate effectively, such that these compounds have the effect of at least preventing or slowing down growth of these microorganisms if not completely destroying them.
[0031] Preferred compounds of this invention are those present in extract of garlic. Garlic extract may be prepared by means known to the art. One procedure is to grind garlic cloves, e.g., in a blender, and mix with saline, preferably 0.9% saline, using about 25 g cloves per 100 ml saline. This is followed by separation of the liquid extract, e.g., by centrifugation or filtration, preferably through a 0.2μ filter. The extract may be stored frozen until used.
[0032] Garlic may also be used in this invention in the form of garlic powder such as commercially available garlic powder.
[0033] Solutions may be prepared using commercially available allicin, e.g., from LKT Laboratories, Inc., St. Paul, Minn. Solutions containing 1 mg allicin per 100 μl of a carrier composed of 60:40:0.1 methanol:water:formic acid are useful in this invention. Allicin may also be prepared by oxidation of commercially available diallyl disulfide, e.g., with hydrogen peroxide/ glacial acetic acid or with perbenzoic or peracetic acid.
[0034] Allicin and other garlic components known to the art to have a growth-inhibiting effect on microorganisms may be isolated from garlic extract or synthetically prepared by means known to the art and used in the compositions and methods of this invention. Analogs and derivatives of such compounds may also be prepared by means known to the art and used in the compositions and methods of this invention.
[0035] Some garlic components which have a growth-inhibiting effect on microorganisms and related analogs include methyl propyl sulfide, allyl methyl sulfide, diallyl sulfide, methyl sulfide, diallyl disulfide, dimethyl disulfide, methyl propyl disulfide, dipropyl disulfide, allyl alcohol, allyl mercaptan, diallyl trisulfide, diallyl tetrasulfide, diallyl pentasulfide, diallyl hexasulfide, methy allyl disulfide, methyl allyl trisulfide, methyl allyl tetrasulfide, methyl allyl pentasulfide, methyl allyl hexasulfide, dimethyl disulfide, dimethyl trisulfide, dimethyl tetrasulfide, dimethyl pentasulfide, dimethyl hexasulfide, diethyl disulfide, propyl allyl disulfide, 2-vinyl-4H-1,3-dithiin, 3-vinyl-4H-1,2-dithiin, (E)-ajoene, (Z)-ajoene, allicin, allyl methyl thiosulfinate, (E)-2,3,7-trithiaocta-4-ene-7-oxide, (E)-4,5,9-trithiadeca-1,6-diene-9-oxide, (Z)-2,3,7-trithiaocta-4-ene-7-oxide, (Z)-4,5,9-trithiadeca-1,6-diene-9-oxide, (E)-4,5,9-trithiadeca-1,7-diene-9-oxide, (Z)-4,5,9-trithiadeca-1,7-diene-9-oxide, 2-propene- 1-sulfinothioic acid S-(Z,E)-1-propenyl ester, 2-propenesulfinothioic acid S-methyl ester, and methanesulfinothioic acid S-(Z,E)-1-propenyl ester.
[0036] A generalized formula for allicin and related compounds useful in this invention is:
[0037] where
[0038] R 1 and R 2 are, independently H, C 1 -C 20 (saturated or unsaturated) alkyl, alkoxy, cycloalkyl or aralkyl;
[0039] X is S, SS, SSS, or SOS, and moieties in which one or more of the sulfur atoms are replaced with SO or OSO;
[0040] n is 0 or 1; and
[0041] Y is R 3m XR 4p where
[0042] m and p are, independently, 0 or 1; and
[0043] R 3 and R 4 are H or C 1 -C 6 (saturated or unsaturated) alkyl, alkoxy, cycloalkyl or aralkyl.
[0044] C 1 -C 6 (saturated or unsaturated) dithiins are also included within the scope of this invention, as are optical isomers and pharmaceutical salts of all the foregoing compounds. Such compounds can be tested for microorganism growth-inhibiting activity by means known to the art and as taught herein.
[0045] One class of compounds useful in this invention are those of the above formula in which X is S═O. Another class of useful compounds is those in which m and p are 1, R 3 is methyl, X is S═O and R 4 is C═C—C. The class of compounds wherein R 1 and R 2 comprise double bonds in cis-configuration, spaced apart from sulfur atoms by two carbons, as in allicin, are preferred.
[0046] A further class of compounds useful in this invention are those having the formula:
[0047] where
[0048] R 1 and R 2 are, independently H, or C 1 -C 6 (saturated or unsaturated) alkyl;
[0049] and optical isomers and pharmaceutical salts thereof.
[0050] A further class of compounds useful in this invention are those of the above formula in which R 1 is allyl and R 2 is allyl ethyl, vinyl, or methyl.
[0051] The storage solution may also contain isoalloxazine or an isoalloxazine analog, or vitamin E or a vitamin E acetate analog, and/or anticoagulant. Isoalloxazine and its analogs are useful for killing and inhibiting microorganisms. Isoalloxazine analogs include all compounds disclosed in U.S. Pat. No. 6,258,577 issued Jul. 10, 2001; U.S. Pat. No. 6,277,377 issued Aug. 21, 2001; PCT Publications WO 0194349A1 published Dec. 13, 2001 and WO 0196340A1 published Dec. 20, 2001; U.S. Pat. No. 6,268,120 issued Jul. 31, 2001; PCT Publication WO 0243485A1 published Jun. 6, 2002; and/or U.S. Patent Publication No. 2001/0024781A1 published Sep. 27, 2001, all of which are incorporated herein by reference to the extent not inconsistent herewith.
[0052] In the methods of this invention, the isoalloxazine and/or related compounds may be added to the solution, before, at the same time, or after addition of the allicin and related compositions of this invention. Preferably such isoalloxazine and/or related compounds are added to blood products at the time of collection or as soon thereafter as practical, i.e., before microorganisms have a chance to proliferate.
[0053] This invention also provides methods of prolonging the storage life of a blood product comprising: adding to said blood product a solution comprising at least an amount effective to inhibit growth of a selected microorganism, of a compound selected from the group consisting of allicin and microorganism-growth-inhibiting analogs and derivatives thereof; and storing said blood product. Platelets are storable in the storage solutions of this invention for a period of at least about five days, more preferably at least about seven days.
[0054] Further provided is a method of storing a blood product comprising: adding to said blood product a solution comprising at least an amount effective to inhibit growth of a selected microorganism, of a compound selected from the group consisting of allicin, and microorganism-growth-inhibiting analogs and derivatives thereof; and storing said blood product.
[0055] A method of treating a patient in need of a blood product is also provided, comprising: providing a blood product; adding to said blood product a solution comprising at least an amount effective to inhibit growth of a selected microorganism, of a compound selected from the group consisting of allicin and microorganism-growth-inhibiting analogs and derivatives thereof; storing said blood product; and administering said blood product to a patient without removing said compound. Preferably the blood product is platelets which are stored for at least about five days, more preferably at least about seven days.
BRIEF DESCRIPTION OF THE FIGURES
[0056] [0056]FIG. 1 is a graph showing the bacteriostatic effect of garlic extract on S. epidermidis in platelets
[0057] [0057]FIG. 2 is a graph showing the bacteriostatic effect of garlic extract on Y. entercolitica in trypticase soy broth (TSB).
[0058] [0058]FIG. 3A is a graph showing the bacteriostatic effect of garlic extract on 1-2 log E. coli in platelets. FIG. 3B is a graph showing the bacteriostatic effect of garlic extract on 2-3 logs E. coli in platelets.
[0059] [0059]FIG. 4A is a graph showing the bacteriostatic effect of garlic extract on 1.0×10 4 Staph. aureus in plasma. FIG. 4B is a graph showing the bacteriostatic effect of garlic extract on 2.5×10 2 Staph. aureus in plasma.
[0060] [0060]FIG. 5 is a graph showing the bacteriostatic effect of garlic extract on Klebsiella pneumoniae in platelets spiked with 1 log/ml.
DETAILED DESCRIPTION
[0061] Blood product storage solutions comprising garlic extract, allicin and analogs and derivatives are provided herein, as well as methods using such compositions to inhibit growth of microorganisms and thereby increase the safety and, in some cases, the storage life of blood products.
[0062] As defined herein, “pharmaceutical salts” are non-toxic salts of acids such as hydrochloric, phosphoric, hydrobromic, sulfuric, sulfinic, formic, toluenesulfonic, methanesulfonic, nitric, benzoic, citric, tartaric, maleic, hydroiodic, alkanoic such as acetic, and the like. Non-toxic pharmaceutical base addition salts include salts of bases such as sodium, potassium, calcium, ammonium, and the like. Those skilled in the art will recognize a wide variety of non-toxic pharmaceutically acceptable addition salts.
[0063] The compounds of this invention may contain an asymmetric carbon atom, and some of the compounds of this invention may contain one or more asymmetric centers, and may thus give rise to optical isomers and diastereomers. While shown without respect to stereochemistry in the above generic formulas, the present invention includes such optical isomers and diastereomers, as well as the racemic and resolved, enantiomerically pure R and S stereoisomers, as well as other mixtures of the R and S stereoisomers and pharmaceutically acceptable salts thereof.
[0064] The term “alkyl” takes its usual meaning in the art and is intended to include straight-chain, branched and cycloalkyl groups. The term includes, but is not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, neopentyl, 2-methylbutyl, 1-methylbutyl, 1-ethylpropyl, 1,1-dimethylpropyl, n-hexyl, 1-methylpentyl, 2-methylpentyl, 3-methylpentyl, 4-methylpentyl, 3,3-dimethylbutyl, 2,2-dimethylbutyl, 1,1-dimethylbutyl, 2-ethylbutyl, 1-ethylbutyl, 1,3-dimethylbutyl, n-heptyl, 5-methylhexyl, 4-methylhexyl, 3-methylhexyl, 2-methylhexyl, 1-methylhexyl, 3-ethylpentyl, 2-ethylpentyl, 1-ethylpentyl, 4,4-dimethylpentyl, 3,3-dimethylpentyl, 2,2-dimethylpentyl, 1,1-dimethylpentyl, n-octyl, 6-methylheptyl, 5-methylheptyl, 4-methylheptyl, 3-methylheptyl, 2-methylheptyl, 1-methylheptyl, 1-ethylhexyl, 1-propylpentyl, 3-ethylhexyl, 5,5-dimethylhexyl, 4,4-dimethylhexyl, 2,2-diethylbutyl, 3,3-diethylbutyl, and 1-methyl-1-propylbutyl. Alkyl groups are optionally substituted. Lower alkyl groups are C 1 -C 6 alkyl and include among others methyl, ethyl, n-propyl, and isopropyl groups.
[0065] The term “cycloalkyl” refers to alkyl groups having a hydrocarbon ring, particularly to those having rings of 3 to 7 carbon atoms. Cycloalkyl groups include those with alkyl group substitution on the ring. Cycloalkyl groups can include straight-chain and branched-chain portions. Cycloalkyl groups include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and cyclononyl. Cycloalkyl groups can optionally be substituted.
[0066] Aryl groups may be substituted with one, two or more simple substituents including, but not limited to, lower alkyl, e.g., methyl, ethyl, butyl; halo, e.g., chloro, bromo; nitro; sulfato; sulfonyloxy; carboxy; carbo-lower-alkoxy, e.g., carbomethoxy, carboethoxy; amino; mono- and di-lower-alkylamino, e.g., methylamino, ethylamino, dimethylamino, methylethylamino; amido; hydroxy; lower-alkoxy, e.g., methoxy, ethoxy; and lower-alkanoyloxy, e.g., acetoxy.
[0067] The term “unsaturated alkyl” group is used herein generally to include alkyl groups in which one or more carbon-carbon single bonds have been converted to carbon-carbon double or triple bonds. The term includes alkenyl and alkynyl groups in their most general sense. The term is intended to include groups having more than one double or triple bond, or combinations of double and triple bonds. Unsaturated alkyl groups include, without limitation, unsaturated straight-chain, branched or cycloalkyl groups. Unsaturated alkyl groups include without limitation: vinyl, allyl, propenyl, isopropenyl, butenyl, pentenyl, hexenyl, hexadienyl, heptenyl, cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, cyclohexadienyl, 1-propenyl, 2-butenyl, 2-methyl-2-butenyl, ethynyl, propargyl, 3-methyl-1-pentynyl, and 2-heptynyl. Unsaturated alkyl groups can optionally be substituted. Double bonds may be cis or trans.
[0068] Substitution of alkyl, cycloalkyl and unsaturated alkyl groups includes substitution at one or more carbons in the group by moieties containing heteroatoms. Suitable substituents for these groups include but are not limited to OH, SH, NH 2 , COH, CO 2 H, OR c , SR c , P, PO, NR c R d , CONR c R d , and halogens, particularly chlorines and bromines where R c , and R d , independently, are alkyl, unsaturated alkyl or aryl groups. Preferred alkyl and unsaturated alkyl groups are the lower alkyl, alkenyl or alkynyl groups having from 1 to about 3 carbon atoms.
[0069] The term “aryl” is used herein generally to refer to aromatic groups which have at least one ring having a conjugated pi electron system and includes without limitation carbocyclic aryl, aralkyl, heterocyclic aryl, biaryl groups and heterocyclic biaryl, all of which can be optionally substituted. Preferred aryl groups have one or two aromatic rings.
[0070] “Aralkyl” refers to an alkyl group substituted with an aryl group. Suitable aralkyl groups include among others benzyl, phenethyl and picolyl, and may be optionally substituted. Aralkyl groups include those with heterocyclic and carbocyclic aromatic moieties.
[0071] The term “alkoxy group” takes its generally accepted meaning. Alkoxy groups include but are not limited to methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, sec-butoxy, isobutoxy, tert-butoxy, n-pentyloxy, neopentyloxy, 2-methylbutoxy, 1-methylbutoxy, 1-ethyl propoxy, 1,1-dimethylpropoxy, n-hexyloxy, 1-methylpentyloxy, 2-methylpentyloxy, 3-methylpentyloxy, 4-methylpentyloxy, 3,3-dimethylbutoxy, 2,2-dimethoxybutoxy, 1-1-dimethylbutoxy, 2-ethylbutoxy, 1-ethylbutoxy, 1,3-dimethylbutoxy, n-pentyloxy, 5-methylhexyloxy, 4-methylhexyloxy, 3-methylhexyloxy, 2-methylhexyloxy, 1-methylhexyloxy, 3-ethylpentyloxy, 2-ethylpentyloxy, 1-ethylpentyloxy, 4,4-dimethylpentyloxy, 3,3-dimethylpentyloxy, 2,2-dimethylpentyloxy, 1,1-dimethylpentyloxy, n-octyloxy, 6-methylheptyloxy, 5-methylheptyloxy, 4-methylheptyloxy, 3-methylheptyloxy, 2-methylheptyloxy, 1-methylheptyloxy, 1-ethylhexyloxy, 1-propylpentyloxy, 3-ethylhexyloxy, 5,5-dimethylhexyloxy, 4,4-dimethylhexyloxy, 2,2-diethylbutoxy, 3,3-diethylbutoxy, 1-methyl-1-propylbutoxy, ethoxymethyl, n-propoxymethyl, isopropoxymethyl, sec-butoxymethyl, isobutoxymethyl, (1-ethyl propoxy)methyl, (2-ethylbutoxy)methyl, (1-ethylbutoxy)methyl, (2-ethylpentyloxy)methyl, (3-ethylpentyloxy)methyl, 2-methoxyethyl, 1-methoxyethyl, 2-ethoxyethyl, 3-methoxypropyl, 2-methoxypropyl, 1-methoxypropyl, 2-ethoxypropyl, 3-(n-propoxy)propyl, 4-methoxybutyl, 2-methoxybutyl, 4-ethoxybutyl, 2-ethoxybutyl, 5-ethoxypentyl, and 6-ethoxyhexyl.
[0072] A “dithiin” is a ring having two sulfur atoms in the ring, one double bond in the ring. appended to the ring.
[0073] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances in which it does not. For example, “optionally substituted phenyl” means that the phenyl radical may or may not be substituted and that the description includes both unsubstituted phenyl radicals and phenyl radicals wherein there is substitution.
EXAMPLES
Example 1. Preparation of Garlic Extract
[0074] Garlic extract was prepared by peeling cloves and storing them in a closed container. They were then mixed with 0.9% saline (25 g of cloves to 100 ml saline) in a blender until liquified, and centrifuged at 12,000 rpm. The supernatant was decanted and filtered through 0.2 μm filter (sterile barrier). The preparation was frozen and stored for use.
Example 2. Preparation of Allicin
[0075] Allicin was prepared by the following process: One gram of fractionally distilled diallyl disulfide was dissolved in 5 ml cold (4° C.) glacial acetic acid. Then 1.5 ml cold 30% hydrogen peroxide was slowly added. After 30 minutes, the temperature was allowed to increase to 12-15° C. Stirring was continued for 4-6 hours until the diallyl disulfide content decreased by only 75-80% (avoiding oxidation to diallyl thiosulfonate). The reaction was stopped with 15 ml water and extracted with 30 ml dichloromethane. Acetic acid was removed by washing with 5% NaHCO 3 then water to pH 6-7. Solvent was evaporated and the material was redissolved in 500 ml water. Unreacted diallyl disulfide was removed by double extraction with 0.1 volume hexane.
Example 3. Platelet Safety
[0076] Two ml of garlic extract (Example 1) were added to two-day old platelets to make the composition equivalent to about 1:100 dilution of the extract. Samples of the platelets were taken before the addition of the garlic extract, after, and the next day.
[0077] Swirl was maintained and at day 3 the platelets continued to metabolize O 2 (indicative by the PO 2 staying at about 80-95), and the pH was stable. Glucose was consumed and lactate produced at typical rates. Most importantly the cells remained viable and did not die. Garlic extract given to platelets at 1:100 extract:platelets had no measurable or visible effect on the platelets.
TABLE 2 Day 2 (pre-garlic) Day 2 (post-garlic) Day 3 Swirl 3 3 3 Lactate 6.06 5.95 7.86 Glucose 17.8 17.5 16.2 pH 7.13 7.23 7.16 PO 2 86 91 84 PCO 2 26 21 21 Cell count 1581 × 10 3 1568 × 10 3 1495 × 10 3
Example 4. Bacteriostatic Effects of Garlic Extraction Platelets on Staphylococcus epidermidis
[0078] Garlic extract was prepared according to the procedure of Example 1. Staphylococcus epidermidis was inoculated into platelets at a 5.0×10 4 and 5.0 10 1 titer. 25 ml samples were prepared having 1:5 garlic extract to platelets and 1:10 garlic extract to platelets. Samples were plated, grown and counted. Results are shown in FIG. 1.
Example 5. Bacteriostatic Effects of Garlic Extract on S. epidermidis TSA
[0079] To test the ability of garlic extract to kill or halt the growth of S. epidermidis (gram positive bacteria), 1 ml. aliquots of garlic extract (Example 10 dilutions (from 1:1 to 1:1000) were mixed with 100 μl of S. epidermidis (1.19×10 8 ) and plated on a trypticase soy agar (TSA) plate where they were allowed to grow for 24 hours at 37° C. A positive control without garlic extract was also plated. Visual inspection after 24 hours revealed that for undiluted garlic extract to 1:3 garlic extract:water dilutions, there was no bacterial growth at 24 hours. For dilutions of 1:4 to 1:10 there were fewer colonies and small colony size compared to control. Effects at dilutions of 1:100 to 1:1000 were negligible. In broth, garlic extract can prevent S. epidermidis from growing over a 96-hour period.
Example 6. Bacteriostatic Effects of Garlic Extract on Yersinia entercolitica in Broth
[0080] Effect on Yersinia entercolitica growth in trypticase soy broth (TSB) was also tested. Three ml. aliquots of 5.0×10 6 cfu/ml were mixed with garlic extract dilutions in cuvettes as follows:
[0081] Control—no garlic w/25 ml TSB
[0082] 1:5 garlic—1.0 ml garlic w/4 ml TSB
[0083] 1:10 garlic—0.5 ml garlic w/4.5 ml TSB
[0084] The cuvettes were vortexed, capped and sealed, and incubated in a 37° C. Rosi incubator at 120 rpm. Samples were spectrophotometrically observed over a 96-hour period. FIG. 2 shows results. Even at 1:10 dilution, Yersinia entercolitica growth is affected.
Example 7. Bacteriostatic Effect of Garlic Extract on Escherichia coli in Platelets
[0085] The procedure of Example 4 was followed to test the bacteriostatic effect of garlic extract on Escherichia coli with platelets, using approximate starting titers of 1 log and 2 logs of E. coli . Results are shown in FIGS. 3A and 3B.
Example 8. Bateriostatic Effect of Garlic Extract on Staphylococcus aureus in Platelets
[0086] The procedure of Example 4 was followed to test the bacteriostatic effect of garlic extract on Staphylococcus aureus in platelets using a starting titer of ˜1.0×10 4 . Results are shown in FIG. 4A. The 1:10 preparation was bacteriostatic for 24 hours and the 1:5 preparation was bacteriostatic for 72 hours.
Example 9. Bacteriostatic Effect of Garlic Extract on Staphylococcus aureus in Plasma
[0087] To test the bacteriostatic effect of garlic extract on Staphylococcus aureus in plasma, plasma was inoculated to a starting titer of ˜2.5×10 2 . After incubation of sample containing no garlic extract, 1:5 garlic extract to plasma, and 1:10 garlic extract to plasma, results were assayed. Results are shown in FIG. 4B.
Example 10. Bacteriostatic Effect of Garlic Extract on Klebsiella pneumoniae in Platelets
[0088] The procedure of Example 4 was followed to test the bacteriostatic effect of garlic extract on Klebsiella pneumoniae in platelets using a starting titer of 5.0×10 2 . Results are shown in FIG. 5.
[0089] It will be readily understood by those skilled in the art that the foregoing description has been for purposes of illustration only and that a number of changes may be made without departing from the scope of the invention. For example, other compounds from allium species, and other allicin analogs and derivatives than those mentioned may be used, preferably those which are not toxic and do not have toxic breakdown products. The embodiments described herein are merely exemplary, and changes and modifications in the specifically-described embodiments can be carried out by one skilled in the art without departing from the scope of the invention. All such changes and modifications are intended to be included within the scope of the invention as defined in the appended claims. | Methods and compositions prolonging the storage life and/or increasing the safety of a blood product, such as whole blood, red blood cells, white blood cells, platelets, serum and aqueous additive solutions for storage of such blood products are provided. Storage solutions of this invention comprise a composition selected from the group consisting of garlic extract, allicin, other microorganism-growth-inhibiting compounds derived from garlic, and analogs and derivatives of allicin and said other compounds, in an amount effective to inhibit growth of at least one selected microorganism which is a bacterium, virus, fungus or parasite. The storage additive solutions of this invention can increase platelet storage life by at least about 20%, preferably at least about 40%. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the control of fume formation in steel mill blast furnace cast houses and more particularly to the suppression and mitigation of fumes from the iron troughs and the iron and the slag runners of the blast furnace casting system.
One of the most critical problems faced by the steel industry is the control of blast furnace cast house emissions. It is evident that the industry must develop new techniques for pollution controls if it is to obviate the substantial capital and operating costs associated with available technology for controlling blast furnace cast house emissions to levels required by governmental environmental protection agencies. Technology for emission reduction through gas cleaning exists and can be accomplished by a number of air pollution control devices which utilize exhaust and filtering equipment which collect and clean the fugitive air. However, it should be recognized that in the United States a great majority of the presently operating blast furnaces were built before 1960 and use the original cast houses in which there are spatial limitations toward retrofitting additional equipment such as pollution collection devices.
2. Description of Prior Art
The known prior art fume control systems which can be used in conjunction with steel mill blast furnaces are directed to the disposal of the fume after it has been generated.
U.S. Pat. No. 3,994,210 discloses method and apparatus by which jets in the form of moving curtains of air are utilized to control and direct the movement of fume from a fume-generating apparatus to an exhaust hood opening.
French Pat. No. 71.13332 is more specifically directed to the channeling of smoke emitted by molten cast iron as it is extracted from a blast furnace through the use of blower nozzles which laterally direct air curtains to limit lateral movement of the smoke and direct it to a ventilating head.
German Pat. No. 2,157,418 discloses an air cleaning device for the pouring platform of a blast furnace, which device comprises suction nozzles connected to a gas cleaner at the outlets of the filling hoppers and/or over the tap holes.
Additionally, there appears in the August 1979 issue of Iron and Steel Engineer, pp. 33-39, an article entitled "Blast Furnace Cast House Emission Control" by A. G. Nicola which sets forth the available technology for collecting the process fugitive emissions generated in the blast furnace cast house.
It is evident that most prior art fume pollution control systems are addressed to the ventilation or exhausting of fumes after they are formed, i.e., they are addressed to the effect rather than the cause.
SUMMARY OF THIS INVENTION
It is a primary object of this invention to provide method and apparatus to suppress and/or mitigate the formation of objectionable fume during the tapping of a blast furnace and the flow and pouring of iron therefrom.
In blast furnace case houses much fume is generated during the tapping of the furnace. It is believed that most of the fume is generated by the iron leaving the furnace contacting the oxygen of the ambient air and thereby forming iron oxide. Some of the fume is also generated by virtue of the sulfur in the molten iron and/or slag coming into contact with oxygen and forming sulfur dioxide.
This invention proposes to suppress the formation of obnoxious fume by providing method and apparatus for isolating much of the air from the molten metal and slag streams as they are discharged from the blast furnace and/or from the molten streams as they flow toward and to the collection vessels.
In the aforementioned Nicola article it is pointed out that basically, the fumes generated in the cast house are approximately 75% iron oxide and there is also outlined the reasons why the transfer of Japanese technology for cast house emission control on existing blast furnaces in the United States is not a simple matter. It further discloses that the primary emission control based upon the Japanese approach consists of capturing the cast house fumes at their source with close fitting hoods. It is very apparent that while hoods and other enclosures are described as being part of the Japanese approach such enclosures are employed as ductwork for directing the ventilating air with the entrained pollutants to collection devices such as baghouses.
Thus, the Nicola article points up the fact that prior cast house emission control is primarily concerned with the evacuation of fumes and emissions after they are formed. The present invention is contradistinctive because it is concerned with the suppression of the formation of the iron oxide fumes. The invention provides method and apparatus which exclude oxidizing gases, including the ambient air, during the tapping of the blast furnace from the area surrounding the tap hole, the iron trough and the iron and the slag runners. It will be recognized that it may not be possible to provide an absolutely air tight system, however, the formation of iron oxide and other pollutants formed by combining with oxygen is suppressed, primarily because there is no purposeful addition of air as an evacuation medium as there is in ventilating systems. However, it will be understood that an inert gas may be circulated over the molten streams from the blast furnace to occlude oxidizing gases and more particularly to restrain the infiltration of ambient air into the molten streams.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a schematic representation in plan view of a typical blast furnace and runner system;
FIG. 2 is a side elevational view of fragmentary portion of a blast furnace and an iron trough together with an enclosure of this invention for the iron trough;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a transverse cross-sectional view of an enclosure for the iron and the slag runners; and
FIG. 5 is a fragmentary longitudinal sectional view of two adjacent enclosures of the type shown in FIG. 4 shown in conjunction with a runner gate and means for creating end curtains.
DESCRIPTION OF PREFERRED EMBODIMENTS
A typical embodiment of this invention is illustrated in FIG. 2 in conjunction with a blast furnace cast house system such as schematically illustrated in FIG. 1. It will be appreciated by those skilled in the art that there are many variations of the iron trough, iron runners, and slag runners used in connection with a blast furnace with which the principals of this invention can be applied.
The blast furnace and the discharge notch are generally designated by the reference characters BF and N, respectively. The molten material, comprising iron and slag, is intermittently tapped from the furnace BF through the notch N which extends downwardly from the outside of the furnace through the water cooled hearth jacket toward the hearth. The notch N is plugged after each cast with a clay mixture forced in the notch hole under pressure by means of a mud gun (not shown) which is latched onto latch support LS. As the notch N is opened during a tapping, the molten material flows out into a large trough IT, generally referred to as an iron trough. There is skimmer means S at the end of the trough IT which serves to skim off the slag from the molten material in the trough. The skimmer means S in some systems may include a dam (not shown) which may serve to help maintain the level of the molten material higher than the bottom of the skimmer plate. At the skimmer S there is an arrangement of gates G and runners SR to carry off the slag S to slag collector means SC, such as a slag pot or a large pit. The iron flowing under the skimmer plate runs down troughs IR, commonly referred to as iron runners, which are also fitted with gates G to selectively divert the flow to each of several iron ladles IL. At the end of a cast or tapping, the mud gun is placed in position to plug the notch hole with clay. It is at this stage that special provision must be made to handle the section of enclosure surrounding the tap or notch hole in order to provide access by the mud gun to the notch.
As indicated above, the present invention relates to the provision of method and apparatus for occluding the ambient air from the surface of the molten stream as it flows from the blast furnace toward the iron ladle and the slag collection means. In accordance with a preferred embodiment of the invention occlusion means in the form of hoods H are provided to minimize the amount of ambient air which contacts the molten streams and without the addition of any air within the hoods as is the practice in forced ventilating hoods. The various types of hoods are further designated by numeral suffixes.
There is provided immediately adjacent to the blast furnace BF a hood H-1 which covers the iron trough. It is preferred to provide separate hoisting and transport mechanism, generally designated by the reference HTM, for lifting and moving the hood H-1 away from the tap hole in preparation for the tapping and plugging procedures. The cross-sectional configuration of hood H-1 is preferably in the form of an inverted U. The hood H-1 is comprised of several panel sections P which are joined together, such as by welding the upturned edges of the outer casings which form stiffening flanges. The section P-1 has a slanted top tapered toward the blast furnace and terminating in a nose portion to provide an end closure which will also accommodate positioning of the hood H-1 beneath the clay gun support LS. The opposite end section P-2 has a vertical wall portion W-1 to likewise provide an end closure. Each of the sections P are provided with insulation to protect the metal cover. Preferably, there are provided two layers of insulation anchored to the cover by metal clips; the innermost layer L-1 in respect to the trough, being of the non-consumable refractory type and the outermost layer L-2, in respect to the trough, having higher insulating quality than the layer L-1. Each of the layers L-1 and L-2 may be applied as by gunning, at the site.
Some of the sections, such as section P-3, are provided with upstanding flanges F which define holes for inserting the fastening means such as hooks of the hoisting and transport mechanism HTM.
The hoods H-2 are provided to enclose the iron runners IR and the slag runners SR. The hoods H-2 are similar in construction as hood H-1 except that they are smaller in their cross-sectional configurations. Also, in a preferred form, the hoods H-2 include the end vertical wall closures W-2. This end wall W-2 may be supplemented with a flexible blanket of insulating material B draped over support rod R or a curtain of inert gas through conduit means such as pipe C-1. Preferably, pipe C-1 is formed to correspond to the end cross-section of hood H-2, i.e., it is generally semi-circular in shape and has a plurality of nozzles for discharging the inert gas and creating the vertical curtain or blanket for occluding the ambient air. The pipe is suitably attached to line supply means through releasable coupling means. The reason for preferring the inert gas curtain type of end seal is that the height of the molten material in the runners will vary and hence it would be impossible to provide a mechanical seal which would be self-adjusting to compensate for the variations in the height of the material flow.
Alternatively and/or additionally, inert gas supply means may be provided within the hoods H in the form of conduit C-2 which extend longitudinally of and on either or both sides of and within the hoods H. The hoods H would thus serve to contain the inert gases and create a blanket over the surface of the molten material. In a less preferred embodiment the inert gases would be used to create a blanket in the absence of the confining hoods H through the use of pipe means extending longitudinally of each side of the troughs and runners.
Alternatively and/or additionally, an inert non-combustible material such as vermiculite may be provided on top of the iron or slag to create a floating blanket FB over the surface of the molten material MM. This floating blanket would be kept in position by the use of suitable means, e.g., a suspended carbon skimmer which extends just below the surface of the molten material.
Also there may be provided between the hoods H and the tops of the troughs and runners yieldable non-combustible sealing means SM, such as sand or refractory fiber felt.
Thus, unlike the prior art systems which rely upon evacuating the cast house air with entrapped emissions, the present invention is directed toward restraining the formation of the objectionable pollutants. Through the use of the method and apparatus of this invention the occlusion of the ambient cast house air from the surface of the molten iron and slag is enhanced and the formation of iron oxides is suppressed. A further advantage of the present invention is one of confining the natural kish which is formed on the surface of the molten iron. A still further and important advantage is that the "hot metal", molten iron, is delivered to the iron ladles at a relatively high temperature since there are no massive air currents moving across the surface of the molten iron in the troughs as there are in air ventilating systems. The hotter molten metal and iron runners result in less iron skull formation in the runners and a concomitant increase in iron yield. Still further, the invention provides method and apparatus which may be readily and safely embodied in existing blast furnace cast house systems and at relatively little cost as compared to pollutant collection systems which require additional equipment and space for the ducts and filter baghouses, which collection systems also pose health and safety hazards because of the problems encountered in the disposal of the collected dust. A further disadvantage of such collection systems is that they consume considerable energy as compared to the system of this invention. | Method and apparatus for suppressing formation of pollutants in a blast furnace casting system by occluding oxidizing gases, including ambient air, from the molten iron and slag discharged from the furnace. | 2 |
TECHNICAL FIELD
[0001] The present disclosure relates generally to a fuel system and, more particularly, to a fuel system having a filter assembly with a valve cover.
BACKGROUND
[0002] A typical fuel system includes a pump that draws fuel from a tank, pressurizes the fuel, and directs the pressurized fuel through a supply passage and filter to one or more fuel injectors. A first check valve is disposed within a return line that extends from the fuel injectors back to the tank, and a second check valve is disposed in parallel with the filter. In order for the fuel system to function properly, the system should be generally free of air and free of undue flow restrictions (e.g., restrictions caused by plugging of the filter).
[0003] Historically, the air-free and restriction-free status of a fuel system was confirmed by way of one or more sight-glasses plumbed in-line with the first and second check valves. For example, a first sight-glass was associated with the first check valve and used to determine that the supply and return passages were free of air, while a second sight-glass was associated with the second check valve and used to determine that the filters were not clogged. In particular, when the first sight-glass was full of fuel, it could be concluded that the supply and return passages were generally air-free. And as long as the second sight-glass was empty of fuel, it could be concluded that the filter was creating little restriction on the fuel flow. Such a system is disclosed in a maintenance manual entitled “645E BLOWER-TYPE ENGINE MAINTENANCE MANUAL”, 5 th edition, which was published in January 1980.
[0004] A conventional sight-glass includes a transparent glass bowl that is inverted, having its rim pressed against a cast filter base. A gasket or other seal is sandwiched between the rim of the glass bowl and a machined face of the base. An arcuate bracket extends from the base at one side of the glass bowl over the closed end of the glass bowl to an opposing side. A bolt is threadingly engaged with the bracket at a center of the glass bowl, and is adjustable to press the center downward toward the rim. This downward pressing functions to urge the rim of the glass bowl against the gasket, thereby sealing the sight-glass against the base.
[0005] Although the use of a sight-glass may be effective in determining the status of a fuel system, the sight-glass can also be problematic. In particular, the sight-glass (e.g., the glass bowl and/or the arcuate bracket holding the glass bowl) is subject to extreme vibration in some applications. These vibrations, if not accounted for, can cause the glass bowl and/or the arcuate bracket to fail.
[0006] The disclosed fuel system and filter assembly are directed to overcoming one or more of the problems set forth above and/or other problems of the prior art.
SUMMARY
[0007] In one aspect, the present disclosure is directed to a filter assembly for a fuel system. The filter assembly may include a base with a first side, and a second side opposite the first side. The filter assembly may also include a filter extending from the first side of the base, a valve extending from the second side of the base, and a metallic cover having a closed end surrounding the valve and an open end located adjacent the second side of the base. The filter assembly may further include a seal sandwiched between the metallic cover and the base, a retainer connected to the base and extending over the metallic cover, and a fastener threadingly engaged with the retainer and protruding inward to press the metallic cover toward the base.
[0008] In another aspect, the present disclosure is directed to another filter assembly for a fuel system. This filter assembly may include a base having a first side and a second side opposite the first side, a filter extending from the first side of the base, and a valve extending from the second side of the base. The filter assembly may also include a cover having a closed end surrounding the valve and an open end located adjacent the second side of the base, and a seal sandwiched between the metallic cover and the base. The filter assembly may further include a retainer having first and second sides connected to the base, and a third side extending over the cover between the first and second sides. The first, second, and third sides may form a generally C-shaped channel. The filter assembly may additionally include a fastener threadingly engaged with the third side of the retainer and protruding inward to press the cover toward the base.
[0009] In yet another aspect, the present disclosure is directed to a fuel system. The fuel system may include a tank, a pump connected to draw fuel from the tank, a plurality of fuel injectors, and a manifold connecting the pump to the plurality of fuel injectors. The fuel system may also include a filter assembly disposed between the pump and the manifold. The filter assembly may have a base with a first side and a second side opposite the first side, a filter extending from the first side of the base, a first valve extending from the second side of the base, and a second valve located adjacent the first valve and extending from the second side of the base. The fitter assembly may additionally have a first metallic cover with a closed end surrounding the first valve and an open end located adjacent the second side of the base, and a second metallic cover with a closed end surrounding the second valve and an open end located adjacent the second side of the base. The filter assembly may further have a seal sandwiched between each of the first and second metallic covers and the base; and a first retainer with first and second sides connected to the base, and a third side extending over the first metallic cover between the first and second sides. The first, second, and third sides of the first retainer may form a first generally C-shaped channel. The filter assembly may also have a second retainer with first and second sides connected to the base, and a third side extending over the second metallic cover between the first and second sides. The first, second, and third sides of the second retainer may form a second generally C-shaped channel. The filter assembly may further have a first fastener threadingly engaged with the third side of the first retainer and protruding inward to press the first metallic cover toward the base, a second fastener threadingly engaged with the third side of the second retainer and protruding inward to press the second metallic cover toward the base, and a safety wire passing through a head of at least one of the first and second fasteners to inhibit loosening of the at least one of the first and second fasteners. The first and second metallic covers may each include a lip located at the open end to engage the seal and having a circular-lay roughness of about 125 μinch.
BRIEF DESCRIPTION OF THE DRAWING
[0010] FIG. 1 is a diagrammatic and schematic illustration of an engine having an exemplary disclosed fuel system;
[0011] FIG. 2 is a cross-sectional illustration of an exemplary disclosed filter assembly that may be used in conjunction with the fuel system of FIG. 1 ; and
[0012] FIGS. 3 and 4 are isometric illustrations of exemplary filter assembly embodiments.
DETAILED DESCRIPTION
[0013] FIG. 1 illustrates an engine equipped with having a fuel system 12 . For the purposes of this disclosure, engine 10 is depicted and described as being a four-stroke diesel engine. One skilled in the art will recognize, however, that engine 10 may embody any other type of internal combustion engine such as, for example, a two-stroke diesel, gasoline, or gaseous fuel-powered engine. Engine 10 may include a block 14 that at least partially defines a plurality of combustion chambers 16 . In the illustrated embodiment, engine 10 includes four combustion chambers 16 . However, it is contemplated that engine 10 may include a greater or lesser number of combustion chambers 16 and that combustion chambers 16 may be disposed in an “in-line” configuration, in a “V” configuration, in an opposing-piston configuration, in a rotary configuration, or in any other suitable configuration.
[0014] As also shown in FIG. 1 , engine 10 may include a crankshaft 18 that is rotatably disposed within block 14 . A connecting rod (not shown) associated with each combustion chamber 16 may connect a piston (not shown) to crankshaft 18 so that a sliding motion of each piston within the respective combustion chamber 16 results in a rotation of crankshaft 18 . Similarly, a rotation of crankshaft 18 may result in a sliding motion of the pistons.
[0015] Fuel system 12 may include components that cooperate to deliver injections of pressurized fuel into each combustion chamber 16 . Specifically, fuel system 12 may include a tank 20 configured to hold a supply of fuel; and a pump 22 connected to draw fuel from tank 20 , to pressurize the fuel, and to direct the pressurized fuel to a plurality of fuel injectors 24 by way of a manifold 26 . Pump 22 may be connected to tank 20 via a suction passage 28 , and to manifold 26 via a supply passage 29 . A check valve 30 may be disposed within suction passage 28 , if desired. Manifold 26 may be connected to tank 20 via a return passage 34 .
[0016] Pump 22 may be connected with crankshaft 18 in any manner readily apparent to one skilled in the art, where a rotation of crankshaft 18 will result in a corresponding rotation of a pump driveshaft. For example, pump 22 is shown in FIG. 1 as being connected to crankshaft 18 through a gear train. It is contemplated, however, that pump 22 may alternatively be driven electrically, hydraulically, pneumatically, or in another appropriate manner.
[0017] Fuel injectors 24 may be disposed within cylinder heads (not shown) of engine 10 , and sequentially fluidly connected to manifold 26 . Fuel injectors 24 may be directly connected to manifold 26 such that all of the fuel flowing through manifold 26 also flows through each individual injector 24 or, alternatively, fuel injectors 24 may be connected to common manifold 26 by a plurality of individual fuel lines 32 . Each fuel injector 24 may be operable to inject an amount of pressurized fuel into an associated combustion chamber 16 at predetermined timings, fuel pressures, and quantities. The timing of fuel injection into combustion chamber 16 may be synchronized with the motion of the corresponding piston (not shown) reciprocatingly disposed therein. In the depicted embodiment, fuel injectors 24 are mechanical unit injectors (MUI injectors). It is contemplated, however that fuel injectors 24 could alternatively embody mechanically-actuated, electronically-controlled unit injectors (MEUI injectors); hydraulically actuated, electronically-controlled unit injectors (HEUI injectors); or any other type of fuel injectors known in the art.
[0018] A filter assembly 36 may be plumbed between pump 22 and manifold 26 , and also between manifold 26 and tank 20 . As shown schematically in FIG. 2 and physically in FIGS. 3 and 4 , filter assembly 36 may include a base 38 , and one or more canister filters (filters) 40 hanging from a lower side 42 of base 38 . First and second check valves 44 , 46 may be mounted to an upper side 48 of base 38 opposite filters 40 . During normal operation (e.g., when filters 40 are not plugged), pressurized fuel from pump 22 may flow into base 38 and split via a pair of branch passages 50 into two parallel flows that pass through filters 40 . The separate flows may then recombine within base 38 and be discharged as a single flow to manifold 26 .
[0019] During abnormal conditions, for example when plugging of one or more of filters 40 creates a restriction to the flow through branch passages 50 , a fuel pressure inside base 38 may rise. This high-pressure fuel, in addition to communicating with filters 40 , may also be directed to check valve 46 via a bypass passage 52 . When the fuel pressure exceeds an opening pressure of check valve 46 (e.g., about 60 psi), check valve 46 may open and allow the fuel to pass back to tank 20 via return passage 34 .
[0020] Check valve 44 may be in communication with return passage 34 (e.g., via a passage 54 formed in base 38 ), and function as a priming valve. In particular, during startup of pump 22 , check valve 44 may remain closed, allowing the fuel pumped into manifold 26 to build in pressure. When manifold 26 has been adequately filled with fuel, and the fuel therein reaches a desired operating pressure (e.g., about 5 psi or higher), check valve 44 may open and allow excess fuel and air to pass from return passage 34 through passage 54 to tank 20 . Thus, during normal operation of fuel system 12 , some fuel should continuously be passing through check valve 44 .
[0021] In earlier iterations of fuel system 12 , sight glasses 56 (shown as dashed lines only in FIG. 2 ) were disposed over check valves 44 and 46 , and formed portions of passages 52 and 54 . In particular, after the fuel was discharged from check valves 44 , 46 , the fuel exited base 38 and entered into an interior space of sight glasses 56 . This fuel then passed from sight glasses 56 back into base 38 to continue its flow through passages 52 and 54 . In this way, the fuel being discharged from check valves 44 and 46 could be visible to an operator of engine 10 . For example, when filters 40 were plugged, fuel would have been visible within the sight glass 56 covering valve 46 ; and when manifold 26 was filled and properly pressurized, fuel would have been visible within the sight glass 56 covering valve 44 . Thus, during normal operation, fuel should only have been visible within the one sight glass 56 covering valve 44 (i.e., the sight glass 56 covering valve 46 should normally have been empty, as long as filters 40 were not plugged). However, for reasons stated above, sight glasses 56 are no longer utilized in the disclosed embodiments.
[0022] In the disclosed embodiments, sight glasses 56 have been replaced with metallic valve covers (covers) 58 (shown only in FIGS. 3 and 4 ). Like the previously used sight glasses 56 , covers 58 may have a dome shape, with a closed end 60 and an open end 62 . A lip 64 may be formed at open end 62 that is received within a machined recess 66 of base 38 . A seal (e.g., a gasket) 68 may be disposed in recess 66 and sandwiched between lip 64 and the internal face of recess 66 . In some embodiments, lip 64 may have a circular-lay roughness of about 100-150 μinch (e.g., about 125 μinch), which may help lip 64 engage with seal 68 to create a fuel-tight interface.
[0023] In the disclosed embodiment, the closed end 60 of each cover 58 is spherical. It is contemplated, however, that the closed end could alternatively be flat, such that cover 58 has more of a cylindrical shape than a domed shape, if desired. Other shapes may also be possible. Cover 58 may be fabricated from a non-corrosive metal, for example stainless steel or aluminum, through a deep-draw process.
[0024] A retainer 70 may pass over the closed end 60 of cover 58 and, together with a fastener 72 , function to press cover 58 against seal 68 . In the embodiment shown in FIG. 3 , a single retainer 70 is used in conjunction with two covers 58 . Retainer 70 may be formed from a generally C-shaped channel that extends lengthwise past the centers of each cover 58 . In particular, retainer 70 may include a first side 74 connected to base 38 at one edge of cover 58 , a second side 76 connected to base 38 at a second edge opposite first side 74 , and a third side 78 that extends between first and second sides 74 , 76 . Each of first and second sides 74 and 76 may be oriented generally perpendicular to third side 78 .
[0025] A threaded hole 80 may be formed within third side 78 of retainer 70 , at a location generally aligned with the center of each cover 58 . Fastener 72 may engage threaded hole 80 , such that rotation of fastener 72 extends a shaft portion of fastener 72 inward through retainer 70 and against the center of the corresponding cover 58 . With this configuration, further rotation of fastener 72 may cause fastener 72 to engage the center of cover 58 and urge cover 58 against seal 68 . In some embodiments, cover 58 may be recessed at fastener 72 to receive a tip of fastener 72 .
[0026] In order for retainer 70 to properly anchor fastener 72 and withstand vibrational loading during operation of engine 10 , retainer 70 must have a minimum thickness at third side 78 . In the disclosed embodiment, the thickness of third side 78 may be at least two-times a wall thickness of cover 58 . For example, the thickness of third side 78 may be about 0.25 inch, while the wall thickness of cover 58 may be about 0.12 inch. The three-sided, generally orthogonal shape of retainer 70 may help to increase a stiffness of retainer 70 that further helps retainer 70 to resist damage caused by the vibrational loading. It is contemplated that additional internal ribbing (not shown) could be formed within retainer 70 , if desired, to further increase the stiffness of retainer 70 .
[0027] In some applications, it may be possible for the vibrational loading of engine 10 to cause fasteners 72 to back out of hole 80 . To help fasteners 72 resist this tendency, a cross-hole 82 may be formed through a head portion of each fastener 72 , and a safety wire 84 may simultaneously pass through cross-holes 82 of both fasteners 72 , thereby binding the rotations of fasteners 72 to each other. This binding may inhibit rotation of either fastener 72 .
[0028] First and second sides 74 , 76 of retainer 70 may connect to base 38 at a plurality of different anchor points. For example, four different ears or tabs 86 may be integrally formed with base 38 , and extend upward from upper surface 48 . Ears 86 may be located outward of first and second sides 74 , 76 , and arranged in pairs that are each generally aligned with one of covers 58 (e.g., the center of the corresponding cover 58 ). A fastener 88 may pass through each ear 86 to engage retainer 70 . It is contemplated that a vibration damper (e.g., a compressive washer —not shown) may be located at the interface of ear 86 and cover 58 , if desired. In this configuration, retainer 70 may be generally fixed to base 38 , such that little (if any) relative pivoting occurs.
[0029] Two separate retainers 90 are used in place of retainer 70 in the embodiment of FIG. 4 . Specifically, one retainer 90 is used to retain each cover 58 in place relative to base 38 . Each retainer 90 , like retainer 70 , may be a generally 3-sided structure formed into a C-shaped channel. A length of retainer 90 , however, may be less than one-half of a length of retainer 70 . In addition, each retainer 90 may be connected to base 38 by way of only two ears 86 (one at each of first and second sides 74 , 76 ). Further, a clearance may exist between upper side 48 of base 38 and lower edges of first and second sides 74 , 76 . With this configuration, each retainer 90 may be able to pivot independently somewhat about an axis passing through its corresponding fasteners 88 . This pivoting motion may help to center fastener 72 with the center of cover 58 . In addition, in some embodiments, cover 58 may be able to pivot and/or translate somewhat relative to the associated retainer 90 (or 70 ), if desired.
[0030] Because covers 58 are metallic, in one embodiment, they may not be translucent in the same manner that the previously-used sight glasses 56 were transparent. As a result, the proper functioning of fuel system 12 may no longer be visually apparent. For this reason, one or more sensors may be connected to base 38 and in fluid communication with the appropriate passages. For example a first pressure sensor 92 may be connected to base 38 and located in fluid communication with passage 52 (referring to FIG. 1 ), and a second sensor 94 may be connected to base 38 and located in fluid communication with passage 54 . Each of these sensors 92 , 94 may be configured to generate signals indicative of fuel pressures within the corresponding covers 58 , the signals then being utilized to determine the air-free and restriction-free status of fuel system 12 .
INDUSTRIAL APPLICABILITY
[0031] The disclosed fuel system and filter assembly may be applicable to any combustion engine where reliable and continuous operation is desired. The disclosed fuel system may help to improve reliability and facilitate continuous operation by reducing a risk of component failure within the filter assembly. In particular, the disclosed filter assembly may include valve covers that are robust, and associated retainers and fasteners that have been designed to reduce and/or withstand vibrational loading of the associated engine.
[0032] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed fuel system and filter assembly. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed fuel system and filter assembly. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents. | A filter assembly is disclosed for use with a fuel system. The filter assembly may have a base with a first side, and a second side opposite the first side. The filter assembly may also have a filter extending from the first side of the base, a valve extending from the second side of the base, and a metallic cover having a closed end surrounding the valve and an open end located adjacent the second side of the base. The filter assembly may further have a seal sandwiched between the metallic cover and the base, a retainer connected to the base and extending over the metallic cover, and a fastener threadingly engaged with the retainer and protruding inward to press the metallic cover toward the base. | 5 |
[0001] This application claims the benefit of the earlier filed Provisional Application Ser. No. 60/196,719, filed Apr. 13, 2000.
FIELD OF THE INVENTION
[0002] The invention pertains to crutches. More particularly, the invention pertains to adjustable and potentially relatively inexpensive crutches.
BACKGROUND OF THE INVENTION
[0003] Crutches have been long been known and have been used by individuals who are recuperating from injuries to hips, legs, ankles or feet. Since users have a variety of physical characteristics, including height and arm length, known crutches which are usually implemented of wood or tubular aluminum provide adjustment in the over-all length of the crutch as well as relatively grip location.
[0004] In known crutches, a plurality of adjustment holes is provided in the tip end such that the over-all length can be altered, increased or decreased, by positioning the tip relatively to the body of the crutch. The tip is usually locked to the body of the crutch with a plurality of screws or other mechanical fasteners.
[0005] The grip or the handle can be positioned adjacent to one of a plurality of holes in the crutch frame or body. One or more screws is extended through the body, through the handle or grip into the other side of the body or frame locking the two parts together.
[0006] Known crutches suffer from two long term and recurring defects. One problem with known crutches is their cost. Despite the fact that crutches have been available for many years, they are still expensive enough that they represent a significant cost to patients. Additionally, known crutches require two separate adjustments, one to adjust the over-all length as noted above and, a second to adjust the position of the grip relative to either end of the crutch.
[0007] There continues to be a need for improvements in crutches. Preferably, different materials might be used to promote cost reduction while at the same time providing adequate strength for usage of the crutches. In addition, it would be desirable to be able to move beyond two-point adjustment configurations to simplify and improve the fitting process. At the same time, improved fitting may well result in greater effectiveness and ease of use by patients than has heretofore been possible.
SUMMARY OF THE INVENTION
[0008] A crutch with a single point adjustment has a two-part body which could be formed, for example, of wood, metal or cured resin. One part of the body has a tip formed thereon. The other part has a curved shoulder end. The two parts of the body slidably engage one another in a telescoping fashion to provide an adjustable axial length.
[0009] A handle or gripping element can be positioned on the body at a selected distance from, for example, the tip end. The grip or the handle is thereupon locked to the two-part body precluding relative movement among any of the parts of the body and the handle.
[0010] In one embodiment, one part of the body is hollow and slidably receives a portion of the second part of the body. The two parts of the body are axially movable relative to one another.
[0011] The portions of the body which include the two telescoping parts exhibit increased strength in response to applied lateral forces due to the presence of one part being received in the other. Preferably, the two parts have substantially identical cross sections at least in the region where they slidably engage one another. Representative cross sections include circular, elliptical, and polygons such as triangular, rectangular, square or other polygonal configurations.
[0012] The grip or handle, in one aspect of the invention, can be formed with two attached, axially oriented, hollow end sections each having an internal cross section compatible with an exterior cross section of one of the parts of the body. The handle can be slidably positioned on the body in accordance with the height and length of arms of the user.
[0013] In another aspect of the invention, one or more pins which can have a variety of cross sections can be inserted into the ends of the handle, as well as the two telescoped body sections thereby locking all three parts together and precluding relative motion therebetween. In another aspect of the invention, first and second pluralities of pins can be coupled through holes in the slidable end of the handle to engage corresponding holes or openings in the telescoped portions of the body of the crutch. Separate metal or plastic fasteners could also be used. All of these fasteners provide a single point adjustment for both length and handle location relative to either end of the crutch.
[0014] In one embodiment of the invention, the body parts and the handle can be molded of a curable resin such as 30 percent glass filled polypropylene. Such material, when cured, resists deflection and breakage and is very inexpensive. Alternately, other curable resins of sufficient strength, such as glass filled nylon, could also be used.
[0015] The molded body parts and handle can be over-molded with a 40 - 70 Durometer thermoplastic rubber. The over-molded material, which could be selected from a variety of commercially available moldable rubbers, is soft and deformable enough to provide a comfortable covering material for the handle as well as to form a cushion or pad at the shoulder end of one part of the body. Similarly, the thermoplastic rubber which is over-molded onto the tip end of the body can be expected to provide a non-slip gripping contact with the ground when the crutch is in use.
[0016] In another aspect of the invention, the two parts of the body as well as the handle can be molded in one or more colors in response to aesthetic requirements.
[0017] In another aspect of the invention, a method of fitting a crutch includes the steps of:
[0018] setting an over-all length of the crutch in response to physical characteristics of a user, without mechanically fixing the length for use;
[0019] positioning a handle on the crutch, relative to an end, in response to physical characteristics of the user, without mechanically fixing the handle for use; and
[0020] mechanically fixing the length and the handle to the crutch for use by means of at least one common fixing element.
[0021] In a further aspect, the fixing element can incorporate a plurality of common locking elements, such as a plurality of spaced apart pins. The pins can be laterally inserted into sliding sections of the handle as well as the two parts of the body of the crutch.
[0022] In yet another aspect of the invention, an adjustable crutch could be manufactured by a process which includes:
[0023] molding an upper body section;
[0024] molding a lower body section;
[0025] molding a core for a handle;
[0026] over-molding a pad on one end of the upper section;
[0027] over-molding a tip on one end of the lower section;
[0028] over-molding a comfortable covering on the core;
[0029] assembling the crutch by sliding the handle onto a free end of one of the sections of the body, slidably engaging free ends of the two sections of the body; and
[0030] inserting a common mechanical locking element to lock the handle as well as the two sections of the body together thereby precluding relative movement therebetween.
[0031] Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 is an exploded view of a crutch in accordance with the present invention;
[0033] [0033]FIG. 2A is a front elevational view of a handle for the crutch of FIG. 1;
[0034] [0034]FIG. 2B is a side elevational view of the handle of FIG. 2A;
[0035] [0035]FIG. 3 is an enlarged, fragmentary, front elevational view of the handle of the crutch of FIG. 1 illustrating various relationships with the body members thereof;
[0036] [0036]FIG. 4 is a sectional view taken along plane 4 - 4 of FIG. 3;
[0037] [0037]FIGS. 5A and 5B are front elevational views of the crutch of FIG. 1 illustrating adjustment for different lengths;
[0038] [0038]FIG. 5C is a side elevational view of the crutch of FIG. 5B;
[0039] [0039]FIGS. 6A, 6B, 6 C, and 6 D are sectional views taken along plane 6 - 6 of FIG. 3; and
[0040] [0040]FIG. 7 is a front elevational view of an alternate embodiment of the crutch of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] While this invention is susceptible of embodiment in many different forms, there are shown in the drawing and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0042] [0042]FIG. 1 is an exploded view of a crutch 10 in accordance with the present invention. The crutch 10 is formed of first and second body sections indicated generally at 12 and 14 . A handle 16 is carried on a crutch 10 , as discussed in more detail subsequently, oriented generally laterally with respect thereto.
[0043] In a preferred embodiment, body sections 12 , 14 and handle 16 would all be injection molded using 30 percent glass filled polypropylene. This resin is not only strong but is relatively inexpensive.
[0044] The handle 16 is molded with a plurality of grooves 16 a , best illustrated in FIG. 2A. Subsequent to molding the members 12 , 14 and 16 , each of them is over-molded in part, as explained below, with a commercially available thermoplastic rubber. Grooves 16 a contribute to locking the over-molded rubber to handle 16 .
[0045] Representative thermoplastic elastomers which are usable on the crutch 10 fall in a range of 40-70 Durometer. The preferred degree of softness is on the order of 50 Durometer.
[0046] Upper body section 12 is formed with first and second, spaced apart, elongated members 20 a , 20 b . The members 20 a , 20 b are molded with a plurality of openings therethrough indicated generally at 22 a and 22 b . As discussed in more detail subsequently, the openings 22 a, b contribute to the implementation of a single point adjustment system for the crutch 10 . The members 20 a, b are joined by a laterally extending web 24 a and a curved upper pad support 24 b.
[0047] The lower body portion 14 is molded with first and second spaced apart, elongated, hollow side sections 30 a , 30 b . Each of the side sections 30 a , 30 b is perforated with a plurality of openings 32 a and 32 b . The side members 30 a, b are joined by a curved lower member 30 c along with an integrally formed stem 30 d.
[0048] A laterally extending molded web 34 a joins the two side sections 32 a , 32 b . Additional molded webbing 34 b and 34 c joins the respective side members 30 a , 30 b to the curved region 30 c.
[0049] Subsequent to the process of molding members 12 , 14 and 16 , each of them is over-molded, in part, with the above-noted thermoplastic rubber. In this regard, curved pad support 24 b is over-molded with the elastomer to form a deformable comfort pad 38 a . The handle 16 is over-molded with deformable cover 38 b . Finally, stem 30 d is over-molded with a tip 38 c . Thus, the crutch 10 includes and is formed preferably of two different types of resins.
[0050] [0050]FIGS. 2A and 2B taken together illustrate additional details of handle 16 . The handle 16 is formed of integrally molded side sections 16 b and 16 c , each of which is hollow. The side sections 16 b , 16 c have an internal cross section which corresponds to the exterior cross section of side sections 30 a , 30 b . Each of the side sections 16 b , 16 c includes a respective set of perforations or openings therethrough 42 a and 42 b . The spacing of the openings 42 a , 42 b is such that they line up with respective ones of the openings 22 a , 22 b and 32 a , 32 b of sections 12 and 14 .
[0051] Handle 16 also carries integrally molded, hinged locking elements 44 . Each of the elements 44 can be pivoted, 44 a , into respective openings 42 a, b of the side sections 16 b , 16 c . As discussed subsequently, elements 44 lock members 12 , 14 and 16 together with a single point adjustment.
[0052] In addition to the side sections 16 b , 16 c sliding over side sections 30 a , 30 b , side sections 20 a, b have an exterior cross section which corresponds to an interior cross section of hollow members 30 a, b . Hence, body member 12 can be telescopingly received into body member 14 to provide for various over-all lengths of the crutch 10 . Adjustment between one length and another of crutch 10 is based upon the openings 22 a, b lining up with respective openings 32 a, b of lower body section 14 .
[0053] [0053]FIGS. 3 and 4 illustrate additional details of the interaction of handle 16 with side members 20 a, b and 30 a, b. As is illustrated therein, side sections 20 a, b are slidably received within side sections 30 a, b. The pluralities of openings 22 a, b, 32 a, b and 42 a, b include members which line up, best illustrated in FIG. 4, in response to the relative positioning of side sections 20 a, b relative to 30 a, b and relative to handle 16 . This alignment not only establishes an over-all length parameter for the crutch 10 , it also locates handle 16 relative to either end thereof.
[0054] Two opposed latch structures 44 - 1 and 44 - 2 , illustrated in FIG. 4, are carried on opposite sides of respective sections 16 b, c. These structures rotate toward each other to engage aligned openings such as openings 22 a - i , 32 a - i and 42 a - 8 exhibited by the three-layer structure. This three-layer structure is formed of side sections 20 a, b, 30 a, b and 16 b, c.
[0055] When extensions or pins, such as 46 a, b, c slidably engage the respective aligned openings such as openings 22 a - i , 32 a - i and 42 a - i , the length of crutch 10 and position of handle 16 thereon are permanently fixed. This thus provides a conveniently adjustable and inexpensive crutch assembly.
[0056] The crutch 10 , when molded of 30 percent glass filled polypropylene can be expected to resist a lateral deflecting force on the order of 160 pounds located at the center of the respective crutch, irrespective of its length, when the crutch 10 is oriented at a 45° angle relative to the horizontal FIGS. 5A and 5B illustrate the relative locations of side members 20 a, b and 30 a, b along with handle 16 for various crutch lengths. FIG. 5C, a side view of the crutch of FIG. 5B illustrates integrally molded lock members 44 - 1 and 44 - 2 .
[0057] As noted above, the interior cross section of handle sections 16 b , 16 c corresponds to the exterior cross section of side sections 30 a, b. Additionally, an exterior cross section of side sections 20 a, b corresponds to an interior cross section of side sections 30 a, b.
[0058] [0058]FIGS. 6A, B, C and D illustrate alternative cross sectional configurations for the members 20 a, b, 30 a, b and 16 b, c of the crutch 10 . FIG. 6A illustrates a rectangular cross section wherein side section 30 a ′ is surrounded by handle side section 16 b ′. Side section 30 a ′ in turn surrounds side section 20 a ′. Other closed polygonal sections come within the spirit and scope of the present invention and may be used. Alternates include triangular, three-sided, cross sections as well as a pentagon, five-sided, cross section all without limiting the scope of the present invention. Circular or elliptical cross sections could also be used.
[0059] [0059]FIG. 7 illustrates a crutch 10 ′ with a curved end 30 c ′ having an alternate shape. Other variations come within the spirit and scope of the invention.
[0060] It will also be understood that while a preferred embodiment has been disclosed as being molded of a curable resin, alternate materials such as wood or metal could be used without departing from the spirit and scope of the present invention. All such alternate embodiments would exhibit single point adjustment not only of crutch length but also of handle position in accordance with the present invention.
[0061] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | An inexpensive molded crutch has a single point adjustment mechanism for length and handle location relative to the ends of the crutch. The body of the crutch can be molded of a curable high strength inexpensive resin in two parts. The two parts telescopingly engage one another to set an over-all length for the crutch. The handle can be slid along one of the sections of the body to an appropriate position relative to either end of the body. The three parts can be locked together by one or more laterally oriented fasteners or pins which pass through one or more openings in each of the molded crutch members. | 0 |
BACKGROUND TO THE INVENTION
[0001] The present invention relates to a wheel assembly for a golf trolley.
[0002] Golf trolleys which can be pushed manually around a golf course are typically of a three-wheeled design, with a pair of rear wheels and a single front wheel. A base support frame is provided between the front and rear wheels, and an upright support frame extends upwardly from a point near the rear of the base support frame. A golf bag is typically rested on the front of the frame and leans rearwardly, over the rear wheels, the top of the golf bag being supported on the upright support frame. A handle extends upwardly and rearwardly from the upright support frame and the golf trolley is pushed from the rear by the handle.
[0003] Three-wheeled manual golf trolleys as described above may be foldable and may be stored compactly. However, many golf players find it difficult to push a golf bag on a trolley around a long and/or hilly course manually, and prefer a powered device.
[0004] Powered golf trolleys are known, and are typically driven by an electric motor powered by a rechargeable battery. However, the batteries must be large, heavy and expensive in order to provide enough stored energy to power a golf trolley around a golf course. This results in a golf trolley which is large and unwieldy, and will not fold up as compactly as a manual trolley. The large battery also takes some time to charge.
[0005] Since the useful lifespan of a battery is limited to a number of charging cycles, powered golf trolleys have a significant ongoing cost of ownership as well as being expensive to purchase in the first place.
[0006] A powered golf trolley typically has driven rear wheels. This requires either an axle between the two rear wheels, or a motor on each of the two rear wheels. An axle between the two rear wheels makes for a trolley which will not fold compactly, and a requirement for two motors increases the purchase cost of the trolley. Driving only one of the rear wheels makes the trolley difficult to steer.
[0007] A driven front wheel is an alternative, solving the problems with rear wheel drive mentioned above. However, the centre of mass of the loaded golf trolley is typically some way rearward of the front wheels, and a driven front wheel will therefore tend to spin due to insufficient traction with the ground.
[0008] It is an object of the invention to reduce or substantially obviate the above mentioned problems.
STATEMENT OF INVENTION
[0009] According to a first aspect of the present invention, there is provided a wheel assembly for a golf trolley comprising a wheel, a motor for driving the wheel, and a battery for powering the motor;
detection means for detecting whether or not the wheel is rotating, and a control unit for controlling the motor, the control unit having at least a first mode of operation in which the motor can be activated only when the wheel is already rotating; a user input means for positioning on a handle of the golf trolley, the user input means being wirelessly connected to the control unit; and releasable connection means for releasably connecting the wheel assembly to a golf trolley.
[0013] The wheel assembly when attached to a golf trolley provides for a ‘power assisted’ vehicle. Because the motor can be activated only when the wheel is already rotating, the power required by the motor will be small compared with the power which would be required to move the golf trolley from a standing start. This in turn means that the battery can be small, lightweight and inexpensive when compared with the batteries which are required for fully powered golf trolleys.
[0014] A golf trolley with the wheel assembly attached is lightweight and easy to handle. The golf trolley is power-assisted which improves the ease with which it can be pushed around a golf course. The battery can be charged quickly and the trolley may be folded for storage.
[0015] It will be understood that the control unit may have further modes of operation. For example, a second mode of operation may be provided in which the motor is activated whenever a button is pressed by a user. However, this second mode of operation will swiftly result in depletion of the battery due to the high power required by the motor to accelerate the vehicle from a standstill. It is therefore preferred to provide a control unit which operates only in accordance with the first mode of operation described above. Nevertheless, even with a flat battery, because of the lightweight nature of the wheel assembly, the golf trolley can be pushed with relative ease, unlike existing powered golf trolleys with a flat battery.
[0016] The control unit in the first mode of operation may automatically activate the motor when the detection means detects that the wheel is rotating.
[0017] Automatic activation provides for an effortless user experience. Pushing the trolley is easy because power assistance is automatically provided once the trolley is being pushed.
[0018] The control unit in the first mode of operation may automatically activate the motor when the detection means detects that the wheel is rotating faster than a predetermined speed. This further serves to preserve battery life, by ensuring that the motor is not activated in order to accelerate the golf trolley. Rather, the motor helps to maintain the trolley at a constant speed, assisted by the manual effort of the user. The predetermined speed may be 2 mph (0.89 m/s).
[0019] The control unit in the first mode of operation may activate the motor only when the detection means detects that the wheel is rotating and the user input means is activated. The user input means may be a pushbutton.
[0020] Providing a pushbutton or other input means allows the user to decide when he wishes to activate the power assistance on his golf trolley. For example, the trolley may be pushed manually on flat parts of the golf course, or for the first part of a round of golf. When the user becomes tired towards the end of the game, or when he is pushing the trolley up hills, power assistance may be desired and may be activated. Nevertheless, the control unit will only activate the motor when requested to do so by the user input means and when the wheel is already rotating. The battery life is thus conserved, because the motor is not powered when the golf trolley is accelerating from a standstill, and the motor is also not powered when the user is content to push the trolley himself.
[0021] Wireless communication of the pushbutton with the control unit for the motor is advantageous, since it allows the wheel assembly to be easily retro-fitted to a golf trolley, the wireless user input means being simply attached to a handle of the trolley, without any wiring being required. Even where the wheel assembly is sold together with the trolley as one product, it is advantageous to be able to remove the wheel assembly from the trolley so that the battery can be charged, perhaps indoors, whilst the bulk of the golf trolley is stored, possibly in a shed where an electricity supply may not be available. Providing wireless user input means as well as releasable attachment means facilitates removal of the wheel assembly from the golf trolley, since there are no wires to disconnect. This also allows the pushbutton to be attached anywhere the user desires on the handle of the golf trolley for comfortable operation.
[0022] Wireless user input means provide the further advantage that there are no wires running along the frame of the golf trolley which might become caught in trees, hedges and the like, or become fatigued due to repetitive folding of the golf trolley.
[0023] The battery may be disposed within the wheel. Providing the battery within the wheel puts the mass of the battery in the same vertical line as the driven wheel, when the golf trolley is in use. This increases the traction between the wheel and the ground, reducing the possibility that the driven wheel will spin.
[0024] Alternatively, the battery may be provided in a housing next to the wheel, substantially directly behind the wheel. Again, this puts the wheel substantially in line with the driven wheel and the weight passes substantially through the wheel. In a further alternative, the battery may be housed in the forks mounting the front wheel.
[0025] In this way, the battery is balanced across the wheel, and the centre of gravity of the battery may still pass through the wheel.
[0026] The releasable connection means may include a connecting member for introduction into a socket on the golf trolley. The connecting member may include a recess for engaging with a locking device on the socket of the golf trolley. A releasable connection means as described is quick and easy to connect and remove, but provides for secure attachment of the wheel assembly to the golf trolley. The locking device may include a large handle for locking and unlocking. A large handle is advantageous, since it can easily be operated by a user whose fingers have become cold after a long period outdoors.
[0027] In use, the wheel may be substantially in front of the connecting member and socket, so that the golf trolley is pushed in a direction substantially in-line with the connecting member and socket.
[0028] According to a second aspect of the invention, there is provided a golf trolley comprising a frame mounting two rear wheels, a front wheel, and a handle;
a motor for driving the front wheel, a battery for powering the motor, detection means for detecting whether or not the front wheel is rotating, and a control unit for controlling the motor; the control unit having at least a first mode of operation in which the motor can be activated only when the front wheel is already rotating, a user input means positioned on a handle of the golf trolley, and the user input means being wirelessly connected to the control unit.
[0032] Advantageously, the front wheel is the driven wheel. The rear wheels may be unpowered. This means that an axle is not required between the rear wheels, resulting in a golf trolley which is easily foldable into a compact unit for storage or carriage. As with the wheel assembly described above, the control unit prevents power from being supplied to the motor until manual effort has been applied to the golf trolley to initially accelerate it from a standstill. As well as ensuring a useful battery life from a small battery, this overcomes the problem that a driven front wheel will tend to spin due to an inadequate downward force provided by the mass of the golf trolley.
[0033] Because the wheel is only powered when it is already moving, power will only be applied when the trolley is being pushed from behind. The forward force applied by the user pushing the trolley forwards will transmit through the frame of the golf trolley, tending to pivot the golf trolley forward on the rear wheels, and this pushing the front wheel into the ground, ensuring that the front wheel finds traction. In this way, a power assisted golf trolley is made to work effectively with a powered front wheel.
[0034] The control unit in the first mode of operation may automatically activate the motor when the detection means detects that the front wheel is rotating. The control unit in the first mode of operation may automatically activate the motor when the detection means detects that the front wheel is rotating faster than a predetermined speed. The predetermined speed may be 2 mph (0.89 m/s).
[0035] The control unit in the first mode of operation may activate the motor only when the detection means detects that the front wheel is rotating and the user input means is activated. The user input means may be a pushbutton. The pushbutton may be mounted in any convenient location on the handle of the golf trolley.
[0036] The battery may be disposed substantially in-line vertically with the front wheel. The battery may be disposed within the front wheel. The battery may be disposed in forks on either side of the wheel. The forks may mount the wheel.
[0037] The front wheel may be part of a front wheel assembly which includes at least the front wheel, the motor, and the battery, the front wheel assembly being detachable from the golf trolley.
[0038] The frame may include a base support frame provided between the front and rear wheels and an upright support frame extending from the rear of the base support frame. The base support frame and the upright support frame may be provided with means for supporting a bag of golf clubs. The frame may be foldable.
[0039] Where the battery is disposed substantially in-line vertically with the front wheel, the mass of the battery serves to push the front wheel downwardly towards the ground. This further reduces the possibility that the front wheel will spin when it is powered.
DESCRIPTION OF THE DRAWINGS
[0040] For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which:
[0041] FIG. 1 shows a perspective view of a wheel assembly in accordance with the first aspect of the invention; and
[0042] FIG. 2 shows a perspective view of a golf trolley in accordance with the second aspect of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
[0043] Referring firstly to FIG. 1 , a wheel assembly for a golf trolley is indicated generally at 10 . The wheel assembly includes a wheel 12 and a wheel mounting 14 .
[0044] The wheel mounting 14 includes a pair of planar side members 16 , extending from a housing 18 . The wheel 12 is mounted on a bearing between the two side members 16 , and the housing passes over and around the wheel 12 . A battery 20 and a control unit 22 are disposed within the housing 18 , and a motor is provided to drive the wheel 12 . The battery 12 may be a Lithium-Ion battery, which provides an excellent power to weight ratio. It is found that a Lithium-Ion battery weighing around 300 g is suitable to provide enough power for power assistance around a typical 18-hole golf course.
[0045] A connecting member 24 extends from the rear of the wheel mounting 14 , and is in the form of a box section. The connecting member 24 includes a recess 26 in one surface, for receiving a bolt of a locking device.
[0046] The control unit 22 includes wireless receiving means for receiving a signal from a wireless pushbutton control 28 , with wireless communication indicated at 29 . In use, the control unit will activate the motor to drive the wheel 12 only when a signal is received from the wireless pushbutton control 28 and when the control unit 22 detects that the wheel is already rotating at a speed of at least 2 mph (0.89 m/s).
[0047] The speed of rotation of the wheel may be detected by Hall-effect sensors in the motor. Alternatively, any other suitable detection means may be used.
[0048] Referring now to FIG. 2 , a golf trolley is indicated generally at 30 . The golf trolley incorporates the wheel assembly 10 as a front wheel. The golf trolley 30 further includes a pair of rear wheels 32 , a base support frame 34 connecting the front and rear wheels, and an upright support frame 36 having a handle 38 .
[0049] A lower jaw 40 is provided on the front of the base support frame 34 , and an upper jaw 42 is provided on the upright support frame 36 . In use, the base of a golf bag 100 may be introduced into and grasped within the lower jaw 40 . The golf bag may then be rested against the upright support frame 36 and held within the upper jaw 42 .
[0050] A socket is provided at the front of the base support frame 34 , for accepting the connecting member 24 of the wheel assembly 10 . The socket includes a locking mechanism having a handle and a cam. The handle is movable in-line with the socket, in the direction in which the connecting member is introduced and removed. Moving the handle operates the cam which acts against a pin, which locates in the recess 26 , moving it between a locked position and an unlocked position. The cam, when in the locked position, holds the pin in the recess and the connecting member in the socket. In the unlocked position, the pin comes out of the recess, allowing unobstructed movement of the connecting member 24 within the socket.
[0051] The above-described locking arrangement is easy to operate, especially where a large handle is provided. A simple push or pull is enough to release or engage the locking mechanism. This is advantageous, since users attempting to operate the locking mechanism will often have cold hands following a long round of golf.
[0052] In use, the wheel assembly 10 is connected to the base support frame 34 , creating a three-wheeled golf trolley 30 . The golf trolley is intended to be pushed forwards from the handle 38 , as indicated by arrow A. As well as propelling the golf trolley forwards, the force is transmitted through the frame of the trolley, pivoting the trolley clockwise as shown in FIG. 2 about the rear wheels 32 . This results in the front wheel being pushed downwardly, into the ground, as indicated by arrow B, improving the traction of the trolley.
[0053] The wireless pushbutton remote control 44 is mounted to the handle 38 of the trolley. When the user requires power-assistance, the button 44 is pushed. The control unit 22 will power the motor to drive the wheel 12 only when the button 44 is being pushed and when the wheel 12 is already rotating at a speed of greater than 2 mph (0.89 m/s) in a forward direction, i.e. in the direction of arrow A.
[0054] The power assisted golf trolley is easy for a golfer to push around a golf course without becoming tired. It is lightweight and easy to store, similar to existing manual golf trolleys. The battery is small, lightweight, and charges quickly. The wheel assembly can be removed from the golf trolley for charging.
[0055] It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
[0056] Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A wheel assembly 10 for a golf trolley ( 30 ) comprises a wheel 12 , a motor for driving the wheel, a battery 20 for powering the motor, detection means for detecting whether or not the wheel 12 is rotating, a control unit 22 for controlling the motor and releasable connection means 24 for releasably connecting the wheel assembly 10 to a golf trolley ( 30 ), the control unit 22 having at least a first mode of operation in which the motor can be activated only when the wheel 12 is already rotating. | 0 |
The present invention relates to decompressing devices adapted to be used in engines for vehicles such as prime mover-equipped bicycles.
More particularly, the invention relates to a decompressing device whereby operations of stopping and starting an engine are related to each other so that, even if the starting operation is made, only in the initial starting period, a decompressing operation may be automatically made for a predetermined time to facilitate starting the engine. The invention further relates to a decompressing device which makes such decompression simply, positively and automatically, without requiring any special operation, is adapted to prime mover-equipped bicycles, and facilitates starting the engine without requiring any special skill and technique when applied to such vehicles.
BACKGROUND OF THE INVENTION
In a prime mover-equipped bicycle, when changing a bicycle running over to an engine running, when the crankshaft is driven by artificially operating the pedal to start the engine, the resistance at the time of the compression stroke of the piston will be transmitted to the pedal and, if no sufficient inertia is given to the crankshaft, the engine will be difficult to start and will be required special skill and technique.
Therefore, there has been suggested a decompressing device whereby the pressure in the cylinder is reduced in the initial starting period of the engine so that the crankshaft may be smoothly rotated in the initial period, and when a sufficient rotating inertia is given, the pressure reduction will be stopped so that thereafter a compression may be easily made by the inertia to secure starting of the engine.
When such decompressing device is applied to a prime mover-equipped bicycle, such problems as discussed hereinbelow will be produced in operating the decompressing device.
Because the decompressing operation is made with a lever or the like separately from the engine starting and speed change, it will be necessary to separately perform a decompressing operation at the time of the starting operation, and the operation will be difficult and complicated. It will also be necessary to return the lever properly in time with the starting and special skill and technique will be required for the operation. Such operations are undesirable in instances in which such vehicles, i.e., prime mover-equipped bicycles, are operated by females and children. It is desired that the engine can be positively started while being simply and easily decompressed, even by females and children.
SUMMARY OF THE INVENTION
The present invention provides a decompressing device which includes a decompression valve resiliently pressed in the closing direction by a spring. Also provided are means for switching an engine on and off, and a starting shaft for starting the engine. An operating member is operatively connected to and operated in conjunction with the means for switching the engine on and off, and opening the decompression valve against the spring. A cam is provided on the starting shaft coaxially with the operating member, and the decompressing operation of the decompression valve is regulated and released through the operating member by relative movement with the cam.
Such problems as difficulty in starting the engine of prime mover-equipped bicycles and the operability of the decompressing device provided to facilitate starting the engine, are effectively solved by the present invention.
An object of the present invention is to provide a decompressing device which is operated relative to the operation of changing the operation and stop of an engine over to each other to automatically decompress the cylinder for a predetermined period, without requiring any special decompressing operation to start the engine.
Another object of the invention is to provide a decompressing device wherein, in a prime mover-equipped bicycle or the like, a decompression is automatically made in the initial starting period of the engine as operatively connected with the operating system of changing the start and stop of the engine over to each other. Therefore, it is completely unnecessary to perform any special complicated and troublesome operations, and special skill and technique in performing decompression returning operations properly timed with the starting is not required and the engine can be started simply, easily and positively.
The present invention provides a decompressing device comprising a cam rotating integrally with a starting shaft and an operating member engaging with the cam and related to a resiliently pressed decompression valve through a connecting member. The operating member is operatively connected with an operating piece starting and stopping the engine. The decompression valve is opened for a predetermined period of the initial starting period of the engine through the cam by the rotation of the starting shaft selectively engaged with the crankshaft by a clutch means to make a decompression action and to regulate an operating system for returning the decompression valve.
Thus, the present invention provides a decompressing device wherein the structure is simple, the operation is regulated by a cam provided on a starting shaft, and the device is therefore positive and highly reliable. Further, the operating system is also operatively connected with the engine starting operation system, to thus automate the above-mentioned decompressing operation. The structure of the decompressing operation system is simplified, generally the number of component parts is reduced, the cost is reduced, and the practicability as applied to prime mover-equipped bicycles is very high.
The present invention provides a decompression device which is high in operability as applied to prime mover-equipped bicycles, facilitates starting the engine, and elevates the practicability of prime mover-equipped bicycles to also be used by females and children.
A preferred embodiment of the present invention shall be explained in detail in the following description, with reference being had to the accompanying drawings. Further objects and advantages of the present invention will become clear from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectioned side view of an engine including a decompressing device, the essential parts of the power transmitting device being sectioned.
FIG. 2 is a cross-sectional plan view of FIG. 1, the respective parts of the power transmitting device being shown as if they were in the same plane (for convenience of explanation).
FIG. 3 is a magnified view of a portion of FIG. 1.
FIG. 4 is a sectioned view of FIG. 3 as seen in the direction indicated by the arrow 4.
FIG. 5 is a view of FIG. 3 as seen in the direction indicated by the arrow 5.
FIG. 6 is an explanatory view showing the relation between the speed changing operation system and the operating system of the decompressing device.
FIG. 7 is an elevational view of a cam.
FIG. 8 is a side view of the cam.
FIG. 9 is a view showing a prime mover-equipped bicycle.
FIG. 10 is an explanatory view showing the movement of a changing operation piece.
DETAILED DESCRIPTION
The embodiment described hereinbelow is of the decompressing device in accordance with the present invention, as applied to a prime mover-equipped bicycle.
FIG. 9 shows a prime mover-equipped bicycle to which the present invention is applied. A prime mover-equipped bicycle 11 is provided in the front part of its frame body 12 with a front fork 14 operated by a handle 13 and in the rear part with a rear fork 16. The front fork 14 and rear fork 16 support respectively a front wheel 15 and rear wheel 17. A change grip 20, which is a hand grip for making a changing operation, is provided at one end of the handle 13. Numeral 18 indicates a riding seat and 19 indicates a fuel tank. The change grip 20 is connected with a speed changing means of a power transmitting device (discussed in detail below) through a change wire 21.
The decompressing device is operatively connected with a means of changing a bicycle running with pedals and an engine power running over to each other and is applied to a prime mover-equipped bicycle provided with two power systems. The power transmitting device shall be explained with reference to FIGS. 1 and 2.
In FIG. 2, there is depicted a sectioned plan view in which respective shafts and gear power transmitting systems are arranged in a plane for the convenience of understanding. A starting or drive shaft 31 fitted with a pedal 30 (FIG. 9) at each of the right and left ends has a gear 32 which is provided in the middle portion meshed with a gear part 34 of an adjacent intermediate drive shaft 33 having thereon a low speed gear 36 and high speed gear 39 on the driving side provided respectively with one-way clutches 35 and 38 each transmitting a power only in one direction. The gears 36 and 39 mesh respectively with a low speed gear 43 and high speed gear 44 on the driven side of an adjacent output shaft 42.
In FIG. 2, the low speed gear 36 on the driving side is on the right side in the drawing and meshes with the gear 43 on the driven side and a projection 37 of a dogtooth clutch and a recess 40 of the high speed gear 39 provided respectively on the intermediate drive shaft 33 are not engaged with each other. Thus, a low speed automatic running will be achieved. When the low speed gear 36 is moved leftwardly by a first shift fork 49 on a spline 41 on the shaft 33 and the projection 37 and recess 40 engage with each other, the power of the high speed gear 39 will be transmitted to the high speed gear 44 of output shaft 42 and output shaft 42 will rotate at a high speed. The low speed rotation and high speed rotation of output shaft 42 will be transmitted through a sprocket 45 secured to output shaft 42 and will be transmitted to a chain 46 and a sprocket 48 of rear wheel 17 (FIG. 9).
A shifter 52 slid by the operation of a second shift fork 51 on a spline 50 is provided on the output shaft 42. Recesses 55 and projections 53 forming a dogtooth clutch are provided respectively on the shifter 52 and a changing gear 54 provided rotatably on the shaft 42 as opposed to the shifter 52. FIG. 2 shows same as separated from each other and the change grip 20 as in the OFF position in FIG. 10, i.e., in the position of the bicycle running. When change grip 20 is rotated to be set in position L in FIG. 10, shift fork 51 will be moved leftwardly in FIG. 2, projections 53 and recesses 55 will be engaged with each other, and the power of pedal drive shaft 31 will be transmitted to changing gear 54 to start the engine.
The changing gear 54 meshes with a gear part 57 of an intermediate shaft 56 provided parallel to the output shaft 42. The shaft 56 is connected through a sprocket 58 provided thereon and a chain 62 with a sprocket 61 provided on an outer member 60 of a centrifugal clutch 59 provided at one end of a crankshaft 81 of an engine 80. An inner member 63 of clutch 59 is provided with clutch shoes 64 of a centrifugally expanding type. A one-way clutch 65 is provided between members 60 and 63 to transmit the pedal power from the outer member 60 to inner member 63 to drive crankshaft 81 only at the time of starting the engine. A flywheel and such ignition devices as a magneto and contact are provided at the other end of the crankshaft 81. The output of engine 80 is transmitted to shaft 56 through clutch 59 and sprocket chain 62, and then to output shaft 42 through the gear part 57 and gear 54 and dogtooth clutch 55, 53.
The shift forks 49 and 51 are operated by a rod 67 which is extended out of a case 68 containing the power transmitting device. A shift lever 69 connected with one end of change wire 21 operated by the change grip 20 is secured to this extension of rod 67. As shown in FIG. 6, the shift lever 69 is connected at one end to a return spring 71 and at the other end to change wire 21. With the operation of change grip 20, shift lever 69 has the position A shown by the solid line as a position in which the engine is off. The position B shown by the broken line and further rotating positions are positions in which the engine is on. In the OFF state, the bicycle is running and the pedal drive system and engine power system are separated from each other by the dogtooth clutch 53, 55.
In FIG. 1, the engine 80 is provided with a cylinder 82, cylinder head 83 and piston 84, which is connected with crankshaft 81 through a connecting rod 85. A through hole 87 connecting a combustion chamber 86 with the outside is provided in a part of cylinder head 83 and has a small diameter part 89 opening at one end to the outside of the cylinder head and a decompression passage 88 consisting of a large diameter part opening at the other end to the combustion chamber 86 with the intermediate portion providing a boundary. A valve seat 90 is provided in the part facing combustion chamber 86 of passage 88. The passage 88 communicates with an exhaust port 92 through a communicating passage 91 provided within cylinder 82.
A decompression valve 100 is provided at the tip thereof with a valve body 101. A rod part 102 of substantially the same diameter is provided at the upper part of the valve body 101. The rod part 102 of the valve 100 is slidably fitted in through hole 87. The valve body 101 faces the valve seat 90, the tip part of the rod part 102 maintains a sufficient clearance from the inside wall of the decompression passage 88 and the base end part of the valve body 101 is extended out of cylinder head 83, slidably closely fitted in the small diameter part 89 connected with the clearance through it. A spring holder 105 is pivoted with a pin 104 to the end of an extension 103 of rod part 102, is channel-shaped in the end section as shown in FIGS. 1 and 3, and is provided to bridge the end part of extension 103.
As shown in detail in FIGS. 4 and 5, a coil spring 110 is provided for decompression valve 100. The coil part 111 of spring 110 is extended at one end. The intermediate part of a first extension 112 is inserted between spring holder 103 and rod extension 103, and is locked with holder 105. A cut circular locking part 113 is formed at the tip of extension 112 and is locked to one end of a link 120 (described hereinbelow). The coil part 111 is also extended at the other end to form a continued loop-shaped pressing part 114. A sealing member such as an O-ring 94 is applied to a flat seat surface 93 provided on the peripheral side of the part through which rod extension 103 projects of the cylinder head 83 and is covered with a flanged seat member 95. The loop-shaped pressing part 114 of spring 110 is applied onto the flange part 96 of the seat member 95 and the peripheral side part, i.e., flange part 96 of seat member 95, is resiliently pressed with pressing part 114 by the valve closing resiliency of spring 110 so that sealing member 94 may be pressed against seat surface 93 to seal it. The loop-shaped pressing part 114 is extended in the end part and the second extension 115 is contacted with a supporting part 97 provided adjacent to sealing surface 93. Thus, spring 110 closes decompression valve 100 and seals the part through which the rod part 102 projects of cylinder head 83.
The locking part 113 of spring 110 is locked to one end of a link 120 (FIG. 1) through a spring receiver 121. The link 120 is pivoted and connected at the other end to a lever 122 which is as shown in FIGS. 1 and 2. In FIG. 2, the lever 122 is shown as developed in a sectioned plan so as to be easily understood.
The lever 122 is connected and secured to an extension out of case 68 of a supporting shaft 125 rotatably borne adjacent to the pedal drive shaft 31 and is resiliently pressed in the axial direction outside the case with a spring 126 compressed and fitted between the side surface on the case side of lever 122 and the outside surface of case 68. The lever 122 is formed to be fork-shaped in a portion thereof. The link 120 is pivoted at one end to one leg 123 of the fork. The other leg 124 of the fork is made an operating piece which is mounted at the lower end, as shown in FIG. 6, on an extended piece 70 formed at one end of shift lever 69 to slidably engage them.
A regulating plate 127 which is a cam engaging piece is secured to the extension end into the case of a supporting shaft 125 provided with lever 122 at the extension end out of the case and is provided in the tip part thereof curved with a engaging part 128 as shown in FIG. 1.
On the adjacent pedal drive shaft 31, a cam 130 is provided axially slidably through a through hole 135 provided with a groove in the middle portion, and is regulated with a positioning pin 136 provided on shaft 31 as shown in FIG. 2. Cam 130 rotates integrally with shaft 31 and is resiliently pressed against one inside wall surface side of case 68 supporting shaft 31 by a spring 137 compressed and fitted between gear 32 and cam 130 on shaft 31.
The details of cam 130 are shown in FIGS. 7 and 8. FIG. 7 shows an elevation thereof, and FIG. 8 shows a side view thereof.
The cam 130 has two steps of outside diameters, a large diameter part 131 and small diameter part 134, which are integrally formed. The large diameter part 131 is provided with cam grooves 132. As shown in FIG. 8, the cam groove 132 starts from the intermediate portion in the width direction (axial direction) of large diameter part 131, inclines toward small diameter part 134 and joins the end surface 133 in the direction of small diameter part 134 on the end surface. As shown in FIG. 7, the cam groove 132 is provided over a predetermined angle on the periphery of large diameter part 131. In this embodiment, two of such cam grooves 132 are provided symmetrically, 180° opposed, on the periphery of large diameter part 131 so as to easily detect the decompressing operation in the rotation of the pedal drive shaft. When the engine is off, that is, at the time of the bicycle running, as shown in FIG. 2, cam 130 will be positioned on shaft 31 leftward by means of spring 137 and, as shown in FIG. 1, engaging part 128 of regulating plate 127 will be in contact in or near the starting point position of cam groove 132 on the periphery of large diameter part 131 or in any position on the periphery fitting said position.
The decompressing operation will now be explained. FIGS. 1, 2 and 6 depict a state at the time of the bicycle running, i.e., when the operation of engine 80 is stopped and decompression valve 100 is opened as separated from the valve seat 90, i.e., combustion chamber 86 is decompressed by communicating with the atmosphere through decompression passage 88, communicating passage 91 and exhaust port 92.
The change grip 20 will be in the OFF position in FIG. 10, the change wire 21 will be in the pulled position, and shift lever 69 connected with it will be set in the OFF position (position A in FIG. 6). Through rod 67 connected with shift lever 69, as shown in FIG. 2, the second shift fork 51 will set shifter 52 in the right OFF position on output shaft 42 so as to be separated from changing lever 54. Thus, only the power of pedal drive shaft 31 will be transmitted to output shaft 42 and a bicycle running will be made without operating the engine. In FIG. 2, shift fork 49 will set low speed gear 36 in the right low speed position, will mesh it with low speed gear 43 and will rotate output shaft 42 at a low speed with the pedal drive.
When shift lever 69 is in the OFF position, as shown in FIG. 6, it will lift the operating piece part 124 of lever 122 and lever 122 will rotate clockwise in FIG. 1 with supporting shaft 125 as a fulcrum, and will be in the OFF position. The regulating plate 127 provided commonly on supporting shaft 125 will rotate in the same direction and engaging part 128 at its tip will mount on the intermediate part in the width direction on the outer periphery of large diameter part 131 of cam 130. When lever 122 is set in the OFF position, link 120 will be pulled to be pushed down. As a result, spring 110 will flex toward cylinder head 83, rod 102 of decompression valve 100 locked in the intermediate portion of extension 112 of spring 110 will be pushed down, valve body 101 will enter combustion chamber 86 to clear valve seat 90, and combustion chamber 86 will communicate with the atmosphere as above-mentioned and will be decompressed. In the OFF state of the bicycle running, decompression valve 100 will be kept open. In this state, extension 115 of spring 110 will be regulated by supporting part 97 to prevent spring 110 from floating up.
In starting the engine, when change grip 20 is rotated to be set in position L shown in FIG. 10, with the relaxation of change wire 21, shift lever 69 will rotate clockwise in FIG. 6 through return spring 71 to be set in the ON position B and will rotate rod 67 in the same direction. With the rotation of rod 67, shift fork 51 will move shifter 52 leftwardly in FIG. 2, and its projections 53 will engage with recesses 55 on changing gear 54. Through the system of gear 54 and gear part 57 and sprocket 58 and 61, the power of pedal drive shaft 31 will be transmitted to clutch outer member 60 to drive same. The crankshaft 81 will be drive through one-way clutch 65 and clutch inner member 63.
When shift lever 69 is set in the ON position, the extension piece 70 will fall and operating piece part 124 of lever 122 in contact with it will be released and will tend to move lever 122 to return with the spring 110 through link 120. In this case, as mentioned above, engaging part 128 of regulating plate 127 will mount on the outer periphery of large diameter part 131 of cam 130 and the rotation of supporting shaft 25 will be regulated. Therefore, lever 122 will regulate link 120, decompression valve 100 will remain pushed down through spring 110, and will be in the decompressing state.
When the pedal driving force is transmitted to engine 80, crankshaft 81 will rotate but, as decompression valve 100 is open, combustion chamber 86 will be decompressed through decompression passage 88 and a decompressing operation will be performed.
The cam 130 will rotate integrally with the rotation of pedal drive shaft 31 and engaging part 128 of regulating plate 127 will engage with the starting point of cam groove 132. As the grooves 132 are disposed 180° opposing each other, this engagement will be made by a pedal rotation drive within at least 180°. With the engagement of engaging part 128 with cam groove 132, as cam groove 132 is as already described, by its guiding action, cam 130 will be moved rightwardly in FIG. 2 on shaft 31 against spring 137 and, at the terminal of the groove, engaging part 128 will reach small diameter part 134. Thereby, as a rotating resiliency is given counter-clockwise in FIG. 1 by the operation of spring 110 through link 120, the regulation of supporting shaft 125 will be released and lever 122 will rotate in said direction, engaging part 128 of regulating piece 127 will drop into small diameter part 134 of cam 130 and will release the regulation of link 120. The link 120 will release the regulation of spring 110. The rod part 102 of decompression valve 100 will be pulled by the resiliency of spring 110, valve body 101 will resiliently closely contact valve seat 90, decompression passage 88 will be closed, and the decompressing operation will be off.
Thus, in case the OFF state of the bicycle running is changed over to the ON state of the engine starting, the engine starting system will be immediately switched on but, within a predetermined rotation range of pedal drive shaft 31, decompression valve 100 will be opened by cam 130, the combustion chamber will be kept decompressed and, when a sufficient rotating inertia is given to crankshaft 81 by the pedal drive, the decompression will be released by cam 130 and the engine will be started. After the engine starts, centrifugal clutch 59 will act so that both the engine power and pedal drive may be transferred to output shaft 42.
As described above, the decompressing device is operatively connected with the shifting operation of changing the bicycle running over to the engine power running and the decompressing operation is automatically performed within a predetermined period in the initial starting period of the engine.
When change grip 20 is further rotated to be set in position H in FIG. 10, the first shift fork 49 will move leftwardly in FIG. 2. The gear 36 while remaining in mesh with gear 43 will engage with the adjacent high speed driving gear 39 through the dogtooth clutch 37, 40, gear 39 will be driven and high speed driven gear 44 will be driven to drive output shaft 42 at a high speed. In this case, gear 33 will escape through one-way clutch 35 and will not interfere, though in constant mesh with gear 43.
With the change of grip 20 from running with the engine power to bicycle running, the pedal drive system will be insulated from the engine power system, lever 122 will be set in the OFF position by shift lever 69 and link 120 will be pulled to open decompression valve 100.
In the above embodiment, at the time of starting the engine, the decompression is maintained by sliding the cam 130 but may be maintained by sliding regulating plate 127. Further, in the above, the explanation was set forth regarding pedal starting, however, even a kick starting system can be adopted. In such case, the above described mechanism may be provided on the kick-starting shaft.
The present invention has been explained in detail in the foregoing, and is believed to be able to be fully understood thereby. | A decompressing device adapted for use in engines for prime mover-equipped bicycles. The decompressing device is operatively connected with the shifting operation of changing the bicycle running over to the engine power running, and the decompressing operation is automatically performed within a predetermined period in the initial starting period of the engine. The decompression is performed simply, and automatically, without requiring special skill and technique. | 5 |
FIELD OF THE INVENTION
This invention relates to a method for treatment of cystinuria by administration of bucillamine or pharmaceutically acceptable salts thereof.
BACKGROUND OF THE INVENTION
Cystinuria is a disease caused by congential metabolic disorders wherein the reabsorbing function of cystine, lysine, ornithine and arginine into renal tubules is hereditarily damaged and an excessive amount of amino acids are excreted into urine. Amino acids except cystine are soluble in urine and do not cause a problem. Cystine, however, is very slightly soluble in urine and crystallizes to form stones in the urinary tract. The main direct complaints of cystinuria patients are colic, hematuria, etc. caused by cystine stones. Sometimes pyelonephritis or cystitis is caused by a secondary infection.
Therapeutic methods can be classified into two surgical methods, namely an operative removal of cystine stones and a destruction of cystine stones by a shock wave, and a dissolution of cystine stones. For dissolution, a fluid intake method, an alkalization method and a medicinal method with D-penicillamine or tiopronin are known (Urol. Clin. North. Am., 14, 339 (1987)).
If a cystine stone is removed by the surgical operation, the cystinuria patients can be released from the direct complaints. However the latter methods, namely the dissolution, still contain a problem of recurrence of cystine stone formation. Furthermore, there exist problems in the surgical methods. For example, the stone sometimes exists at a difficult place to be removed by an operation, and the cystine stone can be hardly destructed by the shock wave because the stone is harder than other kinds of stones. Therefore, the latter method, which can dissolve the cystine stone and prevent a recurrence of the stone formation, is very important for treatment of cystinuria.
However, the fluid intake method and alkalization method have some disadvantages. For example, in the fluid intake method, it is necessary for an adult patient to drink 4-6 liters of water a day and such large water intake is very hard to a patient. In the alkalization method, pH of the urine is raised to dissolve the cystine stones by administration of alkali such as sodium hydrogen carbonate, while it gives good conditions to form phosphate stones.
Therefore, it was devised to convert cystine into a water soluble mixed disulfide by administration of a medical substance having a sulfhydryl group to dissolve the cystine stone and further to prevent a recurrence of the stone formation. D-penicillamine, a medical substance applied first, was effective, but had a disadvantage of serious side effects. It was reported that the use of tiopronin, α-mercaptopropionylglycine, instead of D-penicillamine can reduce the side effects (Proc. Soc. Exptl. Biol. & Med., 129, 927 (1968), Urol. Clin. North. Am., 14, 339 (1987)). However, more effective and safer medical substances are desired for treatment of cystinuria.
Bucillamine, a main ingredient of this invention, has been known as a safe medical substance and to be useful as an anti-rheumatic, a liquefactant of sputum, a suppressant of liver disorders or an anti-cataract agent (Japanese Patent Publications 11888/1985, 5388/1981, 13922/1987 and 13964/1988). It is known that bucillamine is useful in various therapeutic fields, but an application to cystinuria has never been studied.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to a method for treatment of cystinuria by administration of bucillamine of the formula [I] or pharmaceutically acceptable salts thereof. ##STR1##
Examples of pharmaceutically acceptable salts are sodium salt and potassium salt.
Cystinuria is a hereditary disorder characterized by an excessive urinary excretion of cystine etc. and causes a cystine stone formation in urinary tract. Medicinal methods are applied most effectively for treatment of cystinuria. It is known that tiopronin, showing little side effects, can dissolve the cystine stone and prevent a recurrence of cystine stone formation and is useful for treatment of cystinuria. We studied to find more effective medical substances than tiopronin.
As the result of our precise study, we found that bucillamine showed a superior effect on cystinuria. We examined the utility of bucillamine for cystinuria by in vitro test, in which bucillamine was added to buffer solution of cystine and decrease of the concentration of cystine was measured. Tiopronin, a reference compound, was also tested in the same conditions. As shown in the article of pharmacological test in detail, bucillamine clearly decreased the concentration of cystine in buffer solution more effectively than tiopronin. The result proved that bucillamine is useful for treatment of cystinuria.
Bucillamine or salts thereof can be administered orally or parenterally. As the dosage forms, tablets of bucillamine are marketed, and tablet, granule, powder and injections disclosed in Japanese Patent Publications 5388/1981 and 11888/1985, etc. can be used. Further, bucillamine or salts thereof can be formulated in an irrigating solution to dissolve cystine stones by a renal irrigation.
The dosage of bucillamine or salts thereof is adjusted depending on the symptom, dosage from, age, etc. In case of the oral dose, the usual daily dosage is 10-3000 mg, preferably 50-1500 mg or 100-1200 mg, which can be given in one or a few divided doses.
EXAMPLE
Examples of preparation of the irrigating solution are shown below.
______________________________________Formulation 1______________________________________bucillamine 5 gsodium hydroxide q.s.distilled water for injection q.s.total 100 ml______________________________________
Preparation method:
Bucillamine is added to 80 ml of distilled water for injection and pH of the solution is adjusted to 7 with sodium hydroxide. Distilled water for injection is added to the solution to make the total volume 100 ml.
The following irrigating solution of formulation 2 can be prepared by the similar method.
______________________________________Formulation 2______________________________________bucillamine 1 gsodium hydroxide q.s.distilled water for injection q.s.total 100 ml______________________________________
Pharmacological Test
We examined the utility of bucillamine on cystinuria by an in vitro test, in which bucillamine was added to the buffer solution of cystine and a decrease of the concentration of cystine was measured. Tiopronin, a reference compound, was also tested in the same conditions.
Experimental Method
Cystine was dissolved in phosphate buffer solution (0.067M, pH 6.5) in a concentration of 500 μg/ml. Bucillamine was added to the solution in a concentration of 250 or 500 μg/ml. The mixture was incubated at 37° C. After 4 hours, the concentration of cystine was measured by a high performance liquid chromatography. As a reference, tiopronin was tested in the same conditions.
Result
The result is shown in Table 1 by decrement (%) of the concentration of cystine.
TABLE 1______________________________________medical amount of medical decrement of thesubstance substance (μg/ml) concentration of cystine (%)______________________________________bucillamine 250 60.6 500 87.8tiopronin 250 48.5 500 75.3______________________________________
As shown in Table 1, bucillamine clearly decreases the concentration of cystine in buffer solution more effectively than tiopronin. | A method for treatment of cystinuria which comprises administering to a patient in need thereof an effective amount of bucillamine or a pharmaceutically acceptable salt thereof. | 8 |
This is a continuation of application No. 7/138,130 filed Dec. 28, 1987.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an aromatic derivative useful as a pharmaceutical product. More particularly, it relates to an aromatic derivative having actions useful for the therapy of diseases caused by arachidonic acid cascade metabolic products, and a method for the preparation thereof.
2. Description of the Related Art
Arachidonic acid is converted to various leukotrienes (LT) in living bodies by the action of lipoxygenase. These leukotrienes have various physiological activities. For example, LTB 4 participates in the chemotaxis activity of leucocytes, infiltration, agglomeration, degranulation, superoxide anion production, adhesion sthenia into blood vessel endothelium, etc., and LTC 4 and LTD 4 exhibit physiological activities such as smooth muscle contraction of ileum, aspiratory organ system, skin blood vessel contraction, blood vessel transmissive sthenia, depression, etc. (The Leukotrienes, A Biological Council Symposium, P. J. Piper, Raven Press (New York)). At present, the leukotrienes exhibiting these various physiological activities have been known to cause allergic diseases such as bronchial asthma, nasal allergy, ophthalmia, atopic dermatitis, etc., and circulatory organ system diseases such as edema, ischemic heart disease, hypertension, ischemic brain disorder, etc. Also, it has been clarified by recent studies that a large amount of LTB 4 is found in the lesion of psoriasis, but it is not evident whether or not LTB 4 is a direct cause of psoriasis.
On the other hand, a large number of antiinflammatory agents inhibiting arachidonic acid cascade are known in the art. Therefore, it may be considered to be effective for the therapy of allergic diseases and circulatory organ system diseases or psoriasis, etc., as mentioned above, as well as inflammations related thereto, to inhibit both lipoxygenase and cyclooxygenase.
SUMMARY OF THE INVENTION
An object of the present invention is to provide novel substances which inhibit the biosynthesis of chemical mediators produced by lipoxygenase and cyclooxygenase.
Other objects and advantages of the present invention will be apparent from the following description.
In accordance with the present invention, there is provided an aromatic derivative having the formula (I): ##STR4## wherein R 1 and R 2 independently represent a hydrogen atom, hydroxyl, halogen atom, or OR 3 wherein R 3 is C 1 -C 10 alkyl; A--B represents a hydrocarbon moiety having 1 to 10 carbon atoms and containing at least one double bond or a sulfur- or oxygen-containing hydrocarbon moiety having 1 to 10 carbon atoms; n is an integer of 2 to 4; X represents a group ##STR5## and Y represents a hydrogen atom, alkyl having 1 to 5 carbon atoms which may be substituted with aryl; alkenyl having 2 to 5 carbon atoms which may be substituted with aryl or aryl substituted with at least one C 1 -C 5 alkoxy; aryl which may be substituted with at least one carboxyl, C 1 -C 5 alkoxycarbonyl or C 1 -C 5 alkoxy; provided that, when R 1 and R 2 are both hydrogen, the moiety --A--B--(CH 2 ) n --X--Y does not represent ##STR6## wherein n=2 to 4 and R 4 is hydrogen or C 1 -C 5 alkyl.
In accordance with the present invention, there is also provided a method for preparing an aromatic derivative having the formula (I-A): ##STR7## wherein R 1 , R 2 , A-B, and n are as defined above, provided that A is --CH═CH--, X' represents ##STR8## Y" represents a hydrogen atom or C 1 -C 5 alkyl comprising the step of: reacting a compound having the formula (II): ##STR9## wherein R 11 and R 21 independently represent a hydrogen atom, a halogen atom, or OR 3 wherein R 3 is the same as defined above, and R 5 represents C 1 1∝C 5 alkyl, with a compound having the formula (III):
OHC--B--(CH.sub.2).sub.n --X'Y' (III)
wherein X' is as defined above, B represents a hydrocarbon moiety having 1 to 8 carbon atoms, which may contain a double bond and a sulfur or oxygen atom, n is an integer of 2 to 4, and Y' represents the C 1 to C 5 alkyl group, in the presence of a base, optionally followed by a hydrolysis, reduction or deprotection reaction.
The resultant compound (I-A) may be converted to the compound (I) in which X is ##STR10## and Y is aryl substituted with alkoxycarbonyl by reacting the compound (I-A) having --COOH group as X'Y" with amino benzoate H 2 N--Ph--COOR wherein R represents C 1 -C 5 alkyl.
The compound (I-A) may also be converted to the compound (I) in which X is ##STR11## and Y is C 2 -C 5 alkenyl having an aryl group by reacting the compound (I-A) having --COOH group as X'Y" with an alcohol having HO--CH 2 -- m CH═CH--Ar wherein m is 0 to 3 and Ar represents an aryl group which may be substituted with carboxyl, C 1 -C 5 alkoxycarbonyl, or C 1 -C 5 alkoxy.
In accordance with the present invention, there is further provided a method for preparing an aromatic derivative having the formula (I-B): ##STR12## wherein R 1 , R 2 , B, n, X', and Y" are as defined above, comprising the step of:
reacting a compound having the formula (IV): ##STR13## wherein R 11 and R 21 are as defined above with a compound having the formula (V)
Z--CH.sub.2 --B--(CH.sub.2).sub.n --X'Y' (V)
wherein B, n, X', and Y' are as defined above and Z represents a halogen atom or, when B is --CH═CH--, Z represents an acyloxy group, in the presence of a base, optionally followed by a hydrolysis, reduction, or deprotection reaction. The result compound (I-B) may be further converted to the compound (I) having an X-Y moiety other than those included in X'Y" of the compound (I-B) as follows.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferable aromatic derivatives according to the present invention are those having the formula (I) in which R 1 and R 2 independently represent a hydrogen atom or alkoxy having 1 to 5 carbon atoms; --A--B-- represents a combination of two same or different linking groups selected from the group consisting of ##STR14## n is 3 or 4; X represents ##STR15## and Y represents a hydrogen atom, alkyl having 1 to 5 carbon atoms, phenyl which may be substituted with carboxyl, C 1 -C 5 alkoxy carbonyl, or C 1 -C 5 alkoxy, or C 2 14 C 5 alkenyl substituted with phenyl which may be substituted with at least one C 1 -C 5 alkyl or alkoxy.
In the above-mentioned aromatic compounds (I), R 1 and R 2 preferably represent a hydrogen atom or a methoxy group, A in A-B preferably represents --CH═CH--, or --S--CH 2 --, B in A-B preferably represents --CH═CH--, --CH 2 --S--, ##STR16## Furthermore, as to X-Y, when X represents ##STR17## Y preferably represents hydrogen, C 1 -C 5 alkyl, aryl substituted with C 1 -C 5 alkyl, --CH 2 --CH═CH--Ar wherein Ar represents phenyl or phenyl substituted with at least one C 1 -C 5 alkyl or alkoxy group; and when X represents ##STR18## Y preferably represents C 1 -C 5 alkyl or C 2 -C 5 alkenyl substituted with phenyl which may be substituted with at east one C 1 -C 5 alkyl or alkoxy group; and where X represents an oxygen atom, Y preferably represents hydrogen; and when X represents ##STR19## Y preferably represents hydrogen or phenyl substituted with at least one carboxyl or alkoxy carbonyl with C 1 -C 5 alkyl group.
As the above-mentioned substituents, the C 1 -C 5 alkyl groups include, for example, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, and t-butyl; the C 1 -C 5 alkoxy groups include, for example, methoxy, ethoxy, and butoxy; when the compound (I) contains a carboxyl group, it also can be a nontoxic salt formed from an appropriate inorganic or organic base. Such bases may include, as inorganic bases, for example, hydroxides, carbonates, bicarbonates of alkali metals or alkaline earth metals such as sodium, potassium, calcium, and magnesium. As the organic bases, for example, there may be included primary, secondary or tertiary alkylamines such as methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, trimethylamine, ethylamine, diethylamine, and triethylamine; primary, secondary or tertiary alkanolamines such as ethanolamine, diethanolamine, and triethanolamine; diamines such as ethylenediamine, and hexamethylenediamine; cyclic saturated or unsaturated amines such as pyrrolidine, piperidine, morpholine, piperazine, N-methylmorpholine, pyridine.
When the compound (I) contains substituted aryl groups, such as the carboxylic substituents on the aryl group, the substituents may be preferably in the ortho-or para-position.
The above-mentioned compound (I-A) may be prepared by reacting the compound (II) with the compound (III) in the presence of a base, optionally followed by a hydrolysis, reduction, or deprotection reaction.
This reaction (i.e., Wittig reaction) can be carried out by adding a base such as NaH, NaNH 2 , LiN(i-Pr) 2 , or CH 3 ONa to a mixture of a phosphonate compound (II) and an aldehyde (III). This reaction can be carried out in the presence of an appropriate solvent such as benzene, tetrahydrofuran (THF), diglyme, dimethyl formamide (DMF), and dimethylsulfoxide (DMSO). The base is preferably used in an amount of 0.1 to 10 times, more preferably 0.9 to 1.4 times in terms of an equivalent, based on the phosphonate compound (II), and the aldehyde compound (III) is preferably used in an amount of 0.1 to 10 times, more preferably 0.9 to 1.4 times, in terms of an equivalent, based on the phosphate compound (II). The preferable reaction temperature is 0° C. to 150° C., more preferably 10° C. to 80° C. Although the reaction time largely depends upon the compounds and the other reaction conditions, the preferable reaction time is approximately 10 minutes to 24 hours. After the reaction is completed, the desired aromatic derivative can be obtained by a conventional post-treatment.
If desired, the resultant aromatic derivative can be subjected to a hydrolysis, reduction, or deprotection reaction.
For example, when X'Y' in the formula (III) is an ester group or an acyloxy group, the resultant aromatic derivative can be hydrolyzed in any conventional manner, e.g., in the presence of a base such as sodium hydroxide or potassium hydroxide, to obtain the corresponding carboxylic acid derivative or the corresponding alcohol derivative.
When X'Y' in the formula (III) is an ester group, the resultant aromatic derivative can be reduced in any conventional manner. For example, such a reduction reaction can be carried out in the presence of a reducing agent, e.g., LiAlH 4 . Thus, the corresponding alcohol derivatives can be obtained.
When R 11 and R 21 in the formula (II) are alkyloxy, the resultant aromatic derivative can be easily converted to the corresponding alcohol by a known method, as disclosed in, for example, Protective Groups in Organic Synthesis, T. W. Green, A Wiley-Interscience Pulbication, John Wiley & Sons, New York, p. 88-p. 92. The isolation and purification of the desired compound can be carried out in any conventional manner, for example, by extraction, chromatograph separation, or recrystallization.
The non-toxic salts of the aromatic derivative according to the present invention can be readily obtained by a salt formation reaction. Such a salt formation reaction can be carried out by reacting the above-prepared carboxylic acid with the above-mentioned base such as hydroxides or carbonates of alkali metals, ammonium hydroxide, ammonium carbonate, ammonia, or amines in an appropriate solvent.
The above-mentioned compound (I-B) may be prepared by reacting the compound (IV) with the compound (V) in the presence of a base, optionally followed by a hydrolysis, reduction, or deprotection reaction.
The above-mentioned reaction of the compound (IV) with the compound (V) can be effected by anionizing the compound (IV) in the presence of a base such as NaH or CH 3 ONa. Examples of the solvent used in this reaction are tetrahydrofuran (THF), dimethylformamide, diethyl ether, and dioxane. When Z is an allyloxy group and B is --CH═CH-- ##STR20## the reaction should be carried out in the presence of a palladium (O) catalyst. Examples of such Pd (O) catalysts are various palladium complexes described in, for example, Tetrahedron Vol. 42, No. 16, pp. 4361 to 4401, 1986; Accounts of Chemical Research Vol. 13, No. 11, pp 385 to 393, 1980; and "Organic Synthesis with Palladium Compounds" J. Tsuji, Springer-Verlag (1980). Preferable palladium (O) catalysts are tetrakis(triphenylphosphine) palladium (O), bis[bis(1,2-diphenylphosphino)-ethane]palladium (O), and bis[bis(1,3-diphenylphosphine)-propane]palladium (O).
The base is preferably used in an amount of 0.5 to 10 times, in terms of an equivalent, preferably stoichiometrically 1 mole equivalent, based on the thiol compound (IV). The compound (V) is preferably used in an amount of 0.1 to 5 times, more preferably 0.7 to 1.5 times, based on the thiol compound (IV). When the palladium catalyst is used, the catalyst is preferably used in an amount of 0.001 to 1 time, more preferably 0.01 to 0.2 times, in terms of an equivalent, based upon the thiol compound. The reaction temperature is preferably -30° C. to 200° C., more preferably 0° C. to 100° C. and the reaction time is preferably 10 minutes to 100 hours, more preferably 1 to 24 hours.
After the reaction is completed, the desired aromatic derivative can be obtained by a conventional post-treatment, and if desired, the resultant aromatic derivative can be subjected to a hydrolysis, reduction, or deprotection reaction. Thus, the desired compound can be obtained. When the resultant compound is a carboxylic acid, the carboxylic acid can be converted to the corresponding non-toxic salt in the same manner as mentioned above.
Specific examples of the aromatic derivatives according to the present invention are as follows:
(1) 8-(2-Naphthyl)-5,6-trans-5,6-methano-7E-octen-1-ol
(2) 3,4-Dimethoxycinnamic acid ester of (1)
(3) 3,4-Dimethoxycinnamyl alcohol ester of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid
(4) Anthranylic acid amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid
(5) p-Aminobenzoic acid amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid
(6) Methyl ester of (4)
(7) Methyl ester of (5)
(8) Sodium salt of (5)
(9) Sodium salt of (5)
(10) Potassium salt of (4)
(11) Potassium salt of (5)
(12) 4-(3-(2-Naphthyl)-2E-propenylthio) butanoic acid
(13) 8-(2-Naphthyl)-5E,7E,-octadienoic acid
(14) 4-(5-(2-Naphthylvinyl)-2-thiophene) butanoic acid
(15) 7-(2-Naphthylthio)-5-E-heptenoic acid
(16) 7-(2-Naphthylthio)-5,6-trans-5,6-methanoheptanoic acid
(17) 4-(5-(2-Naphthylthiomethyl)-2-thiophene) butanoic acid
(18) 8-(6-Methoxy-2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid
(19) 4-(3-(6-Methoxy-2-naphthyl)-2E-propenylthio) butanoic acid
(20) 8-(6-Methoxy-2-naphthyl)-5E,7E-octadienoic acid
(21) 4-(5-(6-Methoxy-2-naphthylvinyl)-2-thiophene) butanoic acid
(22) 8-(6,7-Dimethoxy-2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid
(23) 4-(3-(6,7-Dimethoxy-2-naphthyl)-2E-propenylthio) butanoic acid
(24) 8-(6,7-Dimethoxy-2-naphthyl)-5E,7E-octadienoic acid
(25) 4-(5-(6,7-Dimethoxy-2-naphthylvinyl)-2-thiophene) butanoic acid
(26) 7-(6,7-Dimethoxy-2-naphthylthio)-5E-heptanoic acid
(27) 7-(2-Naphthylthio)-5,6-trans-5,6-methanoheptanoic acid
(28) Methyl esters of (12)-(27)
(29) Sodium salts of (12)-(27)
(30) Potassium salts of (12)-(27)
(31) 3,4-Dimethoxycinnamyl alcohol esters of (12)-(27)
(32) Anthranylic acid methyl amides of (12)-(27)
(33) p-Aminobenzoic acid methyl amides of (12)-(27)
The aromatic derivative thus obtained in the present invention was found to exhibit inhibitory activity against lipoxygenase and have anti-SRS-A activity.
Accordingly, the compound of the present invention is useful for the therapy or prophylaxis of allergic diseases such as bronchial asthma, nasal allergy, allergic ophthalmia, and atopic dermatitis, circulatory organ system diseases such as edema, ischemic disease, hypertension, and ischemic brain disorder, diseases such as psoriasis, and diseases caused by virus.
EXAMPLES
The present invention will now be further illustrated by, but is by no means limited to, the following Examples and Evaluation Examples.
EXAMPLE 1
Synthesis of 8-(2-Naphthyl)-5,6-trans-5,6-methano-7E-octene-1-ol ##STR21##
A 5 ml amount of an ether solution of 208 mg (0.74 mmol) of the carboxylic acid (1) was added dropwise into a 5 ml ether suspension of 57 mg (1.5 mmol) of LAH under 0° C., and the mixture stirred at room temperature overnight. Aqueous Na 2 SO 4 was added and the organic layer was taken by decantation, dried, concentrated, and thereafter, subjected to silica gel column chromatography (hexane:AcOEt=1:1) to obtain 191 mg (97%) of the alcohol (2).
NMR (δ ppm, CDCl 3 , 60 MHz) 0.5-1.8 (m, 10H), 3.5 (m, 2H), 5.7 (dd, 1H, J=16.0, 8.0 Hz), 6.45 (d, 1H, J=16.0 Hz), 7.0-7.7 (m, 7H).
EXAMPLE 2
Synthesis of Methyl anthranylate amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid ##STR22##
A 4 ml amount of a methanol-free methylene chloride solution of 200 mg (0.71 mmol) of the carboxylic acid (1) was formed and 1 ml of methylene chloride solution of 108 mg (0.71 mmol) of methyl anthranylate was added thereto, and the mixture was cooled to 0° C., followed by an addition of 149 mg (0.72 mmol) of DCC (1,3-dicyclohexyl-carbodiimide). The mixture was stirred at 0° C. for 1.5 hours, and then at room temperature for 4.5 hours. Further, 108 mg of methyl anthranylate and 300 mg (1.4 mmol) of DCC were added, and the mixture was stirred for 2 days. The reaction was completed with water, and the reaction product was extracted with ethyl acetate. The extract was washed with an aqueous potassium hydrogen sulfate, then with saturated aqueous sodium chloride, and the organic layer was dried over anhydrous magnesium sulfate and the solvent was evaporated, followed by silica gel chromatography (hexane:ethyl acetate=8:1), to obtain 90 mg of the acid amide derivative (3).
NMR (δ ppm, CDCl 3 , 60 MHz) 0.6-2.2 (m, 8H), 2.2-2.6 (m, 2H), 3.8 (s, 3H), 5.7 (dd, 1H, J=16.0, 8.0 Hz), 6.45 (d, 1H, J=16.0 Hz), 6.8-7.7 (m, 10H), 7.8 (dd, 1H, J=8.0, 2.0), 8.55 (dd, 1H, J=8.0, 1.0)
IR (cm -1 , neat) 3300, 3280, 3000, 2950, 1700 (Shoulder), 1685, 1640, 1610, 1585, 1525, 1450, 1310, 1260, 1240
EXAMPLE 3
Synthesis of Methyl p-aminobenzoate amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid ##STR23##
A dry methanol-free methylene chloride (2 ml) solution of 100 mg (0.36 mmol) of the carboxylic acid (1) was cooled to -20° C. under N 2 gas. To this solution, 53 μl (0.38 mmol) of triethylamine and 40 μl (0.37 mmol) of pivaloyl chloride were added, and the mixture was stirred at -20° C. for 1 hour. To this mixture was added 2 ml dry methylene chloride solution of 54 mg (0.36 mmol) of methyl p-aminobenzoate, followed by stirring at -20° C. for 30 minutes and at room temperature for 18 hours. The reaction was completed with water and the reaction product was extracted with ethyl acetate. The organic layer was washed with aqueous NaHCO 3 , KHSO 4 and NaCl, and dried, followed by concentration. The concentrate was subsequently subjected to silica gel chromatography (hexane:ethyl acetate=4:1) to obtain 110 mg (75%) of the acid amide derivative (4).
NMR (δ ppm, CDCl 3 , 60 MHz) 2.2-2.6 (m, 2H), 3.75 (s, 3H), 5.7 (dd, 1H, J=1.60 Hz), 6.55 (d, 1H, 16.0 Hz), 7.09 (m, 11H)
EXAMPLE 4
Synthesis of p-Aminobenzoic acid amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid ##STR24##
A 40 mg (0.097 mmol) amount of the amide ester (4) was formed into a solution in methanol (1 ml) and THF (3 ml), which was cooled to 0° C., and 2 ml of 4 N LiOH was added to the solution. The mixture was stirred for 5 hours, and then left to stand for 2 and a half days at 4° C. The mixture was then made acidic with hydrochloric acid, and was extracted twice with ethyl acetate. The organic layer was washed with aqueous NaCl, dried and concentrated to give 38 mg (quant) of the carboxylic acid (5).
NMR (δ ppm, deuter-acetone, 60 MHz) deutero-MeOH 0.6-2.6 (m, 2H), 5.7 (dd, 1H, J=16.0, 8.0), 6.55 (d, 1H, 16.0 Hz), 7.0-8.0 (m, 11H)
EXAMPLE 5
Synthesis of 3,4-Dimethoxycinnamyl alcohol ester of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid ##STR25##
To 2 ml of a methanol-free dry methylene chloride solution of 51 mg (0.18 mmol) of the carboxylic acid (1) was added 4 ml of methylene chloride solution of 50 mg (0.26 mmol) of 3,4-dimethoxycinnamyl alcohol, and subsequently, 2.5 mg (0.02 mmol) of dimethylaminopyridine (hereinafter DMAP) and 64 mg (0.3 mmol) of DCC were added, followed by stirring at room temperature overnight. The reaction was completed by an addition of water, and the reaction product was extracted with ethyl acetate. The organic layer was washed with aqueous KHSO 4 , aqueous NaCl, then dried, concentrated and subjected to silica gel column chromatography to obtain 81 mg (98%) of the ester (6).
NMR (δ ppm, CDCl 3 , 60 MHz): 0.5-2.1 (m, 8H), 2.1-2.6 (m, 2H), 3.75 (s, 3H), 4.65 (d, 2H, J=5.0 Hz), 5.7 (dd, 1H, J=16.0, 8.0 Hz), 5.95 (d, t, 1H, J=16.0, 5.0 Hz), 6.4 (d, J=16 Hz, 1H), 6.45 (d, 1H, J=16.0 Hz), 6.5-6.8 (3H, m), 7.0-7.7 (m, 7H)
IR (cm -1 , neat, CDCl 3 ) 3000, 2950, 1735, 1700, 1650, 1600, 1515, 1460, 1420, 1240
EXAMPLE 6
Synthesis of 3,4-Dimethoxycinnamic acid ester of 8-(2-naphthyl)-5,6-trans-5,6-methano-7 E-octene-1-ol ##STR26##
To a solution of 57 mg (0.21 mmol) of the alcohol derivative (2) and 44 mg (0.21 mmol) of 3,4-dimethoxycinnamic acid in methanol-free dry methylene chloride (4 ml) was added 2.5 mg (0.02 mmol) of DMAP, and the mixture was cooled to 0° C. Then 62 mg (0.3 mmol) of DCC was added, and the mixture was stirred at 0° C. for 1.5 hours and then at room temperature for 16 hours. Further, 60 mg (0.29 mmol) of 3,4-dimethoxycinnamic acid and 60 mg of DCC were added, and the mixture was further stirred at room temperature overnight. Then, the organic layer was washed with aqueous KHSO 4 , aqueous NaCl, dried, concentrated and subjected to silica gel column chromatography (hexane:ethyl acetate=5:1) to obtain 76 mg of the ester derivative (7) (78%).
NMR (δ ppm, CDCl 3 , 60 MHz) 0.5-1.8 (m, 10H), 3.85 (s, 6H), 4.1 (m, 2H), 5.7 (dd, 1H, J=16.0 Hz, 8.0 Hz), 6.15 (d, 1H, J=16.0 Hz), 6.4 (d, 1H, J=16.0 Hz), 6.5-7.1 (m, 3H), 7.1-7.8 (m, 8H)
IR (cm -1 , neat) 2950, 2850, 1735, 1700, 1630, 1600, 1510, 1460, 1420, 1260
EXAMPLE 7
Synthesis of Methyl 4-(3-(2-naphthyl)-2E-propenylthio) butanoate ##STR27##
To 2 ml of a dry THF solution of 160 mg (0.64 mmol) of dimethyl 2-naphthylmethyl phosphonic acid was added 3.2 ml (0.64 mmol) of a 0.2 M THF solution of lithium dicyclohexyl amide, and 5 minutes later, 2 ml of a THF solution of 113 mg (0.64 mmol) of methyl 6-formyl-5-thiahexanoic acid was added, followed by stirring at room temperature for one day. The reaction was completed by the addition of aqueous NH 4 Cl, and the reaction product was extracted with ethyl acetate. The organic layer was washed with aqueous NaCl, dried, concentrated and subjected to silica gel chromatography (hexane:ethyl acetate=4:1) to obtain 37 mg (19%) of the desired product (8).
NMR (δppm, CDCl 3 ) 60 MHz 1.6-2.6 (m, 6H), 3.2 (d, 2H, J=6.0 Hz) 3.6 (s, 3H), 6.0 (1H, dt, J=16.0 Hz, 6.0 Hz), 6.45 (d, 1H, J=16.0 Hz), 7.0-7.7 (m, 7H)
IR (cm -1 , neat) 2950, 1735, 1600, 1505, 1430, 1360
EXAMPLE 8
Synthesis of Methyl 4-(5-(2-naphthylvinyl)-2-throphene) butanoate ##STR28##
To 2 ml of a DMF solution of 250 mg (1 mmol) of dimethyl 2-naphthylphosphonate and 212 mg (1 mmol) of methyl 4-(5-formyl-2-thienyl) butanoate was added 1 ml of a DMF solution of 212 mg of 28% methanol solution of CH 3 ONa, followed by stirring at room temperature for one hour.
The reaction was completed by addition of aqueous NH 4 Cl, and the reaction product was extracted with ethyl acetate. The crude product was subjected to silica gel chromatography (hexane:ethyl acetate=7:1) to obtain 220 mg (68%) of the desired product (9).
NMR (δ ppm, CDCl 3 ): 1.8-2.5 (m, 4H), 2.5-2.9 (m, 2H), 3,55 (s, 3H), 6.4-7.7 (m, 11H)
EXAMPLE 9
Synthesis of Methyl 8-(2-naphthyl)-5E,7E-octadienoate ##STR29##
To a 2 ml dry THF solution of 160 mg (0.64 mmol) of dimethyl 2-naphthylmethyl phosphonate was 3.2 ml (0.64 mmol) of a 0.2M THF solution of lithium diisopropyl amide (LDA), and, 5 minutes later, 2 ml of a THF solution of 100 mg (0.64 mmol) of methyl 6-formyl-5E-hexenoic acid was added, followed by stirring at room temperature for one day. The reaction was completed by the addition of aqueous NH 4 Cl, and the reaction product was extracted with ethyl acetate. The organic layer was washed with aqueous NaCl, dried, concentrated and subjected to silica gel chromatography (hexane:ethyl acetate=4:1) to obtain 73 mg (41%) of the desired product (10).
NMR (δ ppm, CDCl 3 ) 1.5-2.5 (m, 6H), 3.55 (s, 3H), 5.4-6.8 (m, 4H), 7.0-7.8 (m, 7H)
EXAMPLE 10
Synthesis of Methyl 8-(2-(6-methoxynaphthyl)-5,6-trans-5,6-methano-7E octenoate ##STR30##
To 500 μl of a DMF solution of 80 mg (0.29 mmol) of dimethyl 2-(6-methoxynaphthyl) methylphosphonate and 50 mg (0.29 mmol) of methyl 6-formyl-5,6-trans-5,6-methano hexanoate was added 200 μl of a DMF solution of 58 mg (0.3 mol) of a 28% methanol solution of CH 3 ONa, followed by stirring at room temperature for 6 hours. The reaction was completed by the addition of a saturated aqueous solution of ammonium chloride and the reaction mixture was extracted with ethyl acetate. The organic layer was washed with water, and subsequently with a saturated aqueous sodium chloride solution, followed by drying over anhydrous magnesium sulfate. The resultant mixture was concentrated by removing the solvent under a reduced pressure and the crude product was subjected to silica gel chromatography (hexane:ethyl acetate=9:1) to obtain 37 mg (42%) of the desired product (11).
NMR (δ ppm, CDCl 3 ): 0.4-1.0 (m, 3H), 1.0-2.0 (m, 5H), 2.0-2.4 (m, 3H), 3.55 (s, 3H), 3.8 (s, 3H), 5.7 (dd, 1H, J=15 Hz, 8 Hz), 6.4 (d, 1H, J=15 Hz), 6.8-7.6 (m, 6H)
EXAMPLE 11
Synthesis of 7-(6,7-Dimethoxy-2-naphthylthio)-5,6-trans-5,6-methano-hexanoic acid methyl ester ##STR31##
To 4 ml of a DMF solutio nof 71.2 mg (0.32 mmol) of 6,7-Dimethoxy-2-mercaptonaphthalene was added 15 mg (0.37 mmol) of NaH (60% in oil) under nitrogen, followed by stirring under ice cooling, and 4 ml of a DMF solution of 76 mg (0.32 mmol) of 7-bromo-5,6-trans-5,6-methanohexanoic acid methyl ester was added, followed by stirring at room temperature for 2 hours. ethyl acetate and water were added to the reaction mixture, and the aqueous layer was extracted with ethyl acetate. The organic layer was washed with a saturated aqueous sodium chloride solution, dried over anhydrous magnesium sulfate, and then concentrated. The resultant oily product was subjected to silica gel column chromatography (ethyl acetate:hexane=10:1-7:1) to obtain 72.8 mg (60%) of the desired product (12).
1 H-NMR (δ ppm, CDCl 3 ); 0.2-1.0 (m, 4H), 1.1-1.4 (m, 2H), 1.4-1.9 (m, 2H), 2.32 (t, J=7 Hz, 2H), 2.94 (d, J=7 Hz, 2H), 3.64 (s, 3H), 3.98 (s, 6H), 7.0-7.6 (m, 5H) 13 C.NMR (δ ppm, CDCl 3 ); 12.9, 18.2, 19.4, 24.7, 33.1, 33.7, 39.6, 51.3, 55.8, 105.8, 106.2, 126.3, 126.6, 126.7, 127.4, 129.5, 131.9, 149.3, 149.8, 173.8
EXAMPLE 12
Synthesis of 7-(6,7-Dimethoxy-2-naphthylthio)-5-hexenoic acid methyl ester ##STR32##
To 500 mg (2.27 mmol) of 6,7-dimethoxy-2-mercaptonaphthalene in THF (10 ml) and DMF (7 ml) solution was added 100 mg (2.5 mmol) of NaH (60% in oil) under nitrogen, followed by stirring at room temperature for 10 minutes. The mixture was added to 10 ml of a previously prepared THF solution of 450 mg (2.27 mmol) of methyl 7-acetoxy-5-hexenoate and 141 mg (0.11 mmol) of (Ph 3 P) 4 Pd under nitrogen, followed by stirring at 70° C. for 20 minutes. The reaction was completed by the addition of aqueous NH 4 Cl, followed by extracting with ethyl acetate. The organic layer was washed with a saturated aqueous sodium chloride solution and the solvent was distilled off under a reduced pressure. The resultant oily product was subjected to silica gel column chromatography (hexane:ethyl acetate=7:1→4:1) to obtain 98 mg (18%) of the recovered thiol, 260 mg (32%) of methyl 7-(6,7-dimethoxy-2-naphthylthio-5-hexenoate (13), and 320 mg (39%) of the mixture thereof (including impurities).
NMR (δ ppm, CDCl 3 ): 1.45-1.8 (m, 2H), 1.9-2.3 (m, 4H), 3.5-3.7 (m, 2H), 3.6 (s, 3H), 4.0 (s, 6H), 5.4-5.6 (m, 2H), 7.05 (s, 1H), 7.1 (s, 1H), 7.33 (dd, 1H, J=9 Hz, 2 Hz), 7.63 (d, 1H, J=9 Hz), 7.66 (s, 1H).
EVALUATION EXAMPLE 1
LTB 4 production inhibition effect on iris of normal house rabbit
The iris of a normal house rabbit was enucleated, dipped in 1 cc of Tylord solution for control and 1 cc of Tylord solution containing a certain level of medicament, and after 5 minutes, the Tylord solution was passed through a SEP-pack, the portion containing leucotriene was separated by HPLC, and the LTB 4 amount was measured by radioimmunoassay. The results are shown in Table 1. (n=4)
TABLE 1______________________________________ Concentration Inhibition % ofCompound (M) LTB.sub.4 production______________________________________Compound (3) in Example 2 10.sup.-4 95(i.e., Methyl anthranylate 10.sup.-5 95amide of 8-(2-naphthyl)-5,6- 10.sup.-6 89trans-5,6-methano-7 .sub.-- E- 10.sup.-7 67octenoic acid)Compound (7) in Example 6 10.sup.-4 92(i.e., 3,4-Dimethoxy cinnamic 10.sup.-5 88acid ester of 8-(2-naphthyl)- 10.sup.-6 805,6-trans-5,6-methano-7 .sub.-- E- 10.sup.-7 20octene-1-olReference compound* 10.sup.-4 35 10.sup.-5 0 10.sup.-6 -- 10.sup.-7 --______________________________________ *Compound disclosed in JPA-59-222438. (i.e., 8naphthyl)-5,6-trans-5,6-methano-7.sub.-- Eoctenoic acid)
EVALUATION EXAMPLE 2
LTB 4 production inhibition effect on human blood
A 10 -5 M amount of Calcium ionophore was added to human whole blood, followed by adding the compounds listed in Table 2 to evaluate the inhibition effect of these compounds on LTB 4 production. The evaluation was carried out in a manner described in Gresele, P., Arnoult, J., Coene, M. C., Deckmyn, H., and Vermylen, J.: Leukotriene B 4 production by stimulated whole blood: Comparative studies with isolated polymorphonuclear cells, Biochem. Biophys. Res. Commun. 137: 334-342, 1986.
The results are shown in Table 2.
TABLE 2______________________________________ Concentration LTB.sub.4 productionCompound (M) Amount μg/ml______________________________________Control 0 20Compound (3) in Examp1e 2 10.sup.-5 11(i.e., Methyl anthranylate 10.sup.-6 12amide of 8-(2-naphthyl)-5,6- 10.sup.-7 15trans-5,6-methano-7 .sub.-- E-octenoic acid)Compound (7) in Example 6 10.sup.-5 12(i.e., 3,4-Dimethoxy cinnamic 10.sup.-6 12acid ester of 8-(2-naphthyl)- 10.sup.-7 135,6-trans-5,6-methano-7 .sub.-- E-octene-1-ol______________________________________
EVALUATION EXAMPLE 3
Effect on intraocular inflammation by Lipopoly saccharide from E. Coli
(1) Preparation of eye drops
The eye drops of the compound (3), i.e., anthranylic acid amide of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octenoic acid was prepared by formulating 3.8 mg of the compound (3) in 0.1 ml of ethanol followed by adding 0.9 ml of teel oil to obtain eye drops containing 0.38% of compound (3). The pH was 6.8.
The eye drops of the compound (7), i.e., 3,4-dimethoxy cinnamic acid ester of 8-(2-naphthyl)-5,6-trans-5,6-methano-7E-octene-1-ol were prepared by dissolving 5.3 mg of the compound (7) in 0.1 ml of ethanol upon heating at 70° C. to 80° C. followed by adding 0.9 ml of teel oil to obtain eye drops containing 0.53% of compound (7). The pH was 6.8.
(2) Effect of eye drops on endotoxin intraocular inflammation
Into one eye of a white male house rabbit having a body weight of 1.5 to 2.0 kg, were dropped the eye drops of the compounds (3) and (7), at 6 hours, 4 hours, and 1 hour before the experiment, and into the other eye, control eye drops containing 0.1 ml ethanol and 0.9 ml teel oil were dropped in the same manner.
To the vitreous body, 5 μg of lipopoly saccharide from E. coli (commercially available from Sigma) in 50 μl of physiolological saline was dropped. After 20 hours, the aqueous humor was taken and the protein content of the aqueous humor was determined by a Bio-rad assay method and the leucocyte in the aqueous humor was determined by a Neubauer Chamber. The LTB 4 in the aqueous humor was determined by the HPLC and RIA methods.
The results are shown in Table 3.
TABLE 3______________________________________ Leucocyle Aqueous in aqueous protein LTB.sub.4 in aqueousCompound (cells/ml) (mg/ml) (pg/ml)______________________________________Control 10.1 × 10.sup.5 30 150Compound (3) 6.0 × 10.sup.5 40 7.5Control 5.5 × 10.sup.5 33 320Compound (7) 7.5 × 10.sup.5 41 170______________________________________ | 1. An aromatic derivative having the formula (I) or the salt thereof: ##STR1## wherein R 1 and R 2 independently represent a hydrogen atom, hydroxyl, a halogen atom, or OR 3 wherein R 3 is C 1 -C 10 alkyl; A-B represents a hydrocarbon moiety having 1 to 10 carbon atoms and containing at least one double bond or a sulfur- or oxygen-containing hydrocarbon moiety having 1 to 10 carbon atoms; n is an integer of 2 to 4; X represents a group ##STR2## and Y represents a hydrogen atom; alkyl having 1 to 5 carbon atoms which may be substituted with aryl; alkenyl having 2 to 5 carbon atoms which may be substituted with aryl or aryl substituted with at least one C 1 -C 5 alkoxy; aryl which may be substituted with at least one carboxy or C 1 -C 5 alkoxycarbonyl or C 1 -C 5 alkoxy; provided that, when R 1 and R 2 are both hydrogen, the moiety --A--B--(CH 2 ) n --X--Y does not represent ##STR3## wherein n=2 to 4 and R 4 is hydrogen or C 1 -C 5 alkyl. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. application Ser. No. 12/976,329 (now U.S. Pat. No. 8,481,111), filed on Dec. 22, 2010, which claims the benefit of U.S. Provisional Application No. 61/295,343, filed on Jan. 15, 2010, and claims the benefit of Swedish Application No. 1050037-9, filed on Jan. 15, 2010. The entire contents of each of U.S. application Ser. No. 12/976,329, U.S. Provisional Application No. 61/295,343 and Swedish Application No. 1050037-9 are hereby incorporated herein by reference.
TECHNICAL FIELD
The disclosure generally relates to the field of fibre-based panels with wear resistant surface layers for building panels, preferably floor panels. The disclosure relates to building panels with such wear resistance surface and to production methods to produce such panels.
FIELD OF APPLICATION
The present disclosure is particularly suitable for use in floating floors, which are formed of floor panels with a wood fibre core and a decorative wear resistant surface. The following description of technique, problems of known systems and objects and features of the invention will therefore, as a non-restrictive example, be aimed above all at this field of application and in particular at floorings which are similar to traditional floating wood fibre based laminate floorings. The disclosure does not exclude floors that are glued down to a sub floor.
It should be emphasized that embodiments of the disclosure can be used as a panel or as a surface layer, which is for example glued to a core. Embodiments of the disclosure can also be used in applications as for example wall panels, ceilings, and furniture components and similar. Embodiments could also be used in floorings with optional surface materials such as cork or wood, in order to improve wear and design properties.
BACKGROUND
It is well known to produce laminated building panels with a surface comprising laminated paper sheets.
A new type of panel called Wood Fibre Floor (WFF) is disclosed in WO 2009/065769 which shows both products and methods to produce such a product.
Direct pressed laminated building panels usually comprises a core of a 6-12 mm fibre board, a 0.2 mm thick upper decorative surface layer of laminate and a 0.1-0.2 mm thick lower balancing layer of laminate, plastic, paper or like material.
A laminated surface generally comprise two paper sheets, a 0.1 mm thick printed decorative paper and a transparent 0.05-0.1 mm thick overlay paper applied over the decorative paper and intended to protect the decorative paper from abrasion. The print on the decorative non-transparent paper is only some 0.01 mm thick. The transparent overlay, which is made of refined a-cellulose fibres, comprises small hard and transparent aluminium oxide particles. The refined fibres are rather long, about 2-5 mm and this gives the overlay paper the required strength. In order to obtain the transparency, all natural resins that are present in the virgin wood fibres, have been removed and the aluminium oxide particles are applied as a very thin layer over the decorative paper. The surface layer of a laminate floor is characterized in that the decorative and wear resistance properties are generally obtained with two separate layers one over the other.
The printed decorative paper and the overlay are impregnated with melamine resin and laminated to a wood fibre based core under heat and pressure.
The small aluminium oxide particles could have a size in the range of 20-100 microns. The particles could be incorporated in the surface layer in several ways. For example they could be incorporated in the pulp during the manufacturing of the overlay paper. They could also be sprinkled on the wet lacquer during impregnation procedure of the overlay or incorporated in the lacquer used for impregnation of the overlay.
The wear layer could also be produced without a cellulose overlay. In such a case melamine resin and aluminium oxide particles are applied as a lacquered layer directly on the decorative paper with similar methods as described above. Such a wear layer is generally referred to as liquid overlay.
With this production method a very wear resistance surface could be obtained and this type of surface is mainly used in laminate floorings but it could also be used in furniture components and similar applications. High quality laminate floorings have a wear resistance of 4000-6000 revolutions, which corresponds to the abrasion classes AC4 and AC5 measured with a Taber Abraser according to ISO-standard.
It is also known that the wear resistance of a lacquered wood surface could be improved considerably by incorporating aluminium oxide particles in the transparent lacquer covering the wood surface.
The most common core material used in laminate floorings is fibreboard with high density and good stability usually called HDF—High Density Fibreboard. Sometimes also MDF—Medium Density Fibreboard—is used as core. Other core materials such as particleboard are also used.
The WFF floor panels are “paper free” with a surface layer comprising a substantially homogenous mix of wood fibres, binders and wear resistant particles. The wear resistant particles are preferably aluminium oxide particles and the binders are preferably thermosetting resins such as melamine. The wear resistant particles are provided throughout the thickness of the surface layer from the top to the bottom and in contact with the core of the panel. Other suitable materials are for example silica or silicon carbide. In general, all these materials are preferably applied in dry form as a mixed powder on a HDF core and cured under heat and pressure to a 0.2-1.0 mm surface layer.
DEFINITION OF SOME TERMS
In the following text, the visible surface of the installed floor panel is called “front side”, while the opposite side of the floor panel, facing the sub floor, is called “rear side”. The sheet-shaped material that comprises the major part of a panel and provides the panel with the required stability is called “core”. When the core is coated with a surface layer closest to the front side and preferably also a balancing layer closest to the rear side, it forms a semi-manufacture, which is called “floor board” or “floor element” in the case where the semi-manufacture, in a subsequent operation, is divided into a plurality of floor elements. When the floor elements are machined along their edges so as to obtain their final shape with the joint system, they are called “floor panels”. By “surface layer” is meant all layers which give the panel its decorative properties and its wear resistance and which are applied to the core closest to the front side covering preferably the entire front side of the floorboard. By “decorative surface layer” is meant a layer, which is mainly intended to give the floor its decorative appearance. “Wear layer” relates to a layer, which is mainly adapted to improve the durability of the front side.
By “horizontal plane” is meant a plane, which extends parallel to the outer part of the surface layer. By “horizontally” is meant parallel to the horizontal plane and by “vertically” is meant perpendicularly to the horizontal plane. By “up” is meant towards the front side and by “down” towards the rear side.
SUMMARY OF THE INVENTION
An overall objective of embodiments of the disclosure is to provide a building panel, preferably a floor panel with a pale and/or plain colour, e.g. bright white, wear resistant layer that could be produced in a more cost effective way than with the present known technology.
The methods described in WO 2009/065769 include the use of virgin or recycled wood fibres that have the limitation that while using pigments intended to give pale colours, e.g. bright white colour, or very intense colours, the natural colour of the virgin or recycled wood fibre give a less pale or less colourful result due to the natural resins of the fibres. The natural resin makes it difficult to achieve the desired colour and might cause areas that are discoloured. The problems of limited colourfulness could be solved by increasing the amount of the pigments, but this is a rather expensive solution and high pigment loadings could cause other problems such a pigment bleed.
Conventional laminated floors panels have a limitation in making pale coloured or intensively coloured surfaces, due to the limited transparency of the highly wear resistant overlays.
A solution to the problems is to use a dry powder layer comprising a mix of refined fibres binder, pigment and wear resistant particles.
An aspect of the invention is a production method to produce a pale coloured wear resistant surface layer comprising the steps of:
applying a dry powder layer comprising a mix of refined fibres, binder, pigment and wear resistant particles on a carrier; and curing the mix to a colourful or bright white wear resistant layer by applying heat and pressure on the mix.
The binder is preferably a melamine resin and the wear resistant particles aluminium oxide. The pigments for making bright white products are preferably titanium dioxide, lead oxide or other commonly used pigments. The pigments for making very colourful products are a broad variety of both inorganic and organic origin.
The carrier on which the mix is applied is preferably an HDF panel and the resulting panel thereby has wear resistant particles throughout the thickness of the surface layer from the top to the bottom and in contact with the core of the panel.
The refined fibres are fibres that are predominantly free from the natural resins typically found in wood fibres or other natural fibres. Such fibres can be achieved through washing, extraction, bleaching or combinations thereof. An example of such a fibre is Technocel® 150 TAB which can be provided by the company CFF (Germany).
In a preferred embodiment, the amount of resin compared to the amount of refined fibres, e.g., white fibres, in the dry powder layer is higher than about 100%, preferably above about 120% and most preferably in the range of about 120% to 180%. Such ratios have the effect that the processability is increased and that the stain resistance is improved.
A sublayer, a layer scattered on the core, in combination with the dry powder layer above the sublayer, gives even better processability such as embossing depth and higher gloss. In embodiments, the sublayer comprises wood fibres, preferably natural wood fibres or HDF fibres, though refined fibres may be used, and a resin. In a preferred embodiment, the amount of resin compared to the amount of wood fibres is less than about 100%, preferably below about 200%, more preferably below about 300%, and possibly even below about 400%.
A top layer of refined fibres, without any aluminium oxide, placed above the dry powder layer further improves the stain resistance. It also increases the lifetime of the press plates.
Embodiments of the disclosure include the following combination of layers: (1) a sublayer and a dry power layer; (2) a dry powder layer and a top layer; and (3) a sublayer a dry powder layer and a top layer.
It is also possible to use a mix of refined fibres and HDF fibres or any natural wood fibres, i.e., wood fibres that are not refined, in order to decrease the cost and or create other colours.
Many combinations of the ingredients can be made into fully functional products. Two examples are given as to show two functional prototypes of the innovation.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will in the following be described in connection to preferred embodiments and in greater detail with reference to the appended exemplary drawing, wherein:
FIG. 1 Illustrates a floor panel according to an embodiment of the disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
A panel 1 is provided with a wood fibre based core 6 , a homogenous non-transparent decorative surface layer 5 and preferably a balancing layer. The panel 1 is in one embodiment integrally formed in a production process where the surface layer, the core and the balancing layer are formed in the same pressing operation.
FIG. 1 shows the surface layer 5 . It comprises a mixture of refined fibres 14 , small hard wear resistant particles 12 , 12 ′ and a binder 19 . The wear resistant particles ( 12 , 12 ′) are preferably aluminium oxide particles.
The surface layer comprises also colour pigments 15 and/or, optionally, other decorative materials or chemicals. Decorative materials include, for example, materials that may affect design aspect(s) the surface layer. Exemplary design materials include materials effecting texture, reflectivity, shine, luminescence, transparency, etc.
Embodiments of the disclosure offer the advantage that the wear resistant surface layer 5 could be made much thicker than in the known laminated floor panels.
A preferable binder is melamine or urea formaldehyde resin. Any other binder, preferably synthetic thermosetting resins, could be used.
In the method according to embodiments of the invention preferably the same scattering and pressing units as disclosed in WO 2009/065769 are used, preferably together with a structured press plate in the method.
Example W1
Bright White Formulation
On a HDF board with a thickness of 9.8 mm, two backing papers NKR 140 where fixed on backside for balancing, a WFF powder formulation was added, consisting of 40 Wt % refined fibre, 10 Wt % aluminium oxide, 10 Wt % titanium dioxide as pigment and 40 Wt % melamine resin. The WFF powder mix was applied by a so-called scattering machine, which distributed the WFF powder material evenly over the HDF surface. The total amount of WFF powder was 625 g/m 2 . The WFF powder was fixed on the HDF board by spraying a water solution consisting of 97 Wt % de-ionized water, 1 Wt % BYK-345 (wetting agent added to reduce surface tension) and 2 Wt % of Pat 622/E (release agent) on the WFF powder.
The above material was placed into a so-called DPL press. The surface texture consists of a special press plate with hills and valleys with about 300 microns in difference in highest and lowest part. This deep press plate cannot be used when pressing DPL and HPL, the melamine impregnated papers cracks during the pressing. The resulting product is a bright white building panel.
Further examples of powder mixtures are listed below.
Type
W1
W2
W3
W4
Sublayer
W5
HDF Fibre Wt %
0
0
0
0
75
0
White Fibre Wt %
40
40
35
30
0
39
Prefere 4865 Wt %
0
40
45
52
25
0
Kauramine 773 Wt %
40
0
0
0
0
50
TiO2 Wt %
10
10
10
9
0
11
Al2O3 Wt %
10
10
10
9
0
0
Total Wt %
100
100
100
100
100
100
In the mixtures above Prefere 4865 and Kauramine 773 are used, which are examples of melamine formaldehyde resins.
For W3 and W4 the weight ratio of resin compared to the White Fibres (refined fibres) is increased. The increased ratio has the effect that the processability is increased and that the stain resistance is improved. In a preferred embodiment the weight ratio of resin compared to the White Fibres is higher than about 100%, preferably above about 120% and most preferably in the range of about 120% to 180%.
A sublayer, a layer scattered on the core, in combination with any one of the layers W1-W4 above the sublayer gives even better processability such as embossing depth and higher gloss.
A top layer, such as W5, without any aluminium oxide above any one of the layers W1-W4 further improves the stain resistance. It also increases the life time of the press plates.
Example R2
Colourful Red Formulation
On a HDF board with a thickness of 9.8 mm, two backing papers NKR 140 where fixed on backside for balancing, a WFF powder formulation was added, consisting of 42.5 Wt % refined fibre, 10 Wt % aluminium oxide, 5 Wt % Heucosin Spez. Tomatenrot G 10138 as red pigment and 42.5 Wt % melamine resin. The WFF powder mix was applied by a so-called scattering machine, which distributed the WFF powder material evenly over the HDF surface. The totally amount of WFF powder was 625 g/m 2 . The WFF powder was fixed on the HDF board by spraying a water solution consisting of 97 Wt % de-ionized water, 1 Wt % BYK-345 (wetting agent added to reduce surface tension) and 2 Wt % of Pat 622/E (release agent) on the WFF powder.
The above material was placed into a so-called DPL press. The surface texture consists of a special press plate with hills and valleys with about 300 microns in difference in highest and lowest part. This deep press plate cannot be used when pressing DPL and HPL, the melamine impregnated papers cracks during the pressing. The resulting product is a colourful plain red building panel not easily obtained without the refined fibre.
The water solution sprayed on the WFF powder may include, for example, 80-100 Wt % water, preferably de-ionized water, 0-10 Wt % of a wetting agent, and 0-10% of a release agent. More preferably, the water solution may include, for example, 95-98.5 Wt % water, preferably about 97 Wt %, 0.5-2 Wt % wetting agent, preferably about 1 Wt %, and 1-3 Wt % release agent, preferably about 2 Wt %. | A method of manufacturing a surface layer is provided. The method includes applying a sublayer having a mix of wood fibers and a resin on a carrier, applying a powder layer having a mix of refined fibers and a binder on the sublayer, with the sublayer being arranged between the carrier and the powder layer, and curing the powder layer by applying heat and pressure. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to threaded connections and, more particularly, to coupled, threaded connections for use on tubing used in the completion and workover of oil and gas wells.
BACKGROUND OF THE INVENTION
[0002] In the completion and production of an oil/gas well, it is often sometimes necessary to drill out a plug or other down hole obstruction which was used in the construction of the well. An example of this is so called fracing plugs used in fracing operations that are commonly conducted in shale formations. The fracing plugs are typically used to isolate lateral or horizontal sections of the well bore so that successive, isolated sections can be fraced to stimulate production. However, the fracing plugs must be drilled out so that the oil from the formation can flow to the well head for recovery.
[0003] In these types of workover or intervention activities, it is common to use a tubing string to drill out the plugs. In the past, this was conventionally done with work strings of tubing employing so called eight-round or LTC connections. However, in highly deviated or horizontal wells where most fracing occurs, connections employing eight-round threaded components are not sufficiently rugged enough to withstand the changing tension and compression loads that the work/tubing string undergoes.
[0004] Recognizing this problem, many operators elect to use a two-step or dual step threaded connection with a metal to metal radial seal which is an integral connection i.e., there is no coupling between the sections of tubing. While two-step, integral connections for tubing work strings are better than coupled eight-round threaded tubing strings, they are not without disadvantages. For one thing, two-step threaded connections are more expensive to manufacture and more expensive to rethread in the event of damage.
[0005] Ideally, a tubing string used in the activities described above e.g., drilling out of plugs and other well intervention techniques, would be capable of withstanding high make-up torque and could be made-up and broken-out multiple times e.g., 20 or more times, without any significant reduction in break-out torque. Such a connection would last longer and while in use would be more rugged and able to withstand the tension compression and bending loads placed on the connection especially, for example, in more acute bending modes e.g. 20 degrees per 100 feet. In particular, such a tubing string to would be resistant to the threaded connections backing-off to the point where the string separates.
SUMMARY OF THE INVENTION
[0006] In one aspect there is provided a coupled threaded connection which can withstand high make-up torque.
[0007] In another aspect there is provided a threaded, coupled connection which exhibits a break-out torque only slightly less than the make-up torque after repeated makes and breaks.
[0008] In still a further aspect there is provided a threaded, coupled connection comprised of a coupling having first and second boxes and first and second pins which are upset.
[0009] These and further features and advantages will become apparent from the following detailed description, wherein reference is made to the figures in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a longitudinal sectional view showing schematically the characteristics of a threaded connection having a run-out thread on a standard generally uniform O.D. pipe.
[0011] FIG. 2 is a view similar to FIG. 1 but showing the characteristics of a threaded connection having a pull-out thread on a section of a pipe having an upset O.D.
[0012] FIG. 3 is a partial, longitudinal section of one embodiment of the present invention showing a coupled threaded connection with mechanical stops or torque shoulders.
[0013] FIG. 4 is a view similar to FIG. 3 of another embodiment of a coupled, threaded connection of the present invention.
[0014] FIG. 5 is a partial, cross-sectional view of the thread form used in the threaded connections shown in FIGS. 3 and 4 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] The thread form used in the threaded connections of the present invention, described more fully hereafter, is particularly useful in coupled, tubing strings employed as work strings. The terms “box”, “box connection(s)” and similar terms refers to a tubular member having an internally threaded section. The terms “pin”, “pin connection(s)” or similar terms refers to a tubular member having an externally threaded section. It is a feature of the thread form and the threaded connections of the present invention that the threads are tapered having a taper of one inch per foot and a thread pitch of seven threads per inch. The threads used in the threaded connections of the present invention have a thread height of from about 0.042 to about 0.046 inches, particularly about 0.044 inches. Furthermore, the pin or pin connections used in the threaded connections of the present invention are “upset” meaning they have an OD adjacent the threaded sections which is greater than the OD of the pipe to which the pin connection is attached.
[0016] The connections of the present invention are also characterized by the fact that the pins have “pull-out” threads rather than “run-out” threads. For purposes of illustration and comparison between those two types of thread forms, reference is made to FIGS. 1 and 2 . Referring first then to FIG. 1 which schematically depicts a run-out thread, it can be seen that the pin, shown generally as 10 , is formed on one end of a pipe or tubular section 11 and has a threaded section shown generally as 12 , the threaded section 12 extending generally from approximately the pin nose 14 to a location, indicated by the line 16 at which point the threads run-out of the pipe body 11 . As is well known, a run-out thread maintains the same taper per foot (angle) with a thread height decreasing generally after about the last fully engaged full height thread at which point the thread height starts uniformly decreasing. In short, a run-out thread maintains the same taper per foot (angle) with a thread height decreasing as the thread runs out of the body. As can be seen with respect to FIG. 1 , there are a series of lines and surfaces which collectively describe a run-out thread. Line 13 is an imaginary line which is parallel to the long axis of the pin 10 i.e., it is coincident with the ID of the pin 10 . Dotted line 22 depicts the root of the threads while surface line 24 depicts the crests of the threads before the thread height begins to decrease which is generally in an area depicted by line 20 , line 26 depicting the crests of the decreasing thread height threads until the run-out point indicated by line 16 . Line 18 depicts the length of the portion of threaded section 12 where the threads are generally at full height and fully engaged, line 19 generally depicting the length of the threaded portion 12 in which the heights of the threads are decreasing. Thus as can be discerned the thread height of the threads generally between the nose 14 of the pin 10 and line 20 is the difference between dotted line 22 and surface line 24 . The thread height of the decreasing thread height threads is the difference between dotted line 22 and surface line 26 . Thus while the threaded section 12 extends from about the pin nose 14 to about line 16 , the fully engaged full height portion of the threads extends generally from the pin nose 14 to line 20 while the decreasing thread height threads extend from about line 20 to about line 16 . FIG. 1 also shows that the angle A-A of 2.39° is the thread taper which stays constant from about the nose 14 of the pin to the point 16 on the surface of the pin 10 where the threaded section 12 runs-out.
[0017] Referring now to FIG. 2 , there is shown a “pull-out thread”. In general, pull-out threads are characterized by the fact that they maintain the same thread height until the threaded portion reaches a set distance from the nose of the pin at which point the threads pull-out of the pipe body on a different, greater angle. With reference to FIG. 2 , the pin shown generally as 30 is formed on a pipe body 32 and has a pin nose 34 . There is a threaded section indicated generally as 35 which extends generally form the pin nose 34 to a point indicated by the line 36 at which point the threads pull-out of the body. As can be seen, the root of the threads of the threaded portion 35 is on two angles one being a constant angle of 2.39° (relative to the long axis of the pin 30 ) extending generally from pin nose 34 to a point on the pin indicated by line 40 . Commencing at about line 40 the angle or taper of the threads (again relative to the long axis of the pin 30 ) is 4.67° as indicated by angle B-B. The height of the threads of the threaded section extending from about pin nose 34 to about line 40 is the difference between the thread root line 38 and a surface line 42 which defines the crests of the threads of that threaded portion. In short, the angle of the threads between the line 40 and the line 36 increases rather sharply from 2.39° to 4.67° as the thread pulls-out of the body 32 .
[0018] As can be seen by comparing line 10 A of FIG. 1 with line 30 A of FIG. 2 which is a depiction of the wall thickness of the respective pins 10 and 30 , pin 30 has a greater wall thickness than pin 10 . Further, as shown hereafter the minimum diameter of the last engaged thread of the threaded section 35 of pin 30 is greater than the OD of the pipe body on which of pin 10 is formed.
[0019] Referring now to FIG. 3 there is shown one embodiment of the present invention comprising a coupled, shouldered connection. The connection, shown generally as 50 comprises a coupling body shown generally as 52 , only one end of which is shown, it being understood that the other end is the same. Coupling body 52 has an internal, annular, radially inwardly projecting rib 54 , there being a first internal, annular axially facing shoulder 56 formed on rib 54 . A first inwardly projecting, annular thread relief 58 is formed adjacent shoulder 56 . There is a first coupling body end face 60 , and a first internally threaded portion having threads 62 . Accordingly there is formed a first box connection 52 A generally bounded by shoulder 56 and first end face 60 .
[0020] Coupling body 52 also forms a second box connection 52 B having a second annular, axially facing shoulder 66 formed on rib 54 opposite shoulder 56 , and a radially inwardly extending annular thread relief 68 adjacent shoulder 66 , second box connection 52 B being generally bounded by shoulder 66 and a second coupling body end face (not shown).
[0021] Coupled connection 50 also comprises a first pin 70 connected to a first pipe body 71 and a second pin 72 connected to a second pipe (not shown), pins 70 and 72 having first and second pin noses 70 A and 72 A, respectively. First pin 70 has a first upset portion 74 while second pin 72 has a second upset portion (not shown). When made-up as shown in FIG. 3 , first pin 70 and second pin 72 one threadedly received in first box 52 A and second box 52 B, respectively, pin noses 72 A and 70 A being made-up to a desired torque against shoulders 56 and 66 , respectively. Connection 50 , as seen, has a generally flush ID.
[0022] As seen in FIG. 3 , pipe body 71 has an OD of D indicated by arrow C. As also seen there is an arrow D showing the minimum diameter of the last engaged thread of pin connection 70 . As can be seen from the dotted line 80 , the minimum diameter of the last engaged thread indicated by the arrow D is greater than the OD of the pipe body 71 indicated by the arrow C.
[0023] The pull-out feature of threaded connection 50 can be readily appreciated by looking at the threaded area of the pin 70 bounded by the arrows E and F. As can also be seen, there is no thread of first pin 70 which extends beyond the first end face 60 of coupling body 52 , a like situation existing with respect to second pin 72 .
[0024] Referring now to FIG. 4 there is shown another embodiment of the present invention which comprises a coupled connection, shown generally as 90 . Coupled connection 90 comprises a coupling body 92 having a centerline indicated by arrow G which is perpendicular to a longitudinally extending, product axis (not shown), concentric with coupling body 92 , coupling body 92 having a first end 94 and a second end (not shown). Coupling body 92 forms a first box 96 which extends generally from first end face 94 to the center line G of coupling body 92 . A female, threaded section having threads 98 extends between first end face 94 and center line G. There is also a second box 91 which is generally formed between the second end (not shown) extending generally to center line G.
[0025] Coupled connection 90 also includes a first pin 98 having an externally threaded section, comprised of threads 100 . First pin 98 has a first pin nose 102 . Coupled connection 90 also includes a second pin 104 , comprised of threads 105 . Second pin 104 has a second pin nose 106 . As seen in FIG. 4 , when the coupled connection 90 is fully made-up, pin noses 102 and 106 are in abutting relationship. Accordingly, the coupled connection 90 has a substantially flush internal ID.
[0026] First and second pins 98 and 104 are connected to first and second pipe bodies, only first pipe body 103 being shown. As in the case of the embodiments shown on FIG. 3 the minimum diameter of the last engaged thread of the pin connections 98 and 104 are greater than the OD of the pipe bodies e.g., pipe body 103 . Also as in the case of the embodiment shown in FIG. 3 , it can also be seen that the pins 98 and 104 of the coupled connection 90 are pull-out threads as described above. Likewise, there is no thread on the pins 98 and 104 which extends beyond the respective first and second end faces of coupling body 92 .
[0027] FIG. 5 shows the thread form of the threads in the embodiments shown in FIGS. 3 and 4 . Referring thus to FIG. 5 , the thread form, shown generally as 210 , is shown with respect to the threads 212 of a pin 214 threadedly engaged with the threads 216 of a box 218 . Pin threads 212 have a stab flank 220 , a load flank 222 , a root 224 and a crest 226 . Box threads 216 have a stab flank 228 , a load flank 230 , a root 232 and a crest 234 . As seen, in the fully made-up position depicted in FIG. 5 the load flanks 222 , 230 of the pin, box, respectively, are engaged, the respective crests and roots of the pin threads 212 and the box threads 216 , are engaged and there is a clearance, depicted by the arrows X-X, between the stab flanks of the pin threads 212 and the box threads 216 .
[0028] As can also be seen from FIG. 5 , the stab flanks 220 of the pin 214 and stab flanks 228 of the box 218 are at a positive angle designated as Y-Y on FIG. 5 relative to a line passing transversely through the pin/box connection and perpendicular to the product axis 242 . In this regard product axis 242 passes longitudinally through the center line of the pin/box connection and is generally concentric with the OD of the box 218 and the ID of the pin 214 . Generally speaking, the angle Y-Y is from about 8° to about 12°, particularly about 10°. The load flanks 222 of the pin 214 and the load flank 230 of the box 218 when in the fully made-up position as shown in FIG. 5 are at a positive angle Z-Z of from about 2° to about 4° especially about 3° again with respect to the product axis 242 .
[0029] When the pin/box connection of FIG. 5 is made-up, the clearance X-X is from about 0.002 to about 0.004 inches, particularly about 0.003 inches.
[0030] The threaded connections of the present invention using the thread form of FIG. 5 provide unexpected results in terms of a reduced degree of galling typically experienced by Standard API (8 round or LTC) threads. It is known that such Standard API threads typically undergo galling after two to three make-ups but in any event after about five make-ups. In tests conducted on threaded tubing connections made in accordance with the thread form of the present invention, and it has been found that the tubing connections can undergo up to ten or more make-and-breaks without any significant galling. This is a significant advantage since it dramatically increases the usable life of the tubing before it must be reworked or replaced altogether. Furthermore, when in use, this reduced degree of galling ensures pressure integrity.
[0031] The coupled connections of the present invention also have many advantages compared with integral/two-step connections commonly used in tubing work strings. To begin with, a typical two-step connection generally has minimal thread interference, applied torque being borne almost entirely by the load bearing shoulders, which in any event, have low break out torque compared to the make-up torque. The result is that when the connection is made-up, only the torque shoulders and metal-to-metal seals are in contact. The free running threads make virtually no contact at all and accordingly substantially all of the torque is limited to shouldering torque, the metal-to-metal seals primarily acting to hold the connection together. This is to be contrasted with the connections of the present invention which after tests involving 22 makes and breaks, showed no appreciable loss in break-out torque. This flows from the fact that when the connections of the present invention are made-up to full torque values, there is not only torque on the coupling shoulders or the pin to pin ends, there is also torque in the threads which resist backing-out.
[0032] In an actual test on a threaded connection according to the present invention the connection was initially made-up to a torque value of approximately 2,300 foot pounds and an initial break-out torque of 1,800 foot pounds. After the connection had been made-up and broken-out 22 times the final break-out torque was 1,766 foot pounds. In other words the additional stored energy which can be placed into the threaded connections of the present invention when they are fully made-up ensure only minimal loss of break-out torque after repeated makes and breaks. Tests have shown this is not the case with a typical two-step threaded connection. The threaded connection of the present invention is thus characterized, in part, by its repeatability in terms of multiple makes, and breaks with little loss in break-out torque which flows from the fact that over and above the engaged threads bearing load, the stored energy in the shoulders of the connection virtually precludes any backing out even when tubing strings employing the threaded connections of the present invention are used in highly deviated e.g., horizontal wells.
[0033] Although specific embodiments of the invention have been described herein in some detail, this has been done solely for the purposes of explaining the various aspects of the invention, and is not intended to limit the scope of the invention as defined in the claims which follow. Those skilled in the art will understand that the embodiment shown and described is exemplary, and various other substitutions, alterations and modifications, including but not limited to those design alternatives specifically discussed herein, may be made in the practice of the invention without departing from its scope. | A threaded, coupled connection having tapered, buttress-type threads, the threaded portions of the connection having a thread pitch of seven threads per inch. Preferably the pin threads of the coupled connection are pull-out threads. | 5 |
FIELD OF THE INVENTION
The present invention relates to three dimensional (3-D) woven fabrics produced by planar warps or different cross section. Since, in the proposed invention, the woven yarns in each direction are not bent, it is particularly suitable for industrial scale production or 3-D reinforced composite materials.
BACKGROUND OF THE INVENTION
A textile composite is a combination of a resin system with textile fibers (fibers, yarns or labrican, The textile component provides the tensile strength and rigidity. This is due to the molecular orientation of the fiber resulting in a strong and stiff element in the fiber direction. High performance fibers posses high strength or high modulus properties. The most important high performance fibers are composed of glass, graphite, aramid, polyethylene, boron, ceramic or steel. The resin or the matrix component holds the textile reinforcement in a prescribed suspension, provides rigidity and helps to distribute external loads on the material through the fibers. The matrix also protects the fibers from external injury and environmental effects (corrosion, radiation, etc.).
Composite materials produced from high performance fibers are called high performance composites. Such materials are becoming increasingly important in aerospace and aircraft application due to their high-strength and stiffness-to-weight ratios,
Most advanced composites are formed by stacking (laminating) layers of fabric and then bonding them together to one solid structure, The layers may consist of fabrics, tapes, mats or unidirectional fibers laid in several directions. The weakness of the laminated structure is in its tendency to delaminate.
In order to overcome the weakness of delamination, It Is necessary to reinforce the composite structure in three dimensions. One way of achieving it is by using tile non-woven technique. This technique involves "felting" of short-length fibers so that the fibers interlace in three dimensions. The interlacing can be performed by two dimensional punching of short fibers web with needles that orient some of the fibers in the third dimension. When using very short fibers, it is possible to blend the fibers with the resin and process it in conventional polymeric machines such as extruder or injection molder.
The major limitations of the composites made in this way from short fibers are the lack of control on the fiber orientation and the mechanical inferiority of short fibers relative to continuous filaments. Non-woven structures offer limited design or shaping capability but are simple and cheap to produce.
Three dimensional (3-D) fabrics for structural composites are fully integrated continuous fiber assemblies having fiber orientation in the X, Y and Z dimension. Composites made from 3-D fabrics are superior in withstanding multidirectional mechanical stresses and thermal stresses. The three basic classes of integrating fibers, in yarns form, to 3-D structures are braiding, knitting and weaving.
In braiding, fabric is constructed by intertwining or orthogonal interlacing of two or more yarn systems to form an integral structure. The yarns are fed continuously from coned packages to the braiding machine. A 3-D braiding system can produce thin and thick structures in a wide variety of complex shapes. Fiber orientation can be chosen and 0° longitudinal reinforcement can be added, but a true three mutually perpendicular axes of straight yarn segments cannot be achieved.
Knitted fabrics are interlooped structures. The knitting loops are produced either by feeding the yarn in the cross machine direction (weft knit) or along the machine direction (warp knit). The latter is more suitable for 3-D composite reinforcement. Multiaxial warp knit structures consist of warp yarns at 0°, warp yarns at 90° and other yarns at an angle ±0 to the warp yarn direction. These yarns are held together by a chain of tricot stitches. The knitting process involves bending of the yarn in the knitting needle and sometimes piercing of the needles through the yarn layers. Both operations are not recommended for brittle yarns such as glass, boron and graphite.
3-D woven fabrics can be produced by conventional weaving, using multiple warp. The number of layers (warps) used in this method is limited by the friction resulting from the shedding motion and beat-up motion. Using this method, various yarn architectures can be woven. Orthogonal 3-D weaving can be fabricated by maintaining one stationary axis and inserting the yarns orthogonal to the axial yarn's system In an alternating manner. The same method is used for the formation of a tubular 3-D fabric. The advantage of the orthogonal weaving is in the linear yarn reinforcement in all directions. Bending or kinking the reinforcing yarns can cause deterioration in the mechanical properties of the composite material. However, the insertion of the orthogonal yarns through the yarns of the stationary axis, may produce technological problems and even damage to the stationary yarns.
Such a method of weaving is described in the U.S. Pat. No. 3,834,424 to Fukuta et al. King in U.S. Pat. No. 4,001,478 disclosed another method to form a 3-D structure of rectangular cross-section. U.S. Pat. No. 5,085,252 by Mohamed et al. describes a method of forming variable cross-section shaped 3-D fabrics. These patents and others emplby various techniques of inserting weft yarns through a planar array of warp yarns. When the array consists of a population of highly densed warp yarns, which is the case when high volume ratio of fibers is required, the weft Insertion operation can cause injury to the warp yarns.
SUMMARY OF THE INVENTION
There is provided a method for weaving a three-dimensional fabric structure having a predetermined cross-sectional shape comprising the steps of: Providing an aligned and tensioned array of planar warp yarns possibly arranging them into layers in two planar, mutually perpendicular directions, providing a reed and separating the layers of warp by turning said reed, forming a shed in one direction, inserting parallel weft yarns through the shed, beating the weft yarns by means of a comb, and repeating the last three steps in the other planar direction, so as to form three dimensional structure.
In accordance with the present invention, there is provided a method of forming sheds between layers of planar warp yarns, so that the orthogonal weft yarns can easily be inserted in any predetermined directions. The planar warp yarns are threaded through two parallel and perforated plates. The distance between the two parallel plates is large enough to accommodate the shedding and the weft insertion devices. The top plate can slide on the warp yarns. The base plate is used to anchor the ends of the warp yarns.
BRIEF DESCRIPTION OF THE DRAWING
The invention is described by way of illustration with reference to the enclosed schematical Figures, which are not according to scale and in which:
FIG. 1a illustrates a closed shed of a parallel layer of warp yarns
FIG. 1b illustrates an open shed of s parallel layer of warp yarns
FIG. 2a illustrates an open shed of a trapezoidal layer of warp yarns
FIG. 2b illustrates a closed shed of a trapezoidal layer of warp yarns
FIG. 3 is a schematic perspective illustration of the elements of the warping.
FIGS. 4a-4f are schematic illustrations of Step 8 and Steps 30 to 35.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The shedding operation is performed by two reeds. Each layer of the warp yarns is threaded through one slot in the first reed. As can be seen in FIG. 1b, the reed then divides the planar array of the warp yarns into lines or layers. The reed is located at a predetermined distance from the surface of the weave. However, as can be seen in FIG. 1b, when the plane of the reed is in right angle to the warp yarns, it spreads the layers of the warp yarns threaded through it so that the layers, initially parallel to each other, are not so any more, The displacement of the layers depends upon the distance between two consecutive slots of the reed and upon the distance between the reed and the fabric structure. The reed can be turned around an axis parallel to its slots. When the reed is turned, the warp layers slide against its teeth arid the distance between them becomes smaller. At a certain turning angle of the reed, the warp layers are parallel to each other. This position is called "closed shed" (FIG. 1a). In order to fully open the shed, the reed is turned to the position where its plane is perpendicular to the warp yarns in the fabric. This position is called "open shed" (FIG. 1b). In the open shed position (FIG. 1b) it is possible to insert weft yarns underneath the teeth of the reed. These yarns can be beaten up to form a unidirectional layer of yarns in the 3-D fabric.
Since the layers of the warp yarns, threaded through the central slots of the reed, are displaced by a magnitude equal to the thickness of the reed tooth, It may be necessary to use a center tooth of oblong cross section to ensure the required displacement or these layers.
A second reed is situated above the first one. When the planes of the reeds are mutually parallel and perpendicular to the warp yarns in the fabric, the slots or the second reed are oriented at an angle close to or equal to 90° to the slots of the first reed. Each of the planar warp yarns may be threaded to a different slot combination in the reeds. The second reed can be turned in a similar manner to the first one but its rotational axis is perpendicular or close to perpendicular to the rotational axis or the first reed. Since the second reed is located further away from the fabric than the first reed, the angle of the warp layers produced when it is in an open shed position is smaller than the angle of the open shed of the first reed.
To compensate for the discrepancy in the angle, the distance between adjacent teeth-of the second reed should be larger by (R1×B)/A than the distance between adjacent teeth of the first reed, where R1 is the distance between adjacent slots of the first reed, A is the distance of the rotational axis of the first reed from the plain of the fabric and B is the distance between the axes of the reeds. When both reeds are turned to the extent of close shed, all the warp yarns are parallel to each other.
FIG. 2a and FIG. 2b illustrate an alternative shedding operation that can be performed by threading the planar warp yarns, through two perforated plates, in a conical geometry. The number holes per unit area in the top sliding plate is lower than the that of the base plate. Each layer of the warp yarns, in between the plates, is threaded through one slot in the first reed. The reed then divides the planar array of the warp yarns into lines or layers. The reed is located at a predetermined distance from the surface of the weave. When the plane of the reed is parallel to the plates, the layers of the warp yarns threaded through it are spread. The reed can be turned around a central axis parallel to its slots. When the reed is turned, the warp layers are sliding against its teeth and the distance between them becomes smaller. At a certain turning angle of the reed, the warp layers are parallel to each other. This position is called "closed shed". In order to fully open the shed, the reed is turned back to the position where its plane is parallel to the plates. This position is called "open shed".
MODE FOR CARRYING OUT THE INVENTION
The first operation in 3-D weaving according to this invention is the planar warping. FIG. 3 describes the elements of the warping. Warp yarns 3, sized or unsized, are drawn from creels (not shown) and a tensioning device 2 (shown for one yarn only). Each yarn is threaded through the top perforated plate 1, then through a slot in the upper reed, 4X, and through a slot through the bottom reed 4Y. Finally, each yarn is threaded through the base perforated plate 6 and fastened to its bottom surface by means of knotting, bonding or mechanical clamping. The density of threading in the X and Y direction can be varied, by varying hole sizes and spacing in plate 1 of FIG. 3, to suit composites with different yarns in various directions. The density or the reeds and combs described below must correspond with the density of the holes in plate 1. By altering the length or breadth of the area covered by the holes in plate 1 of FIG. 3, the cross sectional shape of the 3-D composite can be modified. Beat up combs 5 consist of teeth with variable, but equal, spacing. They are used in either their open or closed spacing. The minimum spacing corresponds to the distance between two adjacent warp yarns, in a row, in the closed shed position. The maximum spacing is equal to the reed spacing.
The distance between the two parallel plates 1 and 6 is large enough to accommodate the reeds and the combs 5 for the beat up operation, This distance of the perforated plate 1 from the newly formed fabric surface remains constant. This is achieved by a gradual sliding of the perforated plate 1 on the warp yarns as plate 6 is moved down.
The following sequence of motions can be carried out in the weaving process:
1. Reed 4Y is turned to form an open shed in the Y direction.
2. Comb 5ay, with its teeth displaced, is inserted through the open shed under the reed 4Y.
3. Reed 4Y is turned back to close the shed in the Y direction. The teeth of the comb Say close down to meet the density of the warp yarns in the X direction.
4. Reed 4X is turned to form an open shed in the X direction.
5. Parallel weft yarns are inserted, in the X direction, through the open shed of rows of yarns,-under the comb 5ay.
Possible weft insertion can be a rapier mechanism, air pressure, knitting needles, tube guides or others. Using knitting needles (latch needles) to engage weft yarns on one-side of the warp and pull them through the open shed to the other side, is advantageous. It saves trimming the selvage of the yarns inserted. By this method, selvage loops are formed. However, this mode or weft insertion introduces folded weft yarns in each insertion and brittle yarns, such as graphite or glass yarn, may not withstand the bending motion in the eye of the knitting needle.
6. Comb 5ax, with its teeth in open spacing, is inserted through the open shed under the reed 4Y and above the comb 5ay.
7. Reed 4X is turned back to close the shed. Teeth of comb 5ax are put into closed spacing.
8. Comb Say is moved down to beat up the weft yarns.
9. Comb Say is moved up slightly above the surface of the fabric to protect its structure when the shed is farmed in the Y direction.
10. Reed 4Y is turned to form an open shed in the Y direction.
11. Parallel weft yarns are inserted in the Y direction.
12. Comb 5by, with its teeth in open spacing, is inserted through the open sheds under the reed 4Y and above comb 5ax.
13. Reed 4Y is turned back to close the shed. Teeth of comb 5by are put into closed spacing.
14. Comb Say is pulled out.
15. Comb 5ax is moved down to beat up the weft yarns.
16. Comb 5ax is moved up slightly above the surface of the fabric to protect its structure when the shed is formed in the X direction.
17. Reed 4X is turned to form an open shed in the X direction.
18. Parallel weft yarns are inserted, in the X direction, through the open shed of rows of yarns, under the comb 5by.
19. Comb 5bx, with its teeth In open spacing, is inserted through the open shed under the reed 4Y and above the comb 5by.
20. Reed 4X is turned back to close the shed. Teeth of comb 5bx are put into closed spacing.
21. Comb 5ax is pulled out.
22. Comb 5by is moved down to beat up the weft yarns.
23. Comb 5by is moved up slightly above the surface of the fabric to protect its structure when the shed is formed in the Y direction.
24. Reed 4Y is turned to form an open shed in the Y direction.
25. Parallel weft yarns are inserted in the Y direction.
26. Comb 5ay, with its teeth in open spacing, is inserted through the open sheds under the reed 4Y and above comb 5bx.
27. Reed 4Y is turned back to close the shed. Teeth of comb Say are put into closed spacing.
28. Comb 5by is pulled out.
29. Comb 5bx is moved down to beat up the weft yarns.
30. Comb 5bx is moved up slightly above the surface of the fabric to protect its structure when the shed is formed in the X direction.
31. Reed 4X is turned to form an open shed in the X direction.
32. Parallel weft yarns are inserted, in the X direction, through the open shed of rows of yarns, under the comb 5ay.
33. Comb 5ax, with its teeth in open spacing, is inserted through the open sheds under the reed 4Y and above comb 5ay.
34. Reed 4X is turned back to close the shed. Teeth of comb 5ax are put into closed spacing.
35. Comb 5bx is pulled out.
36. Back to stage 8 to complete the cycle of fabric formation. In each cycle either 1-30 for the first cycle or 31-35 and 8-30 for subsequent cycles, four layers or weft yarns, perpendicular to the warp yarns, are inserted.
It should be emphasized that the reed 4Y (the bottom reed) can be design to have teeth with adjustable and variable density. Such reed, although mechanically more complicated to construct, may be used for the beat-up motion.
It will be understood that the various details of the Invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only and does not limit the claims. | Methods for weaving three-dimensional fabric structures which have a desired cross-sectional shape and devices for such weaving in each of two mutually perpendicular directions allow sheds to be formed in planar warps. The sheds enable the insertion of parallel weft yarns through rows of warp yarns. High density three-dimensional fabrics which may be used in the manufacture of advanced composite materials can be woven. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to contraceptive devices and particularly to intrauterine contraceptive devices.
2. Description of the Prior Art
U.S. Pat. No. 3,533,406 discloses an intrauterine contraceptive device having a "T" shape. The device is completely placed into the endometrial cavity where the end of the stem extends toward the cervical os when the cross bar of the "T" lies at the fundus of the uterus. The contraceptive efficacy of the "T" device has proven unacceptable for many families. As a result, the "T" device has been used in many applications as a carrier for contraceptive chemicals such as copper. It is believed that the relatively small cross section of the stem of the "T" device prevents it from having the desired contraceptive effect. The so-called "7" shaped devices have produced effects nearly identical to the "T" devices. Both the "T" and "7" devices are lightweight and embed somewhat in the endometrial tissue. Expulsion rates and bleeding are modest, primarily because of the form and size of the devices.
U.S. Pat. No. 3,881,475 discloses an intrauterine contraceptive device having a pair of loops extending in opposite directions from a common stem. Each loop has a free end. This design has attempted to provide a device wherein the loops are capable of more readily conforming to the walls of the uterine cavity and are soft enough to move with the uterine walls as they move or contract. Higher expulsion rates and removal rates are reported with use of the device.
U.S. Pat. No. 3,937,217 provides an intrauterine contraceptive device which resembles the "T" device but which has a loop formed in the end of the stem and has a less rigid crossbar construction. This patented device has as its primary object the reduction of bleeding, involuntary expulsion and occasional perforation into the cervix associated with the "T" device. Other intrauterine contraceptive devices having similar constructions are described in U.S. Pat. Nos. 3,454,004; 3,457,915; 3,810,456 and 3,842,826.
Thus, it becomes an object of the present invention to provide an intrauterine contraceptive device having the advantages associated with the above-described devices, but with increased contraceptive efficacy, lower expulsion rates and less bleeding and pain for the patient.
SUMMARY OF THE INVENTION
The present invention provides an intrauterine contraceptive device having a relatively thick stem, a downwardly bowed crossbar secured to the top of the stem and a pair of downwardly and inwardly extending arms formed as continuations of the cross bar with the free ends of the arms terminating as enlarged fin-like portions. The crossbar and stem are adapted to lie in the fold between the anterior and posterior walls of the endometrium with the upper portion of the stem being of a round-ended rectangular, elliptical-like cross section with the plane of the long axis thereof being perpendicular to the crossbar and providing a stem thickness of 4 mm to 6 mm between such walls. The shape and resilience of the crossbar and arms serve to propel the device toward the fundus during uterine contractions thereby reducing the chance of expulsion. The simple design makes possible a lightweight device which results in reduced bleeding and pain for the patient. The mentioned 4 mm to 6 mm dimension represents a preferred thickness for the desired results.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the intrauterine contraceptive device of the present invention.
FIG. 2 is a side elevation view of the device.
FIG. 3 is an end elevation view of the device.
FIG. 4 is a bottom plan view of the device.
FIG. 5 is an enlarged section view taken substantially along line 5--5 of FIG. 2.
FIG. 6 is an enlarged, fragmentary section view taken substantially along line 6--6 of FIG. 2.
FIG. 7 is an enlarged section view taken substantially along line 7--7 of FIG. 2.
FIG. 8 is an enlarged section view taken substantially along line 8--8 of FIG. 4.
FIG. 9 is a side elevation view of an alternative embodiment of the invention device.
FIG. 10 is an enlarged section view taken substantially along line 10--10 of FIG. 9.
FIG. 11 is an enlarged section view taken substantially along line 11--11 of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the intrauterine contraceptive device 10 of the present invention includes a relatively thick stem 11, a downwardly bowed crossbar 12 and a pair of inwardly extending arms 13, 14 formed as continuations of crossbar 12. Stem 11 is formed with an upper portion 17 which is somewhat elliptical or of round-ended rectangular shape in cross section. In the specific embodiment, the major or long axis X (FIG. 5) of this section .[.of.]. .Iadd.is .Iaddend.approximately 4 mm with the minor axis Y (FIG. 5) being approximately 2 mm. A continuous circular lip 18 is formed at the base of upper portion 17 to act as an abutment for an inserter tube (not shown). The lower end 19 of stem 11 is circular in cross section and is smaller in cross sectional area than that of upper portion 17. Dimension X provides a desired thickness.
A pair of arms 13, 14 are formed as continuations of crossbar 12 and project downwardly and inwardly toward stem 11 and terminate short of touching the stem. The line of each of the arms 13, 14 defines an included angle of 50° with respect to the central axis of the stem, with 40° to 70° being an acceptable range (see FIG. 2). Also, arms 13, 14 are angled 10° in opposite directions out of the central plane through the stem and cross bar (see FIGS. 1, 3 and 4) to allow the arms to cross over and slide by the lower end 19 of stem 11 during insertion.
For insertion, the lower end 19 of stem 11 slidably fits into the end of an inserter tube. The curved leading portion 22 of device 10 is then inserted into the uterus, at which time crossbar 12 becomes bowed further downwardly and arms 13, 14 cross over stem 11. The device is fully inserted when the crossbar lies adjacent the fundus of the uterus. It should be noted that the device may be constructed with the arms 13, 14 in the same plane with stem 11 and crossbar 12 (i.e., without the above-described 10° offsets). However, with such an alternative construction, the arms 13, 14 do not automatically cross over stem 11 and the inserter tube during insertion unless the physician first rotates the arms out of the mentioned plane so that they will assume a momentary "fix" in an offset position and will retain such fix during insertion. This alternative construction has proven adequate but it does require an added step to be performed by the physician.
The leading portion 22 of the device is tapered, as seen in FIG. 6, to gently dilate the internal os during insertion. Once the device 10 is fully inserted, crossbar 12 and arms 13, 14 return to their normal positions. A small hole 20 in end 19 receives a withdrawal thread 21 useful for removal of the device in the manner well known to those skilled in the art.
As illustrated in FIGS. 7 and 8, crossbar 12 and arms 13, 14 have half-round cross sections which provide atraumatic embedding in the anterior and posterior walls of the endometrium. The unique shape of device 10 allows the device to resist expulsion due to contractions of the uterus and thereby maintain a position at the fundus. Contractions of the fundus of the uterus cause crossbar 12 to bow further and propel further towards the fundus. Contractions of the lower uterine segment impinge on arms 13, 14 and also serve to propel the device toward the fundus. A pair of flat fins 15, 16 are formed at the tips of arms 13, 14 to reduce the possibility of the arms perforating the tissue during contractions of the uterus or during insertion and orient as shown.
The contraceptive efficacy of the device may be primarily attributed to the thickness (approximately 5 mm) of the upper portion 17 of stem 11 as seen in cross section in FIG. 5. A thickness of 5 mm is preferred, with 4.0 to 6.0 mm being an acceptable range. Although device 10 has a greater thickness at the critical point (i.e., upper stem portion 17), the overall mass of the device is substantially less than most contraceptive devices. This reduced mass is the primary reason for the low levels of bleeding and pain associated with the device and the reduced tendency of the uterus to expel the device.
In the illustrated embodiment, shaft 11 has a length of approximately 20 mm with end 19 being 8 mm in length and upper portion 17 being 12 mm. End 19 has an outside diameter of approximately 2 mm, which corresponds with the inside diameter of the inserted tube (not shown). Crossbar 12 spans 30 mm (approximately the lateral dimension of the fundus) and has a radius of curvature on the order of 30 mm. Crossbar 12 and arms 13, 14 are half-round in cross section with an outwardcurved surface and an inward flat surface which has a width of approximately 2 mm. Fins 15, 16 flatten out to approximately 3 mm in width. Since the entire device 10 is not placed within an inserter tube, the device does not have to have a fully resilient "memory" for returning to its normal shape after substantial periods of distortion. As explained above, during insertion only the crossbar 12 and arms 13, 14 are distorted. These members easily return to their normal positions when the device 10 is fully inserted and comes to rest between the anterior and posterior walls of the endometrium.
Referring now to FIGS. 9, 10 and 11, an alternative embodiment intrauterine contraceptive device 10' is illustrated as having a pair of crossbar extensions 30, 31 which extend beyond the intersection point of arms 13', 14'. Extensions 30, 31 provide further atraumatic embedding in the walls of the endometrium. Extensions 30, 31 further resist expulsion due to contractions of the uterus and thereby maintains device 10' in position at the fundus. Thus, where additional atraumatic embedding and expulsion resistance is desired this alternative embodiment may be employed.
From the foregoing description, it may be seen that the art is now provided with an intrauterine contraceptive device having (1) an improved contraceptive efficacy due in large part to the stem thickness which is disposed between the anterior and posterior walls of the endometrium; (2) a very low expulsion rate deriving from the atraumatic embedding of the crossbar and arms in the endometrium and the tendency of the crossbar and arms to propel the device toward the fundus during uterine contractions; (3) a reduced tendency to cause bleeding and pain due to its low mass; and (4) a resilient construction allowing ease of insertion without the physician having to insert the entire device into an inserter tube. Those skilled in the art will recognize that the present invention represents a substantial departure from the prior art and that the invention is not limited solely to the specific embodiment described in detail.
The plastic material used to mold the described device as an integral structure may be polyethelene, an ethylene-vinyl acetate (EVA) copolymer or any like material well known in the art. | An integral intrauterine contraceptive device comprises a relatively thick elongated stem, a downwardly bowed crossbar secured to the top of the stem, and a pair of downwardly and inwardly extending arms formed as continuations of the crossbar. The crossbar and arm construction is designed for atraumatic embedding in the endometrium to reduce expulsion caused by uterine contractions. | 0 |
FIELD OF THE INVENTION
The present invention relates to portable sign stands, and more particularly, to a leg release mechanism for quickly and easily locking a sign stand leg in a retracted or protracted position.
BACKGROUND OF THE INVENTION
There are many uses for signage products today, particularly for traffic control at road construction sites and other work areas along the nation's highways. Many of these signage products utilize portable sign stands or sign holders for temporarily locating and displaying signs of various sizes and shapes. Rigid signs such as aluminum or plywood have typically been used in such applications. However, there has been a recent trend, particularly with portable traffic control signage, towards the use of flexible, roll-up signs, which have been well-received due to their lightweight and compact nature. It is anticipated that this trend will continue due to benefits gained by the compactness, portability and storability of flexible sign systems, as well as the durability of their design and the minimal maintenance required for their upkeep.
In general, various portable sign stands have been developed which utilize an upright that is attached to a base assembly having a leg assembly including a number of legs that pivotally and telescopically extend to support the sign. In addition, the legs are generally positionable between a retracted position wherein the legs are positioned closely parallel to the upright for convenient storage and a protracted position wherein the legs extend outwardly from the upright for securely supporting the sign. A release mechanism is incorporated into the base assembly for releasably securing the legs in the retracted or protracted position. The base assembly often includes a resilient spring member between the leg assembly and the upright to control deflection of the sign whenever a force is applied thereto, such as a gust of wind impinging upon the sign panel.
The flexible roll-up sign has a pair of brace members attached to the corners of a flexible sign panel which in a deployed or use position form a cross configuration. Various fasteners can be used for this purpose including twist lock fasteners, hook and loop type fasteners, snaps, plastic pockets or stretchable rubber or elastic straps. Fasteners of the latter type are marketed and sold by Marketing Displays International, Inc. of Farmington Hills, Mich. under the trademark DuraLatch™. The flexible roll-up sign is releasably secured to the sign stand by a locking mechanism such as a cam lock or lock pin assembly.
Preferred embodiments of the type of sign stands described above are disclosed in the following U.S. patents: U.S. Pat. No. 6,056,250 entitled “Improved Sign Stand For Flexible Traffic Control Signage”, U.S. Pat. No. 6,032,908 entitled “Sign Stand With Cam Release Assembly” and U.S. Pat. No. 5,472,162 entitled “Cap Lock For Sign Stand.” The above-referenced applications are commonly owned by the assignee of the present invention and the disclosures are expressly incorporated by reference herein.
Signage systems of the type described above have several moving parts that must operate easily and repeatedly in adverse conditions with little or no maintenance. These signage systems are commonly set up along busy roads and highways such that continuous efforts are made to improve the ease of use and durability of these systems. In this regard, there is a need to provide a release mechanism for the leg assembly, and more particularly to provide a simpler, more cost-effective release mechanism for the leg assembly which is simple to assemble, quick and easy to operate and requires no significant maintenance and is substantially wear-resistant.
SUMMARY OF THE INVENTION
It is a principle object of the present invention to provide a portable sign stand having an improved leg release mechanism for releasably positioning the legs of the stand between a retracted position and multiple protracted positions.
It is another object of the present invention to provide a method of constructing an improved leg release mechanism, which is low in cost and simple to manufacture and assemble.
It is a further object of the present invention to provide an improved “foot-operated” leg release mechanism for releasably locking the leg assembly in the retracted or protracted positions.
Accordingly, the present invention is directed to a portable sign stand comprising a base assembly having a leg pivotally connected to a base plate and a release mechanism for selectively permitting pivoting of the leg relative to the base plate. The release mechanism includes a lock-pin slidably disposed through a cavity of the leg between a first and second position. In the first position the lock-pin extends into an aperture of the base plate and in the second position the lock-pin is withdrawn from the aperture. A biasing member is disposed within the cavity and in direct connection with the lock-pin for biasing the lock-pin in the first position. When the lock-pin is in the first position pivoting of the leg relative to the base plate is disabled. When the lock-pin is in the second position pivoting of the leg relative to the base plate is enabled.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is an environmental perspective view of the portable sign stand of the present invention;
FIG. 2 is a perspective view of the leg release mechanism of the present invention;
FIG. 3 is a cross-section of the top plan view of the leg release mechanism in a locked mode;
FIG. 4 is a cross-section of the side elevation view of the leg release mechanism;
FIG. 5 is a cross-section of the top plan view of an alternate embodiment of a leg release mechanism in a locked mode; and
FIG. 6 is a cross-section similar to FIG. 5 with the leg release mechanism in a released mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
With reference to the figures and in accordance with the teachings of the present invention, a portable sign assembly 10 is provided having a base assembly 12 and a sign assembly 14 . The base assembly 12 includes a pair of base plates 16 secured to a pair of spring members 18 . An upright 20 extends upward from the spring members 18 for selectively receiving a portion of a vertical brace 22 of the sign assembly 14 . The upright 20 includes a sign release mechanism 24 for selectively fixing the vertical brace 22 within the upright 20 . The sign assembly 14 includes the vertical brace 22 and a horizontal brace 26 for forming a cross configuration for supporting a flexible sign panel 28 . As presently preferred, the spring members 18 are operably disposed between the base assembly 12 and the upright 20 such that the sign assembly 10 is resiliently supported from the base assembly 12 so as to flex when a wind load is applied, thus preventing the portable sign assembly 10 from tipping over. It should be appreciated that while the spring members 18 are depicted as a pair of coil springs, it may comprise a single coil spring or any other component or components that have the required resilience characteristics.
The base assembly 12 further includes four leg assemblies 30 , each leg assembly 30 pivotally connected to the base plates 16 by a threaded fastener 32 . Leg assembly 30 is of the telescopic type having an outer leg section 34 pivotally coupled to the corresponding base plate 16 and an inner leg section 36 telescopically received in the outer leg section 34 and selectively extendable therefrom. A rubber foot 38 is disposed on the end of each inner leg section 36 and functions to improve stability and prevent skidding of the portable sign assembly 10 . As presently preferred, the inner leg section 36 includes a detent (not shown) for releasably holding the inner leg section 36 in an outwardly or fully extended position. The detent may comprise any number of mechanisms well known to those skilled in the art. An example of a preferred detent is illustrated and disclosed in U.S. Pat. No. 4,548,379 which is commonly owned by the assignee of the present invention and the disclosure of which is expressly incorporated by reference herein.
A support strap 42 may be secured to each leg assembly 30 on a side opposite to the base plate 16 for cooperating therewith to enhance the rigidity of the base assembly 12 . As previously described, each leg assembly 30 is pivotally coupled to a corresponding base plate 16 via a threaded fastener 32 . The leg assembly 30 further includes a leg release mechanism 50 disposed through an end of the outer leg section 34 and operable to engage the base plate 16 for positioning and releasably locking the leg assembly 30 in a retracted or stored position, or one of a plurality of protracted or deployed positions.
With particular reference to FIGS. 2 through 4, the leg release mechanism 50 includes a generally J-shaped lock-pin 52 and a leaf spring 54 . The lock-pin 52 includes first and second extensions or legs 56 , 58 interconnected by an arcuate intermediary portion 60 . The first extension 56 is received through an aperture 62 formed in outer leg section 34 and extends into aperture 64 formed in base plate 16 . The second extension 58 is received through an aperture 66 formed in outer leg section 34 . The first extension 56 is slightly shorter than the second extension 58 . The first extension 56 has an ear 68 . 2 formed therein which engages the leaf spring 54 as best seen in FIG. 4 . The first extension 56 also has a second ear 68 . 4 formed therein. The second ear 68 . 4 functions as a stop or limit to the travel of lock-pin 52 by engaging the inner wall 34 . 2 of the outer leg section 34 . As presently preferred, aperture 62 has a radial slot 70 which allow ears 68 . 2 , 68 . 4 to be received therein. Alternately, aperture 62 could be an oversized circular aperture.
A formed end cap 76 is affixed to the end of the second extension 58 . End cap 76 provides an enlarged kick surface area 78 for an operator to position the lock mechanism 50 between the locked and released position. It should be noted, however, that the end cap 76 is optional, and force may be applied directly against the end of the first extension 56 . The end cap 76 , however, provides a larger target area for actuating the lock-pin 50 .
Lock-pin 52 is operably coupled to leaf spring 54 . Specifically, the second extension 58 is disposed through a slot 72 of the leaf spring 54 and is freely slidable relative thereto. A second slot 74 is also provided for passively receiving threaded fastener 32 therethrough. Ear 68 . 2 engages an outer surface 54 . 2 of leaf spring 54 . As presently preferred, the leaf spring 54 is formed from a substantially flat piece of stainless spring steel that has been formed to have a bowed configuration. The leaf spring 54 biases the lock-pin 52 in a first direction (indicated by arrow A in FIG. 3) for locking the leg assembly 30 relative to the base plate 16 , as described in further detail herein.
The lock-pin 52 is adapted to slide in a direction generally perpendicular to the longitudinal axis of the leg assembly 30 so as to be received into one of a plurality of apertures 76 . 2 , 76 . 4 , 76 . 6 formed through the base plate. In this manner, the leg assembly 30 may be locked into multiple positions. When the lock-pin 52 is received into the aperture 76 . 2 , the leg assembly 30 is oriented at approximately three degrees (3°) downwardly from a horizontal as defined by a bottom edge of the base plate 16 . The aperture 76 . 4 is formed in the base plate such that the leg assembly 30 is oriented at approximately fifteen to twenty degrees (15°-20°) downwardly from the horizontal. In this manner, a degree of adjustability is provided for placing the portable sign assembly 10 on an irregular (i.e. non-flat) surface. The third aperture 76 . 6 is formed in the base plate 16 and oriented such that the leg assembly 30 may be locked in a retracted position for compact storage.
With continued reference to FIGS. 2 through 4, operation of the leg release mechanism 50 will be described in detail. In a first, locked position, the leg assembly 30 is pivotally positioned about the threaded fastener 32 such that the lock-pin 52 is aligned with the aperture 76 . 2 . The leaf spring 54 biases the lock-pin 52 in the direction of arrow A (as viewed in FIG. 3 ), whereby an end of the first extension 56 extends into the aperture 76 . 2 and engages the base plate 16 . The ear 68 . 4 functions as a stop or limit for further movement of the lock-pin. In this position, the leg assembly 30 is prevented from further rotation about the threaded fastener 32 , and thus releasably locked into the protracted position.
To move the leg assembly 30 into an alternate position, such as the retracted position, the lock-pin 52 is urged against the bias of the leaf spring 54 by pulling on the arcuate intermediary portion 58 or alternately pushing on the end cap 76 whereby the end of the first extension 56 is withdrawn from engagement with the aperture 76 . 2 . As the lock-pin 52 disengages the base plate 16 , the leaf spring 54 is compressed to a point where it is pressed substantially flat against an inner surface of the outer leg section 34 . With the lock-pin 52 in this position, the leg assembly 30 may be pivotally positioned about the threaded fastener 32 with respect to the base assembly 12 and moved to a point where the lock-pin 52 is aligned with an alternate aperture such as apertures 76 . 4 or 76 . 6 .
In an alternative embodiment, as shown in FIGS. 5 and 6, a lock-pin 152 may include a generally J-shaped member having first and second extensions 156 , 158 interconnected by an arcuate intermediary portion 160 . The second extension 158 of lock-pin 152 is shorter than second extension 58 of lock-pin 52 so as to remain within the interior volume outer leg member 34 when the lock-pin 152 is in the extended position. The leaf spring 54 is identical to that previously described. The first extension 156 is generally longer than the second extension 158 and extends through the leg assembly 30 . The first extension 156 includes a circumferential groove 168 for engaging the leaf spring 54 and is disposed through a first slot 72 of the leaf spring 54 , whereby corresponding edges of the first slot 72 engage the grooves 168 . The second extension 158 is disposed through the first slot 72 of the leaf spring 54 and is freely slidable relative thereto. The free end of the second extension 158 engages the inner wall 34 . 2 of outer leg member 34 to provide a stop or limit to the travel of lock-pin 152 . In general, operation of the alternative embodiment parallels that described hereinabove.
The present invention greatly simplifies the assembly of the leg release mechanism 50 into the leg assembly 30 over other prior art devices. The lock-pin 52 is insert completely through apertures 66 , 70 of the leg assembly 30 , whereby the first extensions 56 , 58 simultaneously are received into the leg assembly 30 . The use of a single lock-pin having a pair of legs eliminates the need to align and couple multiple pieces of conventional lock-pin assemblies. The lock-pin 52 is then held in the extended position. Spring 54 is positioned axially into the interior volume defined by the sidewalls of outer leg section 34 . Extensions 56 , 58 are received within slot 72 and ear 68 . 2 is located on the outer surface 54 . 2 of leaf spring 34 . Spring 54 is preloaded or compressed slightly to position the spring on the underside of ear 68 . 2 . Once properly located, spring 54 and ears 68 . 2 , 68 . 4 cooperate to hold the spring in proper orientation and to bias the lock-pin toward the extended position.
As presently preferred, lock-pin 52 , 152 is formed by bending a constant cross-section piece (e.g. ⅜″ wire stock) to form a generally J-shaped pin. In the case of the first preferred embodiment, the ears 68 . 2 , 68 . 4 may be swaged into lock-pin 52 during the bending operation to provide an engagement element having a diameter that is greater than the nominal diameter of the lock-pin 52 . In this way, a very inexpensive component of the lock mechanism 50 is fabricated. In the case of the second embodiment, slot 168 is machined into lock-pin 152 in a post-bending operation to provide an engagement element having a diameter that is less than the nominal diameter of the lock-pin 152 .
The assembly of leg release mechanism 150 is similar to that previously described with respect to leg release mechanism 50 with the following differences. The second extension 158 of lock-pin 152 is partially received into the outer leg member 34 . Leaf spring 54 is operably coupled to lock-pin 152 by locating leaf spring 54 in groove 168 . Once properly positioned, leaf spring 54 and the free end of second extension 158 cooperate to hold the leaf spring 54 in the proper orientation and to bias the lock-pin 152 toward the extended position.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. | A portable sign assembly having a base assembly which includes a leg member pivotally interconnected with a base plate of the base assembly. A leg release mechanism is further provided for selectively locking a respective leg from pivoting relative to a respective base plate. The release mechanism includes a lock-pin that is slidably disposed through the leg and is biased in a first position by a biasing member disposed within the leg. The lock-pin selectively engages apertures of the base plate for prohibiting pivotal motion between the leg and the base plate. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 11/005,218 filed Dec. 7, 2004, which is the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
Regenerative amplifiers utilizing chirped pulse amplification (CPA) have been the dominant means for obtaining pulse energies greater than a microjoule with pulse durations in the femtosecond to picosecond range. Microjoule to millijoule pulse energies with pulse durations below 10 picoseconds have been found to be particularly useful for micromachining and for medical applications such as Lasik. However, a big stumbling block in the utilization of ultrafast sources for these applications has been that the regenerative amplifier is more of a piece of laboratory equipment and not conducive to the industrial setting.
Alternative sources for microjoule level, ultrafast pulses are emerging; utilizing all fiber chirped pulse amplification designs. Such systems are inherently more stable since they are based on technology similar to that utilized in Telecomm systems. During the past decade, there has been intensive work and success in making such systems practical. However, for higher pulse energies in the millijoule range, regenerative amplifiers will continue to dominate for some time since pulse energies above a millijoule have not been demonstrated in an all fiber system.
For micromachining applications, more industrially compatible regenerative amplifiers are now being developed based on Nd: or Yb: doped materials, rather than the Ti:sapphire that has dominated the scientific market. There are two basic reasons for this change. Commercial markets typically do not require the shorter pulses that can only be obtained from the Ti:sapphire regenerative amplifier, and the Nd: and Yb: based materials can be directly diode pumped, which makes these systems more robust and less expensive. An unresolved technical issue for Nd: or Yb: based regenerative amplifiers is the need for an equally robust seed source for femtosecond or picosecond pulses. The present seed lasers are mode-locked solid-state lasers with questionable reliability. It would be preferable to have a robust fiber seed source similar to that which has been developed for the Ti:sapphire regenerative amplifier, and used where Ti:sapphire regenerative amplifiers are applied to more commercial applications.
In a copending U.S. application Ser. No. 10/960,923, filed which is assigned to the common assignee and the disclosure of which is incorporated by reference in its entirety, the design changes needed for a mode-locked Yb:doped fiber oscillator and amplifier to be utilized as a seed source for a Yb: or Nd: based solid-state regenerative amplifier are described. The purpose of this application is to modify and apply many of the improvements in all fiber chirped pulse amplification systems for application to the seed source of a regenerative amplifier.
SUMMARY OF THE INVENTION
The purpose of this invention is to incorporate the many recent improvements in femtosecond mode-locked fiber lasers and femtosecond fiber chirped pulse amplification systems to regenerative amplifier systems that incorporate femtosecond or picosecond pulse sources based on fiber seed-sources and/or fiber amplifiers.
Yb: and Nd: mode-locked oscillators with fiber amplifiers can be utilized as sources of ultrafast pulses for regenerative amplifiers in order to obtain higher pulse energies than can be realized at this time from all fiber short pulse systems. A8827 (incorporated by reference herein) describes specifically how the sources can be configured to be implemented in such fiber based seed sources for solid state regenerative amplifiers. The femtosecond source and fiber amplifier need to be carefully configured in order to obtain optimum, reliable performance when incorporated into such a system. Recently there have been many improvements in mode-locked fiber sources implemented with fiber amplifiers in chirped pulse amplifier systems that can be utilized in a regenerative amplifier system that typically is based on chirped pulse amplification. Applicable improvements to fiber mode-locked sources are disclosed in Ser. Nos. 09/576,772, 09/809,248, 10/627,069, 10/814,502 and 10/814,319 (all incorporated by reference herein). Alternative suitable femtosecond sources that utilize fiber amplification for pulse conditioning and shortening are described in Ser. No. 10/437,057. One of the difficulties with chirped pulse amplification systems has been in producing reliable and compact pulse stretchers that can be dispersion matched to pulse compressors suitable for high pulse energies.
Significant improvements for dispersion matched fiber stretchers for fiber based chirped pulse amplification are disclosed in Ser. No. 10/992,762 filed Nov. 22, 2004 (incorporated by reference herein). These improvements are also applicable to chirped pulse amplification systems even when solid state bulk mode-locked lasers are utilized as the seed source. Significant improvements have been made in packaging, electronic controls, fabrication processes and optical parameter controls in order to make fiber based femtosecond sources reliable. These engineering improvements can also be utilized in these regenerative amplifier systems and are disclosed in Ser. Nos. 10/606,829, 10/813,163, 10/813,173 and 11/024,948 (all incorporated by reference herein).
Previously, Yb: and Nd: mode-locked oscillators and fiber amplifiers have been utilized as pulse sources for narrow bandwidth, bulk, solid-state amplifiers including regenerative amplifiers that can produce pulses 20 picoseconds or greater. In general, the configuration solutions for these longer pulse sources as described, for example in Ser. No. 10/927,374 (incorporated by reference herein) are different than those described here for sub-picosecond systems. However, the engineering improvements described here will also be applicable for the longer pulse systems, and the bulk amplifier operated as a regenerative amplifier has increased flexibility.
The first important element for a short pulse regenerative amplifier system is the source of short pulses. Femtosecond mode-locked fiber lasers are a good source of such pulses. Typically the fiber oscillator is low power and needs additional amplification for application as a seed source. Other important needs are pulse compression, wavelength flexibility, dispersion control and fiber delivery.
Therefore, it is an object of the present invention to introduce a modular, compact, widely-tunable, high peak and high average power, low noise ultrafast fiber amplification laser system suitable for a seed source for a regenerative amplifier.
It is a further object of the invention to ensure modularity of the system by employing a variety of easily interchangeable optical systems, such as 1) short pulse seed sources, 2) wide bandwidth fiber amplifiers, 3) dispersive pulse stretching elements, 4) dispersive pulse compression elements, 5) nonlinear frequency conversion elements and 6) optical components for fiber delivery. In addition, any of the suggested modules can be comprised of a subset of interchangeable optical systems.
It is a further object of the invention to ensure system compactness by employing efficient fiber amplifiers, directly or indirectly pumped by diode lasers as well as highly integrated dispersive delay lines. The high peak power capability of the fiber amplifiers is greatly expanded by using parabolic or other optimized pulse shapes. In conjunction with self-phase modulation, parabolic pulses allow for the generation of large-bandwidth high-peak power pulses, as well as for well-controlled dispersive pulse stretching. High power parabolic pulses are generated in high-gain single or multi-mode fiber amplifiers operating at wavelengths where the fiber material dispersion is positive.
Parabolic pulses can be delivered or transmitted along substantial fiber lengths even in the presence of self-phase modulation or general Kerr-effect type optical nonlinearities, while incurring only a substantially linear pulse chirp. At the end of such fiber delivery or fiber transmission lines, the pulses can be compressed to approximately their bandwidth limit.
Further, the high energy capability of fiber amplifiers is greatly expanded by using chirped pulse amplification in conjunction with parabolic pulses or other optimized pulse shapes, which allow the toleration of large amounts of self-phase modulation without a degradation of pulse quality. Highly integrated chirped pulse amplification systems are constructed without compromising the high-energy capabilities of optical fibers by using fiber-based pulse stretchers in conjunction with bulk-optic pulse compressors (or low nonlinearity Bragg gratings) or periodically poled nonlinear crystals, which combine pulse compression with frequency-conversion.
The dispersion in the fiber pulse stretcher and bulk optic compressor is matched to quartic order in phase by implementing fiber pulse stretchers with adjustable 2nd, 3rd and 4th order dispersion. Adjustable higher-order dispersion can be obtained by using high numerical aperture single-mode fibers with optimized refractive index profiles by itself or by using standard step-index high numerical aperture fibers in conjunction with linearly chirped fiber gratings. Alternatively, higher-order dispersion can be controlled by using the dispersive properties of the higher-order mode in a high numerical aperture few-moded fiber, by using nonlinearly chirped fiber gratings or by using linearly chirped fiber gratings in conjunction with transmissive fiber gratings. Adjustable 4th order dispersion can be obtained by controlling the chirp in fiber Bragg gratings, transmissive fiber gratings and by using fibers with different ratios of 2 nd , 3 rd and 4 th order dispersion. Equally, higher-order dispersion control can be obtained by using periodically poled nonlinear crystals.
The fiber amplifiers are seeded by short pulse laser sources, preferably in the form of short pulse fiber sources. For the case of Yb fiber amplifiers, Raman-shifted and frequency doubled short pulse Er fiber laser sources can be implemented as widely tunable seed sources. To minimize the noise of frequency conversion from the 1.5 μm to the 1.0 μm regime, self-limiting Raman-shifting of the Er fiber laser pulse source can be used. Alternatively, the noise of the nonlinear frequency conversion process can be minimized by implementing self-limiting frequency-doubling, where the center wavelength of the tuning curve of the doubling crystal is shorter than the center wavelength of the Raman-shifted pulses.
The process of Raman-shifting and frequency-doubling can also be inverted, where an Er fiber laser is first frequency-doubled and subsequently Raman-shifted in an optimized fiber providing soliton-supporting dispersion for wavelengths around 800 nm and higher to produce a seed source for the 1 μm wavelength regime.
As an alternative low-complexity seed source for an Yb amplifier, a modelocked Yb fiber laser can be used. The fiber laser can be designed to produce strongly chirped pulses and an optical filter can be incorporated to select near bandwidth-limited seed pulses for the Yb amplifier.
Presently the mode-locked Yb: doped fiber laser is the preferred oscillator. The preferred source is described Ser. No. 10/627,069 (incorporated herein).
The present invention is similarly directed to a mass-producible passively modelocked fiber laser. By incorporating apodized fiber Bragg gratings, integrated fiber polarizers and concatenated sections of polarization-maintaining and non-polarization-maintaining fibers, a fiber pig-tailed, linearly polarized output can be readily obtained from the laser. By further matching the dispersion value of the fiber Bragg grating to the inverse, or negative, of the dispersion of the intra-cavity fiber, the generation of optimally short pulses with a large optical bandwidth can be induced. In this regard, either positive dispersion in conjunction with negative dispersion fiber gratings or negative dispersion in conjunction with positive dispersion fiber gratings can be implemented. Preferably, the dispersion characteristics of the fiber Bragg grating and the dispersion characteristics of the rest of the intra-cavity elements are matched to within a factor of three. Even more preferably, these characteristics are matched within a factor of two, or within a factor in the range of 1.0 to 2.0. Also preferably, the Bragg grating has a chirp rate greater than 80 nm/cm. More preferably, the Bragg grating has a chirp rate greater than 160 nm/cm. Most preferably, the Bragg grating has a chirp rater greater than 300 nm/cm. To maximize the output power and the pulse repetition rate, the use of wide-bandwidth fiber Bragg gratings with low absolute dispersion is preferable. These fiber Bragg gratings are also used as end-mirrors for the cavity and allow the transmission of pump light to the intra-cavity gain fiber. The fiber Bragg gratings are conveniently produced using phase masks.
Alternatively, fiber couplers can be used inside the fiber cavity. Generally, sections of polarization-maintaining and non-polarization-maintaining fiber can be concatenated inside the fiber cavity. The non-polarization-maintaining section should then be short enough so as not to excessively perturb the polarization state. Intra-cavity sections of non-polarization-maintaining fiber preferably comprise all-fiber polarizers to lead to preferential oscillation of one linear polarization state inside the cavity. Similarly, when directly concatenating polarization-maintaining fiber sections, the length of the individual section should be long enough to prevent coherent interactions of pulses propagating along the two polarization axes of the polarization-maintaining fibers, thereby ensuring a maximum in pulse stability.
Saturable absorber mirrors (SAMs) placed inside the cavity enable passive modelocking. The saturable absorbers (SA) can be made from multiple quantum wells (MQW) or bulk semiconductor films. These saturable absorbers have preferably a bi-temporal life-time with a slow component (>>100 ps) and a fast component (<<20 ps). The realization of the bi-temporal dynamics of the optical nonlinearity is achieved by tailoring the depth profile of the ion-implantation in combination with the implantation dose and energy. The result is that the carriers trap at distinctively different rates in different depth regions of the SAM.
Saturating semiconductor films can for example be grown from aluminum-containing material such as AlGaInAs, the exact composition can be selected depending on the sought band-gap (typically selected to be in the vicinity of the desired operating wavelength of the laser system) and it is also governed by the requirement of lattice-match between the saturating semiconductor film and an underlying Bragg mirror or any other adjacent semiconductor material. Compositional requirements enabling lattice match between semiconductors and/or a certain band gap are well known in the state of the art and are not further explained here.
In aluminum containing semiconductors the surface area can induce a low optical damage threshold triggered by oxidization of the surface. In order to prevent optical damage of aluminum containing surface areas a passivation layer, e.g., InP, InGaAs or GaAs, is incorporated. SA degradation is further minimized by optimizing the optical beam diameter that impinges on the SAM. In one implementation the SAM and an intra-cavity fiber end can be either butt-coupled or brought into close contact to induce modelocking. Here, the incorporation of a precision AR-coating on the intra-cavity fiber end minimizes any bandwidth restrictions from etalon formation between the SAM and the fiber end. Etalons can also be minimized by appropriate wedging of the fiber ends. The beam diameter inside the SAM can be adjusted by implementing fiber ends with thermally expanded cores. Alternatively, focusing lenses can be directly fused to the fiber end. Moreover, graded-index lenses can be used for optimization of the focal size and working distance between the fiber tip and SA surface.
Wavelength tuning of the fiber lasers can be obtained by heating, compression or stretching of fiber Bragg gratings or by the incorporation of bulk optic tuning elements.
The use of bi- or multi-temporal saturable absorbers allows the design of dispersion compensated fiber laser operating in a single-polarization state, producing pulses at the bandwidth limit of the fiber gain medium.
Further improvement of the femtosecond Yb doped fiber oscillator can include an integral mass produced master oscillator, power amplifier design (MOPA) which is describe in Ser. No. 10/814,502 (incorporated by reference herein).
One embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements is partially transmissive and has a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. The fiber amplifier is optically connected to the mode-locked fiber oscillator through a bi-directional optical connection such that light from the mode-locked fiber oscillator can propagate to the fiber amplifier and light from the fiber amplifier can propagate to the mode-locked fiber oscillator.
Another embodiment of the present invention comprises a method of producing laser pulses. In this method, optical energy is propagated back and forth through a gain fiber by reflecting light from a pair of reflective elements on opposite ends of the gain fiber. Less than about 60% of the light in the gain fiber is reflected back into the gain fiber by one of the reflectors. The pair of reflective elements together form a resonant cavity that supports a plurality of resonant optical modes. The resonant optical modes are substantially mode-locking to produce a train of pulses. The train of optical pulses is propagated from the laser cavity through one of the reflectors to a fiber amplifier along a bi-directional optical path from the laser cavity to the fiber amplifier where the laser pulses are amplified.
Another embodiment of the present invention comprises a fiber-based master oscillator power amplifier comprising a mode-locked fiber oscillator, a fiber amplifier comprising a gain fiber, and bi-directional optical path between the mode-locked fiber oscillator and the fiber amplifier. The mode-locked fiber oscillator comprises a resonant cavity and a gain medium. The mode-locked fiber oscillator produces a plurality of optical pulses. The bi-directional optical path between the mode-locked fiber oscillator and the fiber amplifier permits light from the mode-locked fiber oscillator to propagate to the fiber amplifier and light from the fiber amplifier to propagate to the mode-locked fiber oscillator. The mode-locked fiber oscillator comprises a first segment of fiber and the fiber amplifier comprises a second segment of optical fiber. The first and second segments form a substantially continuous length of optical fiber. In some embodiments, the first and second segments are spliced together. The first and second segments may be fusion spliced. The first and second segments may also be butt coupled together with or without a small gap, such as a small air gap, between the first and second segments.
Another embodiment of the present invention comprises a method of producing laser pulses comprising substantially mode-locking longitudinal modes of a laser cavity to produce laser pulses and propagating the laser pulses from the laser cavity to a fiber amplifier. The laser pulses are amplified in the fiber amplifier. Amplified spontaneous emission emitted from the fiber amplifier is received at the laser cavity. A first portion of the spontaneous emission enters the laser cavity. A second portion of the amplified spontaneous emission from the laser cavity is retro-reflected back to the fiber amplifier to cause the second portion to be directed away from the cavity toward the fiber amplifier.
Another embodiment of the present invention comprises a fiber master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a first portion of optical fiber and a pair of reflectors spaced apart to form a fiber optic resonator in the first fiber portion. At least one of the fiber reflectors comprises a partially transmissive fiber reflector. The mode-locked fiber oscillator outputs a plurality of optical pulses. The fiber amplifier comprises a second portion of optical fiber optically connected to the partially transmissive fiber reflector to receive the optical pulses from the mode-locked oscillator. The second portion of optical fiber has gain to amplify the optical pulses. The first portion of optical fiber, the partially transmissive fiber reflector, and the second portion of optical fiber comprise a continuous path formed by optical fiber uninterrupted by non-fiber optical components.
Another embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator and a fiber amplifier. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements comprises a partially transmissive Bragg fiber grating having a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. A fiber amplifier is optically connected to the oscillator through an optical connection to the partially transmissive Bragg fiber grating.
Another embodiment of the present invention comprises a master oscillator power amplifier comprising a mode-locked fiber oscillator, a fiber amplifier, and a pump source. The mode-locked fiber oscillator comprises a pair of reflective optical elements that form an optical resonator. At least one of the reflective optical elements is partially transmissive and has a reflection coefficient that is less than about 60%. The mode-locked fiber oscillator outputs a plurality of optical pulses. A fiber amplifier is optically connected to the oscillator through an optical connection to the at least one partially transmissive reflective optical elements. The pump source is optically connected to the mode-locked fiber oscillator and the fiber amplifier to pump the mode-locked fiber oscillator and the fiber amplifier.
However, for most embodiments for a source for a regenerative amplifier the pulses need to be conditioned before amplification. Ser. No. 10/814,319 (incorporated by reference herein) addresses the utilization of modules so that the correct performance can be obtained from the femtosecond source for the seeder or a portion of the seeder for the regenerative amplifier system. Parameter controls available through these modules can be utilized for the optimization of the output from the regenerative amplifier.
One embodiment of the invention thus comprises a pulsed fiber laser outputting pulses having a duration and corresponding pulse width. The pulsed laser comprises a modelocked fiber oscillator, an amplifier, a variable attenuator, and a compressor. The modelocked fiber oscillator outputs optical pulses. The amplifier is optically connected to the modelocked fiber oscillator to receive the optical pulses. The amplifier comprises a gain medium that imparts gain to the optical pulse. The variable attenuator is disposed between the modelocked fiber oscillator and the amplifier. The variable attenuator has an adjustable transmission such that the optical energy that is coupled from the mode-locked fiber oscillator to the amplifier can be reduced. The compressor compresses the pulse thereby reducing the width of the pulse. Preferably a minimum pulse width is obtained.
Another embodiment of the invention comprises a method of producing compressed high power short laser pulses having an optical power of at least about 200 mW and a pulse duration of about 200 femtoseconds or less. In this method, longitudinal modes of a laser cavity are substantially mode-locked to repetitively produce a laser pulse. The laser pulse is amplified. The laser pulse is also chirped thereby changing the optical frequency of the optical pulse over time. The laser pulse is also compressed by propagating different optical frequency components of the laser pulse differently to produce compressed laser pulses having a shortened temporal duration. In addition, the laser pulse is selectively attenuated prior to the amplifying of the laser pulse to further shorten the duration of the compressed laser pulses.
Another embodiment of the invention comprises a method of manufacturing a high power short pulse fiber laser. This method comprises mode-locking a fiber-based oscillator that outputs optical pulses. This method further comprises optically coupling an amplifier to the fiber-based oscillator through a variable attenuator so as to feed the optical pulses from the fiber-based oscillator through the variable attenuator and to the amplifier. The variable attenuator is adjusted based on a measurement of the optical pulses to reduce the intensity of the optical pulses delivered to the amplifier and to shorten the pulse.
Another embodiment of the invention comprises a pulsed fiber laser outputting pulses having a pulse width. The pulsed fiber laser comprises a modelocked fiber oscillator, an amplifier, and a spectral filter. The modelocked fiber oscillator produces an optical output comprising a plurality of optical pulses having a pulse width and a spectral power distribution having a bandwidth. The amplifier is optically connected to the modelocked fiber amplifier for amplifying the optical pulses. The spectral filter is disposed to receive the optical output of the modelocked fiber oscillator prior to reaching the amplifier. The spectral filter has a spectral transmission with a band edge that overlaps the spectral power distribution of the optical output of the modelocked fiber oscillator to attenuate a portion of the spectral power distribution and thereby reduce the spectral bandwidth. The pulse width of the optical pulses coupled from the mode locked fiber oscillator to the fiber amplifier is thereby reduced.
Another embodiment of the invention comprises a method of producing compressed optical pulses. In this method, longitudinal modes of a fiber resonant cavity are substantially mode-locked so as to produce a train of optical pulses having a corresponding spectral power distribution with a spectral bandwidth. The optical pulses are amplified and compressed to produce compressed optical pulses. The spectral bandwidth of the spectral power distribution is reduced such that the compressed optical pulses have a shorter duration.
Another embodiment of the invention comprises a pulsed fiber laser comprising a modelocked fiber oscillator, an amplifier, one or more optical pump sources, a pulse compressor, and a pre-compressor. The modelocked fiber oscillator comprises a gain fiber and a pair of reflective optical elements disposed with respect to the gain fiber to form a resonant cavity. The modelocked fiber oscillator produces a train of optical pulses having an average pulse width. The amplifier is optically connected to the modelocked fiber amplifier such that the optical pulses can propagate through the amplifier. The fiber amplifier amplifies the optical pulses. The one or more optical pump sources are optically connected to the modelocked fiber oscillator and the fiber amplifier to pump the fiber oscillator and fiber amplifier. The pulse compressor is optically coupled to receive the amplified optical pulses output from fiber amplifier. The pulse compressor shortens the pulse width of the optical pulses output by the fiber amplifier. The pre-compressor is disposed in an optical path between the modelocked fiber oscillator and the fiber amplifier. The pre-compressor shortens the duration of the optical pulses introduced into the fiber amplifier such that the pulse duration of the optical pulses output by the compressor can be further shortened.
Another embodiment of the invention comprises a method of generating short high power optical pulses. The method comprises substantially mode-locking optical modes of a laser cavity to produce an optical signal comprising a plurality of laser pulses having an average pulse width. The optical signal comprises a distribution of frequency components. The method further comprises compressing the optical pulses and amplifying the compressed optical pulses to produce amplified compressed optical pulses. The amplified compressed optical pulses are further compressed subsequent to the amplifying using a dispersive optical element to differentiate between spectral components and introducing different phase shifts to the different spectral components.
Another embodiment of the invention comprises a pulsed fiber laser comprising a modelocked fiber oscillator, a fiber amplifier, an optical pump source, and a pulse compressor. The modelocked fiber oscillator outputs optical pulses. The fiber amplifier is optically connected to the modelocked fiber oscillator and amplifies the optical pulses. The optical pump source is optically connected to the fiber amplifier. The pulse compressor is optically coupled to receive the amplified optical pulses output from the fiber amplifier. The pulsed fiber laser further comprises at least one of (i) a first optical tap in the optical path between the modelocked fiber oscillator and the fiber amplifier and a first feedback loop from the first tap to control the modelocked fiber oscillator based on measurement of output from the first optical tap, and (ii) a second optical tap in the optical path between the fiber amplifier and the compressor and a second feedback loop from the second tap to control the fiber amplifier based on measurement of output from the first optical tap.
Another embodiment of the invention comprises a pulsed light source comprising a light source module, an isolator module, an amplifier module, and a compressor module. The light source module comprises an optical fiber and outputs optical pulses. The isolator module comprises an optical isolator in a housing having input and output fibers. The input fiber is optically coupled to the optical fiber of the light source module. The optical isolator is disposed in an optical path connecting the input and output fibers such that the optical pulses introduced into the input fiber are received by the isolator and permitted to continue along the optical path to the output coupler. The amplifier module comprises an amplifying medium and has an optical input optically connected to the output fiber of the isolator module to amplify the optical pulses. The compressor module is optically coupled to the amplifier module to compress the optical pulses.
Up to this point a mode-locked fiber laser or a bulk solid state mode-locked laser as the seed source for the fiber amplifier and regenerative amplifier has been disclosed. Other sources can also be utilized such a laser-diodes or microchip lasers. In Ser. No. 10/437,057 (incorporated by reference herein), it is disclosed how to modify these sources to give higher energy and shorter pulses through amplification and pulse compression in fiber amplifiers. An advantage of these sources that is mentioned in Ser. No. 10/437,057 is the repetition rate can be variable. It is a true advantage to match the repetition rate of the source to that of the regenerative amplifier.
Thus, one object of this invention is to convert relatively long pulses from rep-rate variable ultrafast optical sources to shorter, high-energy pulses suitable for seed sources in high-energy ultrafast lasers including a regenerative amplifier. Another object of this invention is to take advantage of the need for higher pulse energies at lower repetition rates so that such sources can be cost effective.
A gain switched laser diode as is used in telecom systems can be used as the initial source of pulses. In this case, the diode is operated at a much lower repetition rate. The pulses are still amplified in fiber amplifiers. Fiber amplifiers can be used as constant output power devices. The upper-state lifetime in typical doped amplifier fibers such as Ytterbium and Erbium is in the millisecond range so that these amplifiers can amplify pulse trains with the same efficiency at repetition rates from 10's of kHz to 100's of GHz and beyond. If the amplifier is amplifying pulses at 10 kHz rather than at 10 GHz at constant power, then the pulse energy will be six orders of magnitude higher. Again, with such high peak powers, pulse compression methods need to be different and unique. One first embodiment uses conventional compression by spectral broadening the pulses in an optical fiber with positive group velocity dispersion (GVD) and then compressing the pulse with diffraction gratings. The object of the pulse compression is to convert the 3-25 picosecond pulses from the gain switched laser diode to pulses that are subpicosecond.
Another source starts with pulses from a low cost Q-switched microchip laser. These lasers give pulses as short as 50 picoseconds but typically 250 picoseconds to 1.0 nanosecond. The pulse peak powers are typically 1-10 kW with pulse energies 6 orders of magnitude higher than from telecom laser diodes. Microchip lasers could be a very cost effective source for pulses less than 10 picoseconds with suitable pulse compression methods. Single mode fiber compression has thus far been limited to pulses shorter than 150 ps and peak powers less than 1 kW. Before compression the pulse can be further amplified in a regenerative amplifier.
Once a suitable femtosecond source has been identified further improvements have been made in the incorporation of these lasers in chirped pulse amplification systems where the amplifier has been a fiber amplifier. In Ser. No. 10/813,163, many improvements to the fiber chirped pulse amplification (FCPA) configuration have been made for a configuration that is more robust and suitable to an industrial environment. Here it has been realized that these improvements can be also utilized for fiber lasers seeding solid state amplifiers and particular solid state regenerative amplifiers. Specifically, the improvements for the FCPA configuration that are disclosed in Ser. No. 10/813,163 can be utilized in a regenerative amplifier seeded with a fiber laser configuration. The simplest embodiments are for the replacement of the power amplifier in FIGS. 1 and 11 of this application with a regenerative amplifier.
The following topics that are covered in Ser. No. 10/813,163 are relevant to this configuration.
1) Functional segmentation of opto-mechanical components into modular devices to produce manufacturable industrial laser systems with Telcordia-grade quality and reliability. 2) Polarization fidelity within and between modules 3) Provision for tap units for test, monitoring or feedback 4) Spectral matching of oscillator to amplifier 5) Selection of the length of an amplifier to cut ASE at the lasing wavelength 6) Active stabilization of the optical performance of gain fiber in a laser or amplifier. The stabilization is realized by actively adjusting the pump source wavelength by changing the source temperature in order to match pump wavelength with the absorption spectrum of the gain medium. The temperature dependent spectrum in the gain fiber is cloned in the same type of fiber, and thus used as a monitor. Accurate control of the gain performance over a wide range of operating temperatures is possible implementing this method. 7) Extraction of one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and compensation for detrimental effects on the spatial characteristics of the extracted chirped pulse, caused by dispersion in that deflector.
The invention thus relates to the technologies necessary to overcome the above problems and limitations of the prior art, to build a hybrid fiber and solid-state based chirped pulse amplification laser system suitable for industrial applications, with the fiber in a modular and compact laser design with all modules replaceable. The modules are designed and manufactured to telecom standards and quality.
Environmentally stable laser design is crucial for industrial application. An industrial laser system can be, for example, characterized by an output power variation below 0.5 dB over an environmental temperature range from 0 to 50 degrees Celsius, and by compliance with the vibration, thermal shock, high temperature storage and thermal cycling test criteria in Telcordia GR-468-CORE and GR-1221-CORE. This target can be achieved by functional segmentation of the components and packaging the modular device with Telcordia-qualified packaging technology. Before the modules are assembled into a system, they are tested and assembled separately.
Included in the modules are tap units that allow taking out signals along the propagation path in an integrated design. This is necessary for the optimization of each module as it is assembled, and important in the spectral matching along the chain of modules.
Polarization units are provided to prevent the buildup of side-pulses from orthogonal polarization light.
The acousto-optical down counter module can be designed to operate as a bandwidth filter. For further modulation of the signal an additional pulse extractor can be included near the end of the output. This unit suffers from dispersion due to the large bandwidth of the pulse. The compressor can be used to correct for this dispersion as disclosed hereafter.
The invention also relates to a means to extract one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and to compensate for the detrimental effects on the spatial characteristics of the extracted chirped pulse caused by dispersion in that deflector. An important aspect of this system is to manage the spectrum of the pulse in the system while maintaining the ability to correct for dispersion and compress the pulse back to the femtosecond regime. Two principal embodiments of this type will be described. The first is the case where the spectral content of the seed pulse is small. In this case a nonlinear amplifier may be employed for the generation of additional spectrum while spectral filtering is employed to obtain a compressible pulse. The second case is where the spectrum from the source is larger than necessary. Nonlinear affects can be limited in the amplifier chain in this case, while spectral filtering is again employed to obtain a compressible pulse. An additional attribute that is necessary for many applications is the reduction of the ASE at the output. Specific amplifier designs are used to cut the ASE at the output wavelength. The compressor can be used as an optical spectral filter to this end.
Once gain performance is attained, a method for active stabilization of the optical performance of the gain fiber in a laser or amplifier is disclosed to maintain this performance. The present invention stabilizes the temperature dependent absorption of a gain fiber over a wide environmental temperature variation by an active feedback loop. A piece of fiber, optically identical with the gain fiber itself, is used as a spectral filter for monitoring the emission spectrum of the pump diode. The absorption spectrum of the filter fiber follows that of the gain fiber if both fibers are packaged so that the fibers are in proximity to each other. The transmission of the pump light through the filter fiber clones exactly the absorption characteristics of the gain fiber at a given package temperature. The temperature of the pump diode is controlled by a feedback loop such that the transmission through the filter fiber is maintained at the minimum. Importantly, the filter fiber functions as an active temperature sensor of the gain fiber. Precise spectral control of the gain at any fiber or package temperature can thus be realized.
As mentioned above, an important field of use for this system is in micromachining. An additional feature needed for this application field is the capability to start and stop the pulse stream while moving the targeted material in place. One method to do this is to control the down counter. However, this leads to problems with gain stabilization in the amplifier and excessive ASE on target. These problems have been addressed in Ser. No. 10/813,173 “Method and Apparatus for Controlling and Protecting Pulsed High Power Fiber Amplifier Systems” (incorporated by reference herein). However, another means to stop the pulse stream is to utilize an optical switch at the output.
The invention extracts one or more chirped pulses from a series of such pulses using an acousto-optic deflector, and compensates for the detrimental effects on the spatial characteristics of the extracted chirped pulse caused by dispersion in that deflector. The instant invention has the additional advantage that the means to compensate for dispersion in the acousto-optic deflector can be used to compress the duration of the chirped pulse. This is accomplished by placing the AOM in proximity to a grating compressor.
Further improvements for correction of higher order dispersion terms in fiber chirped pulse amplification systems are disclosed in Ser. No. 10/992,762 (incorporated by reference herein). These can be applied to chirped pulse amplification systems with regenerative amplifiers.
Here, an ultra-compact high energy chirped pulse amplification systems based on linearly or nonlinearly chirped fiber grating pulse stretchers and photonic crystal fiber pulse compressors. Alternatively, photonic crystal fiber pulse stretchers and photonic crystal fiber compressors can also be implemented. For industrial applications the use of all-fiber chirped pulse amplification systems is preferred, relying on fiber-based pulse compressors and stretchers as well as fiber-based amplifiers.
Fiber-based high energy chirped pulse amplification systems of high utility can also be constructed from conventional optical components such as pulse stretchers based on long lengths of conventional fiber as well as bulk grating compressors. The performance of such ‘conventional’ chirped pulse amplification systems can be greatly enhanced by exploiting nonlinear cubicon pulse formation, i.e. by minimization of higher-order dispersion via control of self-phase modulation inside the amplifiers.
Finally, a particularly compact seed source for an Yb fiber-based chirped pulse amplification system can be constructed from an anti-Stokes frequency shifted modelocked Er fiber laser amplifier system, where a wavelength tunable output is obtained by filtering of the anti-Stokes frequency shifted output. The noise of such an anti-Stokes frequency shifted source is minimized by the amplification of positively chirped pulses in a negative dispersion fiber amplifier.
The preceding improvements have been focused on systems operating close to 1 μm. These systems appear to be the most suitable for industrial applications. However, Ti:sapphire regenerative amplifiers are presently the dominant design. Frequency doubled erbium fiber lasers are utilized for the more industrial Ti:sapphire systems. FCPA front ends are suitable for higher repetition rates utilizing an electro-optic pulse selector as is disclosed in Ser. No. 10/960,923. FCPA systems operating in the 1.5 telecomm wavelength which are then frequency doubled would be suitable for a Ti:sapphire amplifier or regenerative amplifier system.
The invention in Ser. No. 10/606,829 (incorporated by reference herein) provides an erbium fiber (or erbium-ytterbium) based chirped pulse amplification system operating at a wavelength of approximately 1550 nanometers. The use of fiber amplifiers operating in the telecommunications window enables telecommunications components and telecommunications compatible assembly procedures to be used, with superior mechanical stability
It is found that electronic controls are needed for reliable operation for these complex systems. In Ser. No. 10/813,173 (incorporated by reference herein), the implementation of electronic controls are described which prevent catastrophic damage in a short pulse amplifier system as well as maintaining constant output power over the life of the system. These systems are very applicable in a regenerative amplifier system seeded by a fiber laser. The damage issues will also be a concern in a regenerative amplifier system. However, more importantly these front end systems normally will encompass nonlinear optical processes in the fiber amplifiers. These nonlinear optical processes are very dependent on laser intensity. Thus, to maintain the desired results over the life of the system, careful control of the optical powers is needed particularly in the nonlinear optical components in the system.
It is thus an object of the present invention to provide a high power fiber amplifier system with means for controlling the pump diode current and the gain of the fiber amplifier such that the output pulse energy is constant as the pulse width and repetition rate are adjusted during operation. This includes keeping the pulse energy constant during turn-on of the pulse train.
It is a further object of the invention to provide means for controlling the temperature of the fiber amplifier pump diode such that the pump diode wavelength is maintained at a fixed value with changes in diode current.
It is also an object of the invention to provide means for protecting the high power amplifier from damage due to gain buildup in excess of the damage threshold of the amplifier by monitoring the repetition rate of the injected oscillator pulses or external signal, and shutting off or reducing the pump diode current if the repetition rate falls below this threshold.
It is also an object of the invention to provide for monitoring of the amplitude of the seed pulses and to protect the high power fiber amplifier from damage by shutting off the pump diode if the amplitude of the injected pulses falls outside a safe threshold.
It is also an object of the invention to provide a high power amplifier system with means for controlling the amplitude of the seed pulse such that the output energy of the power amplifier is constant.
The above and other objects of the invention are met by providing a device and method for controlling the diode current of the pump diode in a high power fiber amplifier, the device comprising a means for setting the pump diode current or power, monitoring such current or power, and maintaining the diode current or power at a constant value. Typically the current of the diode is controlled to correct for long term decrease on its output due to aging. In contrast, in accordance with an embodiment of the present invention, the pump diode current is controlled to dynamically control the gain of the power amplifier to maintain uniform pulse energy as the repetition rate and the pulse temporal width is changed. This includes turning the pump diode on sufficiently in advance and ramping up the current to produce equal power for the first pulses when the unit is turned on.
The device also provides a means for calculating and/or storing the desired pump diode current setting as a function of system pulse width and repetition rate, such that the energy of the output pulse is maintained at a desired value as the pulse width and repetition rate are varied.
A device in accordance with an embodiment of the invention also provides a means for calculating and storing the appropriate pump diode temperature setting as a function of the pump diode current setting, such that the emission wavelength of the pump diode is maintained at a wavelength that provides maximum absorption of the pump diode energy by the fiber amplifier medium as the pump diode current is varied.
Means are also provided to monitor the repetition rate of the injected pulses into the amplifier system, to compare it to the predetermined repetition rate, and if lower than this repetition rate, to disable or reduce the current to the amplifier pump diode to prevent it from being damaged.
The exemplary device discussed above also provides a means for comparing the amplitude of the pulse being injected into the fiber amplifier with a predetermined minimum amplitude value and if lower than this predetermined minimum, a means to disable or reduce the current to the amplifier pump diode to prevent it from being damaged. A device in accordance with an embodiment of the invention also provides a means of selecting and attenuating the seed pulses such that the amplified output pulses are of uniform energy.
It is an even further object of the invention to monitor the repetition rate of the oscillator and to provide a means for calculating the required down counter divide ratio needed to obtain a lower repetition rate.
It is also an object of the invention to synchronize the oscillator with an external reference signal. It is also an object of the invention to vary this external reference in frequency, and have the oscillator repetition rate vary accordingly.
It is an even further object of the invention to vary the external reference in frequency, and have the oscillator repetition rate vary accordingly, and also have the down counted repetition rate vary accordingly. However, this variation will be of a limited range compared to an all fiber system due to the operation repetition rate of a regenerative amplifier.
Finally, these regenerative amplifier systems will be utilized in many cases for micromachining. Improvements for FPCA systems have been developed that are unique for a fiber seed source. Ser. No. 10/813,389 (incorporated by reference herein), describes the benefit for changing the pulse shapes that allow the change of the material processing properties of that laser. These methods include allowing the addition of heat by the addition of longer pulses. The physical means for changing these pulse shapes and building a all fiber chirped pulse amplification system suitable for material processing is described Ser. No. 10/813,269 (incorporated by reference herein). As is mentioned in Ser. No. 10/813,269 some of these changes in the seed source for a fiber chirped pulse amplification systems will also be suitable for regenerative amplifier systems. Herein further methods of obtaining various pulse changes are described.
The invention thus provides methods of materials processing using bursts of laser light comprised of ultrashort pulses in the femtosecond, picosecond and nanosecond ranges, wherein parameters of the pulses comprising the burst, such as pulse width, pulse separation duration, pulse energy, wavelength and polarization, are manipulated to induce desirable properties in the processed material.
While a precise and controlled removal of material is achieved using ultrashort pulses, there are situations when having a small amount of thermal effect retained by the material from the previous pulse prior to being irradiated by a subsequent ultrashort pulse is beneficial. In addition, it is well known that the properties of most materials have some dependence on temperature. For example, the absorption of light by silicon is very dependent on temperature. Hence, heating such a target material can help initiate the ablation process at lower threshold fluence and may produce a smoother surface. In general, the thermal and physical effect or any change in structure caused by the prior pulse influences the laser matter interaction with the next pulse.
The ablation threshold energy density, as a function of pulse width, can vary significantly from the square root of t as pulse widths enter the femtosecond range. These ultrashort pulses can be used to micro-machine cleanly without causing significant heat. These ultrashort pulses also have deterministic thresholds compared to the statistical thresholds of longer pulses.
The present invention may be used in micro-machining with bursts of pulses having pulse shapes that cannot be quantified by a single pulse width in order to describe their micro-machining properties. For example, a burst comprises a 100 femtosecond pulse and a one nanosecond pulse, where the one nanosecond pulse contains ninety percent of the energy and the 100 femtosecond pulse contains ten percent of the energy. The threshold for ablation of gold is a little over 0.3 J/cm 2 for the 100 femtosecond pulse and 3.0 J/cm 2 for the one nanosecond pulse. Thus, if the burst is focused to output 0.3 J/cm 2 , then ablation will occur during the 100 femtosecond pulse, and not during the one nanosecond pulse. If the one nanosecond pulse impinges upon the surface first, it will have no affect while the 100 femtosecond pulse will ablate. Thus, the one nanosecond predominant pulse will not leave a heat affected zone. However, if the 100 femtosecond pulse is right before the one nanosecond pulse, then the 100 femtosecond pulse will change the absorption properties of the material so the one nanosecond pulse will also interact with the material. In this case, the ablation process would be predominantly heat related. If the one nanosecond pulse is increased to 100 nanoseconds, then the pulse energy content in the long pulse can be increased by ten-fold but the threshold is still determined by the ultrashort pulse and remains fixed even with one percent of the total energy in the ultrafast pulse.
Thus, in one embodiment of the present invention, the long pulse is before the ultrafast pulse if the pulse repetition rate is substantially greater than or equal 100 kilohertz. In another embodiment of the present invention, a portion of the long pulse follows after the ultrafast pulse, and adding a pedestal on the short pulse can create the long pulse. Micro-machining can be accomplished with an ultrashort pulse, where substantial energy is in a long pulse pedestal (>ten picoseconds) and where the long pulse pedestal adds a thermal machining mechanism.
The present invention can perform laser machining on material using a burst of ultrashort laser pulses and tailors the pulse width, pulse separation duration, wavelength and polarization to maximize the positive effect of thermal and physical changes achieved by the previous pulse on the laser matter interaction in a burst-machining mode. Better processing results can be achieved by manipulating the pulse width, the pulse separation duration and the pulse energies of pulses within a burst. The wavelength and polarization of a laser beam also strongly affect the absorption of the laser beam, and have to be varied pulse-to-pulse in a burst in order to produce maximum laser-matter interaction.
Besides the methods of manipulating laser beam parameters described above to achieve desired results, the present invention also includes methods to achieve the thermal and physical enhancement of a material during laser processing. In an embodiment of the present invention, the background light (commonly referred to as Amplified Spontaneous Emission (ASE)) is controlled to provide a constant source of energy for achieving thermal and physical changes to enhance the machining by individual ultrashort pulses. ASE is often emitted simultaneously and co-linearly with the ultrashort pulse from an amplified fiber laser. There are a number of ways to change the ASE ratio in the laser. Examples are changing the ultrashort pulse input energy into the amplifier, changing its center wavelength or changing the diode pump power to the amplifier. Another means more variable is within the compressor of the laser. As disclosed in application Ser. No. 10/813,163 the spectral output of the ASE can be designed to be at a different wavelength then that of the ultrashort pulse. Thus, in the compressor, where the spectral components are physically separated, a component can be placed to block or partially block the ASE, as disclosed in application Ser. No. 10/813,163. The ratio between the ASE and the ultrashort pulse energy can be controlled to vary the amount of preheating applied to the target material. In another embodiment of the invention, a pedestal of an ultrashort pulse is controlled. The pedestal is similar to a superimposed long-pulse with lower amplitude.
The invention is based on the interaction with a material of laser pulses of different pulse widths, pulse separation duration, energy, wavelength and polarization in a burst mode. The positive aspects of pulses having different pulse widths, pulse separation duration, energies, wavelengths and polarization are utilized, and a negative aspect of one pulse complements a positive aspect of another pulse. The coupling of laser energy during interaction of successive laser pulses with a material induces various thermal, physical and chemical couplings. The induced coupling involves microscopic change of electronic structure, phase transition, structural disintegration and/or other physical changes. For example, pulses with different pulse widths in a burst induce coupling that is different from a burst having pulses with the same pulse width.
An aspect of the invention provides a method of materials processing using laser light. The method comprises applying bursts of laser light to a target area of a material at a predetermined repetition rate. Preferably, the burst repetition rate is large enough for multipulse pulses generated within the round trip time of the regenerative amplifier, although lower repetition rates can be used. The burst of laser light comprises a first pulse and a second pulse of laser light displaced in time, although more pulses could be used in the burst as necessary. The first pulse has a first pulse width and the second pulse has a second pulse width, and predetermined parameters of the first pulse are selected to induce a change in a selected property of the processed material. The second pulse has a second pulse width, and predetermined parameters of the second pulse are selected based upon the property change induced by the first pulse. The first pulse width is generally in the nanosecond range, and the second pulse width is generally in the picosecond to femtosecond range. However, as stated previously it can be reversed. Predetermined parameters include pulse energy, pulse wavelength, pulse separation duration and pulse polarization vector. These parameters of the first and second pulses are controlled as well to machine the target area of the processed material.
A still further aspect of the present invention provides a method of materials processing that is similar to the previous aspect, except that the first and second pulses of the burst of laser light are overlapped in time, instead of being displaced in time. More pulses could be used in the burst as necessary. The first pulse has a first pulse width and the second pulse has a second pulse width, and the first pulse width can be greater than the second pulse width. The first pulse has a first pulse width and predetermined parameters of the first pulse are selected to induce a change in a selected property of the processed material. The second pulse has a second pulse width, and predetermined parameters of the second pulse are selected on based upon the property change induced by the first pulse. The first pulse width is generally in the nanosecond range, and the second pulse width is generally in the picosecond to femtosecond range. Predetermined parameters include pulse energy, pulse wavelength, pulse separation duration and pulse polarization vector which are controlled as well to machine the target area of the processed material. In addition, the second pulse may include a pedestal to facilitate thermally heating the processed material.
In yet another aspect of the present invention, an apparatus for generating optical pulses, wherein each pulse may have individualized characteristics, is provided. The apparatus comprises a laser means for generating the bursts of pulses, a control means that controls the laser means and a beam manipulation means for monitoring the pulse width, wavelength, repetition rate, polarization and/or temporal delay characteristics of the pulses comprising the pulse bursts. The apparatus generates feedback data based on the measured pulse width, wavelength, repetition rate, polarization and/or temporal delay characteristics for the control means. In one embodiment of the present invention, the laser means may comprise a fiber amplifier that uses stretcher gratings and compressor gratings. The beam manipulation means can comprise a variety of devices, e.g., an optical gating device that measures the pulse duration of the laser pulses, a power meter that measures the power of the laser pulses output from the laser means or a photodiode that measures a repetition rate of the laser pulses. Another beam manipulation means optically converts the fundamental frequency of a percentage of the generated laser pulses to one or more other optical frequencies, and includes at least one optical member that converts a portion of the fundamental of the laser pulses into at least one higher order harmonic signal. The optical member device may comprise a non-linear crystal device with a controller that controls the crystal's orientation. Preferably, the means for converting an optical frequency includes a spectrometer that measures predetermined parameters of pulses output from the non-linear crystal device and generates feedback for the control means.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification illustrate embodiments of the invention and, together with the description, serve to explain the aspects, advantages and principles of the invention. In the drawings,
FIG. 1 is a block diagram showing the basic components of the present invention.
FIG. 2 is an illustration of a modular, compact, tunable system for generating high peak and high average power ultrashort laser pulses in accordance with the present invention;
FIG. 3 is an illustration of an embodiment of a Seed Module (SM) for use in the present invention;
FIG. 4 is a diagram graphically illustrating the relationship between the average frequency-doubled power and wavelength which are output at a given range of input power according to one embodiment of the present invention.
FIG. 5 is an illustration of an embodiment of a Pulse Compressor Module (PCM) for use with the present invention;
FIG. 6 is an illustration of an embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
FIG. 7 is an illustration of a second embodiment of a Seed Module (SM) for use with the present invention;
FIG. 8 is an illustration of a third embodiment of a Seed Module (SM) for use with the present invention;
FIG. 9 is an illustration of a fourth embodiment of a Seed Module (SM) for use with the present invention;
FIG. 10 is an illustration of a fifth embodiment of a Seed Module (SM) for use with the present invention;
FIG. 11 is an illustration of an embodiment of the present invention in which a Fiber Delivery Module (FDM) is added to the embodiment of the invention shown in FIG. 1 ;
FIG. 12 is an illustration of an embodiment of a Fiber Delivery Module (FDM) for use with the present invention;
FIG. 13 is an illustration of a second embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
FIG. 14 is an illustration of a third embodiment of a Pulse Stretcher Module (PSM) for use with the present invention;
FIG. 15 is an illustration of an embodiment of the present invention in which pulse picking elements and additional amplification stages are added.
FIG. 16 is an illustration of another embodiment of the present invention where a fiber amplifier is operated with at least one forward and one backward pass, in combination with optical modulators such as pulse picking elements.
FIG. 17 is a diagram of a cladding pumped fiber cavity design according to a first embodiment of the invention.
FIG. 18 a is a diagram of a saturable absorber mirror according to an embodiment of the invention.
FIG. 18 b is a diagram of a saturable absorber mirror according to an alternative embodiment of the invention.
FIG. 19 is a diagram of the proton concentration as a function of depth obtained after proton implantation into a saturable semiconductor film.
FIG. 20 is a diagram of the measured bi-temporal reflectivity modulation obtained in a semiconductor saturable mirror produced by ion-implantation with selective depth penetration.
FIG. 21 a is a diagram of a scheme for coupling a saturable absorber mirror to a fiber end according to an embodiment of the invention.
FIG. 21 b is a diagram of a scheme for coupling a saturable absorber mirror to a fiber end according to an alternative embodiment of the invention.
FIG. 22 is a diagram for increasing the optical bandwidth of a fiber laser according to an embodiment of the invention.
FIG. 23 is a diagram of a core pumped fiber cavity design according to an embodiment of the invention.
FIG. 24 is a diagram of a core pumped fiber cavity design using intra-cavity wavelength division multiplexers and output couplers according to an embodiment of the invention.
FIG. 25 is a diagram of a core pumped fiber cavity design using intra-cavity wavelength division multiplexers and a butt-coupled fiber pig-tail for output coupling according to an embodiment of the invention.
FIG. 26 is a diagram of a cladding pumped fiber cavity design using an intra-cavity output coupler according to an embodiment of the invention.
FIG. 27 is a diagram of a cladding pumped fiber cavity design using intra-cavity fiber output couplers according to an embodiment of the invention.
FIG. 28 a is a diagram of a passively modelocked fiber laser based on concatenated sections of polarization maintaining and non-polarization maintaining fiber sections according to an embodiment of this invention.
FIG. 28 b is a diagram of a passively modelocked fiber laser based on concatenated sections of long polarization maintaining fiber sections according to an embodiment of this invention.
FIG. 28 c is a diagram of a passively modelocked fiber laser based on short concatenated sections of polarization maintaining fiber and additional sections of all-fiber polarizer according to an embodiment of this invention.
FIG. 29 is a diagram of a dispersion compensated fiber laser cavity according to an embodiment of this invention.
FIG. 30 is a diagram of a dispersion compensated fiber laser cavity according to an alternative embodiment of this invention, including means for additional spectral broadening of the fiber laser output.
FIG. 31 is a diagram of a design based on a fiber based MOPA having the fewest bulk optical components, according to a further embodiment.
FIG. 32 is an embodiment which includes monitoring electronics and feedback control of a fiber based pulse source.
FIG. 33 a illustrates a module usable for polarization correction or as variable attenuation in a fiber based laser system.
FIG. 33 b illustrates a particularly preferred embodiment for a fiber solid-state regenerative amplifier system.
FIG. 34 shows a source of ultra-fast pulses based upon a microchip laser.
FIG. 35 illustrates a source based on a DFB laser and a lithium niobate pulse generator.
FIG. 36 illustrates a system allowing independent control of higher order dispersion and self-phase modulation.
FIG. 37 illustrates an algorithm for a control system for ensuring mode-locking.
FIG. 38 illustrates an embodiment enabling the gain bandwidth of the regenerative amplifier to be easily matched to the fiber amplifier system.
FIG. 39 illustrates a generic scheme for the amplification of the output of a FCPA system in a bulk optical amplifier.
FIG. 40 illustrates an embodiment employing a series of chirped gratings operating on different portions of the spectrum, for elongating the pulse envelope.
FIGS. 41 and 42 show a laser diode-based multiple pulse source, and a laser system including this source.
FIGS. 43 a - 43 c show outputs of the pulse source of FIG. 41 in graphic form.
FIG. 44 illustrates a wavelength router scheme usable with the embodiment of FIG. 41 ; and
FIG. 45 illustrates a fiber splitter arrangement useable in the embodiment of FIG. 41 .
DETAILED DESCRIPTION OF THE INVENTION
A generalized illustration of the system of the invention is shown in FIG. 1 . The pulses are generated in a short pulse source 11 . These are coupled into a pulse conditioner 12 for spectral narrowing, broadening or shaping, wavelength converting, temporal pulse compression or stretching, pulse attenuation and/or lowering the repetition rate of the pulse train. The pulses are subsequently coupled into an Yb: or Nd: fiber amplifier 13 . Pulse stretcher 14 provides further pulse stretching before the amplification in the regenerative amplifier 15 that is based on an Nd: or Yb: doped solid-state laser material. The compressor 16 compresses the pulse back to near transform limit. The six basic subsystems described here are each subject to various implementations, as is described in the subsequent embodiments.
A generalized illustration of one embodiment of the short pulse source 11 is shown in FIG. 2 . The pulses generated in a laser seed source 1 (seed module; SM) are coupled into a pulse stretcher module 2 (PSM), where they are dispersively stretched in time. The stretched pulses are subsequently coupled into the fundamental mode of a cladding-pumped Yb fiber amplifier 3 (amplifier module, AM1), where the pulses are amplified by at least a factor of 10. Finally, the pulses are coupled into a pulse compressor module 4 (PCM), where they are temporally compressed back to approximately the bandwidth limit.
The embodiment shown in FIG. 2 is modular and four sub-systems; the SM 1 , PSM 2 , AM1 3 and PCM 4 . The sub-systems can be used independently as well as in different configurations, as described in the alternative embodiments.
In the following, discussion is restricted to the SM-PSM-AM1-PCM system. The SM 1 preferably comprises a femtosecond pulse source (seed source 5 ). The PSM preferably comprises a length of fiber 6 , where coupling between the SM and the PSM is preferably obtained by fusion splicing. The output of the PSM is preferably injected into the fundamental mode of the Yb amplifier 7 inside the AM1 module 3 . Coupling can be performed by fusion splicing, a fiber coupler or a bulk-optic imaging system between PSM 2 and the fiber amplifier 7 . All fibers are preferably selected to be polarization maintaining. The PCM 4 is preferably a dispersive delay line constructed from one or two bulk optic diffraction gratings for reasons of compactness. Alternatively, a number of bulk optic prisms and Bragg gratings can be used inside the PCM 4 . Coupling to the PCM 4 can be performed by a bulk optic lens system as represented by the single lens 8 in FIG. 2 . In the case of a PCM that contains fiber Bragg gratings, a fiber pig-tail can be used for coupling to the PCM.
As an example of a femtosecond laser seed source, a Raman-shifted, frequency-doubled Er fiber laser is shown within an SM 1 b in FIG. 3 . The femtosecond fiber laser 9 can be a commercial high energy soliton source (IMRA America, Inc., Femtolite B-60™) delivering ≈200 fs pulses at a wavelength of 1.57 μm and a pulse energy of 1 nJ at a repetition rate of 50 MHz.
For optimum Raman-shifting from 1.5 μm to the 2.1 μm wavelength region, a reduction in the core diameter (tapering) along the length of the polarization maintaining Raman-shifting fiber 10 is introduced. A reduction of the core diameter is required to keep the 2nd order dispersion in the Raman-shifter close to zero (but negative) in the whole wavelength range from 1.5 to 2.1 μm. By keeping the absolute value of the 2nd order dispersion small, the pulse width inside the Raman shifter is minimized, which leads to a maximization of the Raman frequency shift (J. P. Gordon, “Theory of the Soliton Self-frequency Shift,” Opt. Lett., 11, 662 (1986)). Without tapering, the Raman frequency-shift is typically limited to around 2.00 μm, which even after frequency-doubling is not compatible with the gain bandwidth of Yb fiber amplifiers.
In this particular example, a two-stage Raman shifter 10 consisting of 30 and 3 m lengths of silica ‘Raman’ fiber (single-mode at 1.56 μm) with core diameters of 6 and 4 μm respectively, was implemented. Due to the onset of the infrared absorption edge of silica at 2.0 μm, it is beneficial to increase the rate of tapering towards the end of the Raman shifter 10 . In the present example, conversion efficiencies up to 25% from 1.57 μm to 2.10 μm were obtained. Even better conversion efficiencies can be obtained by using a larger number of fibers with smoothly varying core diameter, or by implementing a single tapered fiber with smoothly varying core diameter.
Frequency-conversion of the Raman-shifted pulses to the 1.05 μm region can be performed by a length of periodically poled LiNbO3 (PPLN) crystal 11 with an appropriately selected poling period. (Although throughout this specification, the preferable material for frequency conversion is indicated as PPLN, it should be understood that other periodically-poled ferroelectric optical materials such as PP lithium tantalate, PP MgO:LiNbO 3 , PP KTP, or other periodically poled crystals of the KTP isomorph family can also be advantageously used.) Coupling with the PPLN crystal II occurs through the use of a lens system, represented in FIG. 3 by lenses 12 . The output of the PPLN crystal 11 is coupled by lenses 12 into output fiber 13 . Conversion efficiencies as high as 16% can so be obtained for frequency-doubling of 2.1 μm resulting in a pulse energy up to 40 pJ in the 1 μm wavelength region. The spectral width of the frequency-converted pulses can be selected by an appropriate choice of the length of the PPLN crystal 11 ; for example a 13 mm long PPLN crystal produces a bandwidth of 2 nm in the 1.05 μm region corresponding to a pulse width of around 800 fs. The generated pulse width is approximately proportional to the PPLN crystal length, i.e., a frequency converted pulse with a 400 fs pulse width requires a PPLN length of 6.5 mm. This pulse width scaling can be continued until the frequency-converted pulse width reaches around 100 fs, where the limited pulse width of 100 fs of the Raman-shifted pulses limits further pulse width reduction.
In addition, when the frequency-converted pulse width is substantially longer than the pulse width of the Raman-shifted pulses, the wide bandwidth of the Raman-pulses can be exploited to allow for wavelength-tuning of the frequency-converted pulses, i.e., efficient frequency conversion can be obtained for pulses ranging in frequency from 2(ω 1 −δω) to 2(ω 1 +δω), where 2δω is the spectral width at half maximum of the spectrum of the Raman-shifted pulses. Continuous wavelength tuning here is simply performed by tuning the temperature of the frequency-conversion crystal 11 .
The amplified noise of the Raman-shifter, PPLN-crystal combination is minimized as follows. Self-limiting Raman-shifting of the Er fiber laser pulse source can be used by extending the Raman shift out to larger than 2 μm in silica-based optical fiber. For wavelengths longer than 2 μm, the infrared absorption edge of silica starts to significantly attenuate the pulses, leading to a limitation of the Raman shift and a reduction in amplitude fluctuations, i.e., any increase in pulse energy at 1.5 μm tends to translate to a larger Raman-shift and thus to a greater absorption in the 2 μm wavelength region, which thus stabilizes the amplitude of the Raman-shifted pulses in this region.
Alternatively, the noise of the nonlinear frequency conversion process can be minimized by implementing self-limiting frequency-doubling, where the center wavelength of the tuning curve of the doubling crystal is shorter than the center wavelength of the Raman-shifted pulses. Again, any increase in pulse energy in the 1.5 μm region translates into a larger Raman-shift, producing a reduced frequency conversion efficiency, and thus the amplitude of the frequency-doubled pulses is stabilized. Therefore a constant frequency-converted power can be obtained for a large variation in input power.
This is illustrated in FIG. 4 , where the average frequency-converted power in the 1 μm wavelength region as a function of average input power at 1.56 μm is shown. Self-limiting frequency-doubling also ensures that the frequency-shifted wavelength in the 1 μm wavelength region is independent of average input power in the 1.56 μm wavelength region, as also demonstrated in FIG. 4 .
Several options exist for the PSM 2 . When a length of fiber 6 (stretching fiber) is used as a PSM as shown in FIG. 2 , an appropriate dispersive delay line can then be used in the PCM 4 to obtain near bandwidth-limited pulses from the system. However, when the dispersive delay line in the PCM 4 consists of bulk diffraction gratings 14 as shown in FIG. 5 , a possible problem arises. The ratio of |3 rd /2 nd |-order dispersion is typically 1-30 times larger in diffraction grating based dispersive delay lines compared to the ratio of |3 rd /2 nd |-order dispersion in typical step-index optical fibers operating in the 1 μm wavelength region. Moreover, for standard step-index fibers with low numerical apertures operating in the 1 μm wavelength regime, the sign of the third-order dispersion in the fiber is the same as in a grating based dispersive delay line. Thus a fiber stretcher in conjunction with a grating-based stretcher does not typically provide for the compensation of 3 rd - and higher-order dispersion in the system.
For pulse stretching by more than a factor of 10, the control of third-order and higher-order dispersion becomes important for optimal pulse compression in the PCM 4 . To overcome this problem, the stretcher fiber 6 in the PSM 2 can be replaced with a length of fibers with W-style multi-clad refractive index profiles, i.e., ‘W-fibers’ (B. J. Ainslie et al.) or holey fibers (T. M. Monroe et al., ‘Holey Optical Fibers’ An Efficient Modal Model, J. Lightw. Techn., vol. 17, no. 6, pp. 1093-1102). Both W-fibers and holey fibers allow adjustable values of 2nd, 3rd and higher-order dispersion. Due to the small core size possible in W and holey fibers, larger values of 3rd order dispersion than in standard single-mode fibers can be obtained. The implementation is similar to the one shown in FIG. 1 and is not separately displayed. The advantage of such systems is that the PSM can work purely in transmission, i.e., it avoids the use of dispersive Bragg gratings operating in reflection, and can be spliced into and out of the system for different system configurations.
An alternative PSM 2 with adjustable values of 2 nd , 3 rd and 4 th order dispersion is shown in FIG. 6 . The PSM 20 a is based on the principle that conventional step-index optical fibers can produce either positive, zero or negative 3rd order dispersion. The highest amount of 3rd order dispersion in a fiber is produced by using its first higher-order mode, the LP 11 mode near cut-off. In FIG. 6 , the 4 th and 3 rd order dispersion of the PSM 20 a is adjusted by using three sections 15 , 16 , 17 of pulse stretching fiber. The 1st stretcher fiber 15 can be a length of fiber with zero 3rd-order and appropriate 4 th -order dispersion. The 1st stretcher fiber 15 is then spliced to the 2 nd stretcher fiber 16 , which is selected to compensate for the 3 rd -order dispersion of the grating compressor as well as the whole chirped-pulse amplification system. To take advantage of the high 3 rd -order dispersion of the LP 11 mode the 1st stretcher fiber 15 is spliced to the 2 nd stretcher fiber 16 with an offset in their respective fiber centers, leading to a predominant excitation of the LP 11 mode in the 2nd stretcher fiber 16 . To maximize the amount of 3rd-order dispersion in the 2nd stretcher fiber 16 , a fiber with a high numerical aperture NA>0.20 is preferred. At the end of the 2nd stretcher fiber 16 , a similar splicing technique is used to transfer the LP 11 mode back to the fundamental mode of the 3 rd stretcher fiber 17 . By an appropriate choice of fibers, the 4th-order dispersion of the whole amplifier compressor can be minimized. The 3 rd stretcher fiber 17 can be short with negligible dispersion.
The transfer loss of the whole fiber stretcher assembly is at least 25% due to the unavoidable 50% or greater loss incurred by transferring power from the LP 11 mode to the LP 01 mode without the use of optical mode-converters. Any residual energy in the LP 01 mode in the 2nd stretcher fiber can be reflected with an optional reflective fiber grating 18 as shown in FIG. 6 . Due to the large difference in effective index between the fundamental and the next higher-order mode, the grating resonance wavelength varies between 10-40 nm between the two modes, allowing for selective rejection of one mode versus the other for pulses with spectral widths between 10-40 nm.
The energy loss of the fiber stretcher assembly can be made to be insignificant by turning the 3 rd stretcher fiber 17 into an Yb amplifier. This implementation is not separately shown.
When 4th-order dispersion is not significant, the 1st stretcher fiber 15 can be omitted. 4 th order dispersion can also be compensated by using a 1st stretcher fiber with non-zero 3 rd order dispersion, as long as the ratio of 3 rd and 4 th order dispersion is different between the 1 st and 2 nd stretcher fiber.
The Yb-doped fiber inside the AM1 3 can have an Yb doping level of 2.5 mole % and a length of 5 m. Both single-mode and multi-mode Yb-doped fiber can be used, where the core diameter of the fiber can vary between 1-50 μm; though the fundamental mode should be excited in case of a MM fiber to optimize the spatial quality of the output beam. Depending on the amount of required gain, different lengths of Yb-doped fiber can be used. To generate the highest possible pulse energies, Yb fiber lengths as short as 1 m can be implemented.
Pulse compression is performed in the PCM 4 . The PCM 4 can contain conventional bulk optic components (such as the bulk diffraction grating pair shown in FIG. 5 ), a single grating compressor, or a number of dispersive prisms or grisms or any other dispersive delay line.
Alternatively, a fiber or bulk Bragg grating can be used, or a chirped periodically poled crystal. The chirped periodically poled crystal combines the functions of pulse compression and frequency doubling (A. Galvanauskas, et al., ‘Use of chirped quasi-phase matched materials in chirped pulse amplification systems,’ U.S. application Ser. No. 08/822,967, the contents of which are hereby incorporated herein by reference) and operates in transmission providing for a uniquely compact system.
Other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing disclosure and teachings.
In particular, the SM 1 can be used as a stand-alone unit to produce near bandwidth limited femtosecond pulses in the frequency range from 1.52-2.2 μm, and after frequency conversion in a nonlinear crystal also in the frequency range from 760 nm to 1.1 μm. The frequency range can be further extended by using a fluoride Raman-shifting fiber or other optical fibers with infrared absorption edges longer than silica. Using this technique wavelengths up to around 3-5 μm can be reached. In conjunction with frequency-doubling, continuous tuning from 760 nm to 5000 nm can be achieved. The pulse power in the 2 μm region can be further enhanced by using Tm or Ho-doped fiber. With such amplifiers, near bandwidth-limited Raman-soliton pulses with pulse energies exceeding 10 nJ can be reached in single-mode fibers in the 2 μm wavelength region. After frequency-doubling, femtosecond pulses with energies of several nJ can be obtained in the 1 μm region without the use of any dispersive pulse compressors. Such pulses can be used as high energy seed pulses for large-core multi-mode Yb amplifiers, which require higher seed pulse energies than single-mode Yb amplifiers to suppress amplified spontaneous emission.
An example of an ultra-wide tunable fiber source combining an Er-fiber laser pulse source 19 with a silica Raman-shifter 20 , a Tm-doped amplifier 21 and a 2 nd fluoride glass based Raman shifter 22 is shown in the SM 1 c of FIG. 7 . An optional frequency-doubler is not shown for converting into the 900 nm to 1050 nm range. This would be a means for obtaining a high power source in this range. For optimum stability all fibers should be polarization maintaining, As another alternative to the Er-fiber laser pulse source a combination of a diode-laser pulse source with an Er-amplifier can be used; this is not separately shown.
As yet another alternative for a SM, SM 1 d is shown in FIG. 8 , and contains a frequency-doubled high-power passively mode-locked Er or Er/Yb-fiber oscillator 23 in conjunction with a length of Raman-shifting holey fiber 24 . Here the pulses from the oscillator 23 operating in the 1.55 μm wavelength region are first frequency-doubled using frequency doubler 25 and lens system 26 , and subsequently the frequency-doubled pulses are Raman-shifted in a length of holey fiber 24 that provides soliton supporting dispersion for wavelengths longer than 750 nm or at least longer than 810 nm. By amplifying the Raman-shifted pulses in the 1 μm wavelength regime or in the 1.3, 1.5, or 2 μm wavelength regime and by selecting different designs of Raman-shifting fibers, a continuously tunable source operating in the wavelength region from around 750 nm to 5000 nm can be constructed. The design of such a source with a number of attached amplifiers 27 is also shown in FIG. 8 .
For optimum Raman self-frequency shift, the holey fiber dispersion should be optimized as a function of wavelength. The absolute value of the 3rd order dispersion of the holey fiber should be less than or equal to the absolute value of the 3rd order material dispersion of silica. This will help ensure that the absolute value of the 2nd order dispersion remains small over a substantial portion of the wavelength tuning range. Moreover the value of the 2nd order dispersion should be negative, and a 2nd order dispersion zero should be within 300 nm in wavelength to the seed input wavelength.
As yet another alternative for a seed source for an Yb amplifier, anti-Stokes generation in a length of anti-Stokes fiber can be used. After anti-Stokes generation, additional lengths of fiber amplifiers and Raman-shifters can be used to construct a widely wavelength-tunable source. A generic configuration is similar to the one shown in FIG. 8 , where the frequency-doubling means 25 are omitted and the Raman-shifter means 24 are replaced with an anti-Stokes generation means. For example, to effectively generate light in the 1.05 μm wavelength regime in an anti-Stokes generation means using an Er fiber laser seed source operating at 1.55 μm, an anti-Stokes generation means in the form of an optical fiber with small core diameter and a low value of 3 rd order dispersion is optimum. A low value of 3 rd order dispersion is here defined as a value of 3 rd order dispersion smaller in comparison to the value of 3 rd order dispersion in a standard telecommunication fiber for the 1.55 wavelength region. Moreover, the value of the 2 nd order dispersion in the anti-Stokes fiber should be negative.
As yet another alternative seed-source for an Yb amplifier, a passively modelocked Yb or Nd fiber laser can be used inside the SM. Preferably an Yb soliton oscillator operating in the negative dispersion regime can be used. To construct an Yb soliton oscillator, negative cavity dispersion can be introduced into the cavity by an appropriately chirped fiber grating 29 , which is connected to output fiber 36 as shown in FIG. 9 ; alternatively, negative dispersion fiber such as holey fiber (T. Monroe et al.) can be used in the Yb soliton laser cavity. A SM incorporating such an arrangement is shown as SM 1 e in FIG. 9 . Here the Yb fiber 30 can be polarization maintaining and a polarizer 31 can be incorporated to select oscillation along one axis of the fiber (coupling being accomplished with lenses 32 ). For simplicity, the Yb fiber 30 can be cladding pumped from the side as shown in FIG. 9 . However, a passively modelocked Yb fiber laser incorporating conventional single-mode fiber with conventional pumping through a WDM can also be used. Such an arrangement is not separately shown. In FIG. 9 , SA 28 is used to induce the formation of short optical pulses. The grating 35 is used for dispersive control, and as an intra-cavity mirror. The pump diode 33 delivers pump light through V-groove 34 .
An arrangement incorporating a holey fiber can be nearly identical to the system displayed in FIG. 9 , where an additional length of holey fiber is spliced anywhere into the cavity. In the case of incorporating a holey fiber, the fiber Bragg grating does not need to have negative dispersion; equally the Bragg grating can be replaced with a dielectric mirror.
Most straight-forward to implement, however, is an Yb oscillator operating in the positive dispersion regime, which does not require any special cavity components such as negative dispersion fiber Bragg gratings or holey fiber to control the cavity dispersion. In conjunction with a ‘parabolic’ Yb amplifier (or ordinary Yb amplifier), a very compact seed source for a high-power Yb amplifier system can be obtained. Such a Yb oscillator with an Yb amplifier 40 is shown in FIG. 10 , where preferably the Yb amplifier 40 is a ‘parabolic’ Yb amplifier as discussed below. Elements which are identical to those in FIG. 9 are identically numbered.
The SM 1 f in FIG. 10 comprises a side-pumped Yb amplifier 40 as described with respect to FIG. 9 , though any other pumping arrangement could also be implemented. The Yb fiber 44 is assumed to be polarization maintaining and a polarizer 31 is inserted to select a single polarization state. The fiber Bragg grating 37 has a reflection bandwidth small compared to the gain bandwidth of Yb and ensures the oscillation of pulses with a bandwidth small compared to the gain bandwidth of Yb. The Bragg grating 37 can be chirped or unchirped. In the case of an unchirped Bragg grating, the pulses oscillating inside the Yb oscillator are positively chirped. Pulse generation or passive modelocking inside the Yb oscillator is initiated by the saturable absorber 28 . The optical filter 39 is optional and further restricts the bandwidth of the pulses launched into the Yb amplifier 40 .
To optimize the formation of parabolic pulses inside the Yb amplifier 40 inside the SM 1 f , the input pulses should have a bandwidth small compared to the gain bandwidth of Yb; also the input pulse width to the Yb amplifier 40 should be small compared to the output pulse width and the gain of the Yb amplifier 40 should be as high as possible, i.e., larger than 10. Also, gain saturation inside the Yb amplifier 40 should be small.
As an example of a parabolic amplifier a Yb amplifier of 5 m in length can be used. Parabolic pulse formation is ensured by using a seed source with a pulse width of around 0.2-1 ps and a spectral bandwidth on the order of 3-8 nm. Parabolic pulse formation broadens the bandwidth of the seed source to around 20-30 nm inside the Yb amplifier 40 , whereas the output pulses are broadened to around 2-3 ps. Since the chirp inside parabolic pulses is highly linear, after-compression pulse widths on the order of 100 fs can be obtained. Whereas standard ultrafast solid state amplifiers can tolerate a nonlinear phase shift from self-phase modulation only as large as pi (as well known in the state of the art), a parabolic pulse fiber amplifier can tolerate a nonlinear phase shift as large as 10*pi and higher. For simplicity, we thus refer to a large gain Yb amplifier as a parabolic amplifier. Parabolic amplifiers obey simple scaling laws and allow for the generation of parabolic pulses with spectral bandwidths as small as 1 nm or smaller by an appropriate increase of the amplifier length. For example, a parabolic pulse with a spectral bandwidth of around 2 nm can be generated using a parabolic amplifier length of around 100 m.
Since a parabolic pulse can tolerate large values of self-modulation and a large amount of spectral broadening without incurring any pulse break up, the peak power capability of a parabolic amplifier can be greatly enhanced compared to a standard amplifier. This may be explained as follows. The time dependent phase delay Φ nl (t) incurred by self-phase modulation in an optical fiber of length L is proportional to peak power, i.e.
Φ nl ( t )=γ P ( t ) L,
where P(t) is the time dependent peak power inside the optical pulse. The frequency modulation is given by the derivative of the phase modulation, i.e., δω=γL[∂P(t)/∂t]. For a pulse with a parabolic pulse profile P(t)=P 0 [1−(t/t 0 ) 2 ], where (−t 0 <t<t 0 ), the frequency modulation is linear. It may then be shown that indeed the pulse profile also stays parabolic, thus allowing the propagation of large peak powers with only a resultant linear frequency modulation and the generation of a linear pulse chirp.
The chirped pulses generated with the Yb amplifier 40 can be compressed using a diffraction grating compressor as shown in FIG. 5 . Alternatively, the pulses can be left chirped and compensated with the compressor after the regenerative amplifier.
In addition to the passively modelocked Yb fiber laser 44 shown in FIG. 10 , alternative sources could also be used to seed the Yb amplifier. These alternative sources can comprise Raman-shifted Er or Er/Yb fiber lasers, frequency-shifted Tm or Ho fiber lasers and also diode laser pulse sources. These alternative implementations are not separately shown.
In FIG. 11 a fiber delivery module (FDM) 45 is added to the basic system shown in FIG. 2 . The PSM 2 is omitted in this case; however, to expand the peak power capability of the amplifier module a PSM 2 can be included when required. The Yb amplifier 7 shown in FIG. 11 can be operated both in the non-parabolic or the parabolic regime.
In its simplest configuration, the FDM 45 consists of a length of optical fiber 46 (the delivery fiber). For a parabolic amplifier, the delivery fiber 46 can be directly spliced to the Yb amplifier 7 without incurring any loss in pulse quality. Rather, due to the parabolic pulse profile, even for large amounts of self-phase modulation, an approximately linear chirp is added to the pulse allowing for further pulse compression with the PCM 4 . The PCM 4 can be integrated with the FDM 45 by using a small-size version of the bulk diffraction grating compressor 14 shown in FIG. 5 in conjunction with a delivery fiber. In this case the delivery fiber in conjunction with an appropriate collimating lens would replace the input shown in FIG. 5 . A separate drawing of such an implementation is not shown. However, the use of the PCM 4 is optional and can for example be omitted, if chirped output pulses are required from the system. In conjunction with a PCM 4 , the system described in FIG. 11 constitutes a derivative of a chirped pulse amplification system, where self-phase modulation as well as gain is added while the pulse is dispersively broadened in time. The addition of self-phase modulation in conventional chirped pulse amplification systems typically leads to significant pulse distortions after pulse compression. The use of parabolic pulses overcomes this limitation.
To obtain pulse widths shorter than 50 fs, the control of third order and higher-order dispersion in a FDM module or in an optional PSM becomes significant. The control of higher-order dispersion with a PSM was already discussed with reference to FIGS. 2 and 6 ; the control of higher-order dispersion in a FDM is very similar and discussed with an exemplary embodiment of the FDM 45 a shown in FIG. 12 . Just as in FIG. 2 , the large third-order dispersion of a W-fiber can be used to compensate for the third-order dispersion of a bulk PCM 4 . Just as in FIG. 6 , by using fibers 15 , 16 , 17 with different values for higher-order dispersion in the FDM, the higher order dispersion of the whole system including a PCM 4 consisting of bulk diffraction gratings may be compensated.
Alternative embodiments of PSMs are shown in FIGS. 13 and 14 , which are also of practical value as they allow the use of commercially available linearly chirped fiber Bragg gratings in the PSM, while compensating for higher-order dispersion of a whole chirped-pulse amplification system comprising PSM as well as PCM. As another alternative, nonlinearly chirped fiber Bragg gratings can also be used in the PSM to compensate for the dispersion of the PCM. Such an arrangement is not separately shown.
Alternatively, the pulses can be left chirped and compensated with the compressor after the regenerative amplifier. This would mean not utilizing the PCM. This design would place additional design challenges on the dispersion correction in the PSM.
To avoid the use of W-fibers or the LP 11 , mode in the PSM, an alternative embodiment of a PSM as shown in FIG. 13 is shown as PSM 2 b . Here a negatively linearly chirped Bragg grating 47 is used in conjunction with a single-mode stretcher fiber 48 with negative third-order dispersion and circulator 49 . The introduction of the negative linearly chirped Bragg grating increases the ratio of (3 rd /2 nd )-order dispersion in the PSM 2 b , allowing for the compensation of the high value of 3 rd order dispersion in the PCM 4 , when a bulk diffraction grating compressor is used. The PSM 2 b can also contain W-fibers in conjunction with a linearly chirped fiber Bragg grating to further improve the flexibility of the PSM.
As yet another alternative embodiment of a PSM for the compensation of higher-order dispersion the arrangement in FIG. 14 is shown as PSM 2 c , comprising a positively linearly chirped fiber Bragg grating 50 , circulator 49 and another fiber transmission grating 51 . Here the positively linearly chirped fiber Bragg grating 50 produces positive 2nd order dispersion and the other fiber transmission grating 51 produces an appropriate amount of additional 2 nd 3 rd and 4 th order dispersion, to compensate for the linear and higher order dispersion inside the PCM module. More than one fiber transmission grating or fiber Bragg grating can be used to obtain the appropriate value of 3 rd and 4 th and possibly even higher-order dispersion.
To increase the amplified pulse energy from an Yb amplifier to higher pulse energies, pulse picking elements and further amplification stages can be implemented as shown in FIG. 15 . In this case, pulse pickers 52 are inserted in between the PSM 2 and the 1 st amplifier module AM1 3 a , as well as between the 1st amplifier stage AM1 3 a and 2 nd amplifier stage AM2 3 b . Any number of amplifiers and pulse pickers can be used to obtain the highest possible output powers, where the final amplifier stages preferably consist of multi-mode fibers. To obtain a diffraction limited output the fundamental mode in these multi-mode amplifiers is selectively excited and guided using well-known techniques (M. E. Fermann et al., U.S. Pat. No. 5,818,630 and U.S. application Ser. No. 10/424,220) (both incorporated by reference herein). The pulse pickers 52 are typically chosen to consist of optical modulators such as acousto-optic or electro-optic modulators. The pulse pickers 52 down-count the repetition rate of the pulses emerging from the SM 1 by a given value (e.g. from 50 MHz to 5 KHz), and thus allow the generation of very high pulse energies while the average power remains small. Alternatively, directly switchable semiconductor lasers could also be used to fix the repetition rate of the system at an arbitrary value. Further, the pulse pickers 52 inserted in later amplifier stages also suppress the build up of amplified spontaneous emission in the amplifiers allowing for a concentration of the output power in high-energy ultra-short pulses. The amplification stages are compatible with PSMs and PCMs as discussed before; where the dispersion of the whole system can be minimized to obtain the shortest possible pulses at the output of the system.
Amplifier module AM1 3 a can be designed as a parabolic amplifier producing pulses with a parabolic spectrum. Equally, the parabolic pulses from AM1 3 a can be transformed into pulses with a parabolic pulse spectrum in a subsequent length of pulse-shaping or pulse stretching fiber 53 as also shown in FIG. 15 , where the interaction of self-phase modulation and positive dispersion performs this transformation. This may be understood, since a chirped pulse with a parabolic pulse profile can evolve asymptotically into a parabolic pulse with a parabolic spectrum in a length of fiber. The parabolic pulse shape maximizes the amount of tolerable self-phase modulation in the subsequent amplification stages, which in turn minimizes the amount of dispersive pulse stretching and compression required in the PSM 2 and PCM 4 . Equally, parabolic pulse shapes allow the toleration of significant amounts of self-phase modulation in the PSM 2 without significant pulse distortions.
Once the pulses are stretched, the detrimental influence of self-phase modulation in subsequent amplifiers can be minimized by using flat-top pulse shapes. A flat-top pulse shape can be produced by inserting an optional amplitude filter 54 as shown in FIG. 15 in front of the last amplifier module to produce a flat-top pulse spectrum. A flat-top spectrum is indeed transformed into a flat-top pulse after sufficient pulse stretching, because there is a direct relation between spectral content and time delay after sufficient pulse stretching. It can be shown that even values of self-phase modulation as large as 10*π can be tolerated for flat-top pulses without incurring significant pulse distortions.
An amplitude filter as shown in FIG. 15 may in turn also be used to control the amount of higher-order dispersion in the amplifier chain for strongly chirped pulses in the presence of self-phase modulation when reshaping of the pulse spectrum in the amplifier can be neglected, i.e., outside the regime where parabolic pulses are generated. In this case self-phase modulation produces an effective amount of higher-order dispersion of:
β n SPM = γ P 0 L eff ⅆ n S ( ω ) ⅆ ω n | ω = 0 ,
where P 0 is the peak power of the pulse and S(ω) is the normalized pulse spectrum. L eff is the effective nonlinear length L eff =[exp(gL)−1]/g, where L is the amplifier length and g is the amplifier gain per unit length. Thus by accurately controlling the spectrum of strongly chirped pulses with an amplitude filter as shown in FIG. 15 , any amount of higher-order dispersion can be introduced to compensate for the values of higher-order dispersion in a chirped pulse amplification system. It can indeed be shown for 500 fs pulses stretched to around 1 ns, a phase shift of ≈10π is sufficient to compensate for the third-order dispersion of a bulk grating compressor (as shown in FIG. 5 ) consisting of bulk gratings with 1800 grooves/mm. Attractive well-controllable amplitude filters are for example fiber transmission gratings, though any amplitude filter may be used to control the pulse spectrum in front of such a higher-order dispersion inducing amplifier.
As another embodiment for the combination of an amplifier module with a pulse picker, the configuration displayed in FIG. 16 can be used. Since very high energy pulses require large core multi-mode fibers for their amplification, the control of the fundamental mode in a single-pass polarization maintaining fiber amplifier may be difficult to accomplish. In this case, it may be preferred to use a highly centro-symmetric non-polarization maintaining amplifier to minimize mode-coupling and to obtain a high-quality output beam. To obtain a deterministic environmentally stable polarization output from such an amplifier, a double-pass configuration as shown in FIG. 16 may be required. Here a single-mode fiber 55 is used as a spatial mode filter after the first pass through the amplifier 56 ; alternatively, an aperture could be used here. The spatial mode filter 55 cleans up the mode after the first pass through the multi-mode amplifier 56 , and also suppresses amplified spontaneous emission in higher-order modes that tends to limit the achievable gain in a multi-mode amplifier. Lenses 60 can be used for coupling into and out of amplifier 56 , spatial mode filter 55 , and pulse pickers 52 a and 52 b . The Faraday rotator 57 ensures that the backward propagating light is polarized orthogonal to the forward propagating light; the backward propagating light is coupled out of the system at the shown polarization beam splitter 58 . To optimize the efficiency of the system, a near-diffraction limited source is coupled into the fundamental mode of the multi-mode fiber 56 at the input of the system, where gain-guiding can also be used to further improve the spatial quality of the beam amplified in the multi-mode fiber. To count-down the repetition rate of the pulse train delivered from a SM and to suppress amplified spontaneous emission in the multi-mode amplifier, a 1st optical modulator 52 a can be inserted after the first pass through the multi-mode amplifier. An ideal location is just in front of the reflecting mirror 59 as shown. As a result a double-pass gain as large as 60-70 dB could be obtained in such a configuration, minimizing the number of amplification stages required from amplifying seed pulses with pJ energies up to the mJ energy level. This type of amplifier is fully compatible with the SMs, PSMs and PCMs as discussed before, allowing for the generation of femtosecond pulses with energies in the mJ regime. As another alternative for the construction of a high-gain amplifier module, a count-down of the repetition rate from a pulse train delivered by a SM can also be performed with an additional 2nd modulator 52 b prior to injection into the present amplifier module as also shown in FIG. 16 . The repetition rate of transmission windows of the 1st modulator 52 a should then be either lower or equal to the repetition rate of the transmission window of the 2nd modulator 52 b . Such a configuration is not separately shown. FIG. 16 shares some similarities with FIG. 5 of U.S. Pat. No. 5,400,350, which is hereby incorporated by reference.
FIG. 17 represents an embodiment of the femtosecond fiber oscillator embodied in a fiber laser cavity 100 . A polarization-maintaining gain fiber 101 has a core 102 and cladding region 103 . The fiber core 102 is doped with rare-earth ions, such as Yb, Nd, Er, Er/Yb, Tm or Pr, to produce gain at a signal wavelength when the laser is pumped with diode laser 104 . The fiber core can be single-mode or multi-mode. The fiber laser cavity 100 further contains an integrated fiber polarizer 105 and a chirped fiber Bragg grating 106 . Both of these elements, 105 and 106 , are generally constructed of short fiber pigtails (e.g., 0.001-1 m in length), which are preferably fusion-spliced to fiber 101 using splices 107 , 108 and 109 . Alternatively, fiber polarizer 105 can be spliced in front of beam expander 110 . When using multi-mode fiber, splice 107 is selected to match the fundamental mode in the gain fiber 101 .
An exemplary integrated fiber polarizer in accordance with the invention comprises a polarization-maintaining undoped polarizer fiber (PF), with two orthogonal polarization axes, where the loss along one polarization axis is significantly higher than the loss along the other polarization axis. Alternatively, a very short section (less than 1 cm) of non-birefringent fiber (i.e., non-polarization-maintaining fiber) can be sandwiched between two sections of polarization-maintaining fiber, where the polarization axes of the polarization-maintaining fibers are aligned with respect to each other. By side-polishing the non-birefringent fiber, e.g., down to the evanescent field of the fiber core, along one of the axes of the birefringent fiber, and coating the polished region with metal, high extinction polarization action can be obtained along one of the axes of the birefringent fiber. The design of side-polished fiber polarizers is well known in the field and not discussed further here.
For optimum laser operation, the fiber polarization axes of the PF are aligned parallel to the polarization axes of the gain fiber 101 . To ensure stable modelocked operation, the polarizer preferably effectively eliminates satellite pulses generated by any misalignment between the polarization axes of the PF and the gain fiber 101 .
Neglecting any depolarization in the all-fiber polarizer itself, it can be shown by applying a Jones matrix calculation method that for a misalignment of the polarization axes of gain fiber 101 and fiber polarizer 105 by α degrees, the linear reflectivity R from the right-hand side of the cavity varies approximately between R=1−0.5 sin 2 2α and R=1 depending on the linear phase in the gain fiber 101 . If the group delay along the two polarization axes of the gain fiber is larger than the intra-cavity pulse width, any satellite pulse is suppressed by sin 4 α after transmission through the polarizer. Typical fiber splicing machines can align polarization-maintaining fibers with an angular accuracy of less than ±2°; hence any reflectivity variation due to drifts in the linear phase between the two polarization eigenmodes of fiber 101 can be kept down to less than 3×10 −3 , whereas (for sufficiently long fibers) any satellite pulses obtained after transmission through the polarizer can be kept down to less than 6×10 −6 when using an integrated polarizer.
The chirped fiber Bragg grating 106 is preferably spliced to the PF 105 at splice position 108 and written in non-polarization-maintaining fiber. In order to avoid depolarization in the fiber Bragg grating, the Bragg grating pig-tails are preferably kept very short, e.g., a length smaller than 2.5 cm is preferable between splice locations 108 and 109 . To obtain a linear polarization output, a polarization-maintaining fiber pig-tail is spliced to the left-side of the fiber Bragg grating at splice location 109 . The laser output is obtained at a first fiber (or cavity) end 111 , which is preferably angle-cleaved to avoid back-reflections into the cavity. An alternative preferred design is with the fiber grating written in polarization-maintaining fiber.
Fiber Bragg grating 106 serves two functions. First, it is used as an output mirror (i.e., it feeds part of the signal back to the cavity) and, second, it controls the amount of cavity dispersion. In the present implementation, the chirped fiber Bragg grating has a negative (soliton-supporting) dispersion at the emission wavelength in the wavelength region near 1060 nm and it counter-balances the positive material dispersion of the intra-cavity fiber. To produce the shortest possible pulses (with an optical bandwidth comparable to or larger than the bandwidth of the gain medium), the absolute value of the grating dispersion is selected to be within the range of 0.5-10 times the absolute value of the intra-cavity fiber dispersion. Moreover, the fiber Bragg grating is apodized in order to minimize any ripple in the reflection spectrum of the grating. Accordingly, the oscillation of chirped pulses is enabled in the cavity, minimizing the nonlinearity of the cavity and maximizing the pulse energy. Chirped pulses are characterized in having a pulse width which is longer than the pulse width that corresponds to the bandwidth limit of the corresponding pulse spectrum. For example the pulse width can be 50%, 100%, 200% or more than 1000% longer than the bandwidth limit.
Alternatively, the oscillation of chirped pulses is also enabled by using negative dispersion fiber in conjunction with positive dispersion chirped fiber Bragg gratings. Pulses with optical bandwidth comparable to the bandwidth of the gain medium can also be obtained with this alternative design.
A SAM 112 at a second distal fiber end 113 completes the cavity. In an exemplary implementation a thermally expanded core (TEC) 110 is implemented at cavity end 113 to optimize the modelocking performance and to allow close coupling of the SAM 112 to the second fiber end 113 with large longitudinal alignment tolerances. Etalon formation between the fiber end 113 and the SAM 112 is prevented by an anti-reflection coating deposited on fiber end 113 (not separately shown). In the vicinity of the second fiber end 113 , fiber 101 is further inserted into ferrule 114 and brought into close contact with SAM 112 . Fiber 101 is subsequently fixed to ferrule 114 using, for example, epoxy and the ferrule itself is also glued to the SAM 112 .
The pump laser 104 is coupled into the gain fiber 101 via a lens system comprising, for example, two lenses 115 and 116 and a V-groove 117 cut into fiber 101 . Such side-coupling arrangements are described in, for example, U.S. Pat. No. 5,854,865 ('865) to L. Goldberg et al. Alternatively, fiber couplers can be used for pump light coupling.
An exemplary design for a SAM in accordance with the present invention is shown in FIG. 18 a . For example, SAM 200 includes an InGaAsP layer 201 with a thickness of 50-2000 nm. Further, layer 201 is grown with a band edge in the 1 μm wavelength region; the exact wavelength is defined by the sought emission wavelength of the fiber laser and can vary between 1.0-1.6 μm. The InGaAsP layer 201 is further coated or processed with a reflective material such as Au or Ag. A dielectric mirror or semiconductor Bragg reflector 202 is located beneath layer 201 and the entire structure is attached to heat sink 203 , based on, for example, metal, diamond or sapphire.
In order to cover a broad spectral range (e.g., greater than 100 nm) metallic mirrors are preferred. When using a metallic mirror it is advantageous to remove the substrate (InP) by means of etching. When using HCl as an etching solvent the etching selectivity between InGaAsP and InP can be low, depending on the compound composition of InGaAsP. An etch-stop layer is beneficial between the substrate and the InGaAsP layer. InGaAs can be a proper etch-stop layer. When adding an InGaAs layer with a band-gap wavelength shorter than 1.03 μm, lattice relaxations can be avoided by keeping the thickness below 10 nm.
The InGaAsP layer can further be anti-reflection coated with layer 204 on its upper surface to optimize the performance of the SAM. Because of the saturable absorption by InGaAsP, the reflectivity of the SAM increases as a function of light intensity, which in turn favors the growth of short pulses inside the laser cavity. The absence of Al in the saturable absorber layer prevents oxidization of the semiconductor surfaces in ambient air and thus maximizes the life-time and power handling capability of the structure.
Instead of InGaAsP, any other Al-free saturable semiconductor can also be used in the construction of the SAM. Alternatively, Al-containing semiconductors can be used in the SAM with appropriately passivated surface areas. Surface passivation can, for example, be accomplished by sulfidization of the semiconductor surface, encapsulating it with an appropriate dielectric or with an Al-free semiconductor cap layer. An AlGaInAs absorber layer grown lattice-matched on InP can be surface-passivated with a thin (about 10 nm range) cap layer of InP. AlGaInAs with a higher band gap energy than the absorber layer can also be used for a semiconductor Bragg reflector in combination with InP. Among concepts for semiconductor Bragg mirrors lattice-matched to InP, an AlGaInAs/InP combination has an advantage over an InGaAsP/InP Bragg reflector due to its high refractive index contrast.
Instead of a bulk semiconductor saturable absorber, a MQW saturable absorber structure as shown in FIG. 18 b may also be used. In this case, the SAM 205 conveniently comprises MQW structures 206 , 207 and 208 separated by passive spacer layers 209 - 212 in order to increase the saturation fluence and depth-selective ion-implantation concentration of each MQW section. Additional MQW structures can further be used, similarly separated by additional passive spacer layers. To reduce the wavelength and location sensitivity of the MQW saturable absorbers, the width of the spacer layers varies from spacer layer to spacer layer. Furthermore, multiple bulk layers with thicknesses larger than 500 Å can replace the MQW structure. The MQW layers, in turn, can contain several layers of quantum wells and barriers such as, for example, InGaAs and GaAs, respectively. Top surface 209 can further be anti-reflection coated (not shown); a reflective structure is obtained by including mirror structure 213 . The entire structure can be mounted on heat sink 214 .
The control of the response time of the saturable absorption for concomitant existence of fast and slow time constants is realized by introducing carrier trap centers with depth controlled H+ (or other ions) implantation. The implantation energy and dose are adjusted such that part of the absorbing semiconductor film contains a minimal number of trap centers. For example the semiconductor layer with the minimal number of trap centers can be selected to be at the edge of the optical penetration range of exciting laser radiation. Such a design serves only as an example and alternatively any semiconductor area within the optical penetration range can be selected to contain a minimal number of trap centers. Hence distinctive bi-temporal carrier relaxation is obtained in the presence of optical excitation. As an illustration of depth selective ion implantation, FIG. 19 shows the measurement of the depth profile of H+ ion implantation of an InGaAsP absorber film taken from secondary ion mass spectroscopy (SIMS).
The obtained bi-temporal carrier life-time obtained with the semiconductor film with a proton concentration as shown in FIG. 19 , is further illustrated in FIG. 20 . Here the reflectivity modulation (dR/R0) of a semiconductor saturable mirror due to excitation of the saturable mirror with a high energy short pulse at time t=0 is shown as a function of time delay. The measurement was obtained with a pump-probe technique, as well known in the art. FIG. 20 clearly displays the bi-temporal response time due to fast (<1 ps) and slow (>>100 ps) recovery. The distinctive fast response originates from the depth region with high trap concentration, while the slow component results from the rear depth region with a much lower trap center concentration.
When employing this absorber in the laser system described with respect to FIG. 17 , Q-switched mode-locking is obtained at intracavity power levels of a few mW. At the operating pump power level, stable cw mode-locking evolving from Q-switch mode-locking is observed. In contrast, no Q-switching and no mode-locking operation is obtained with the same semiconductor material implanted uniformly with protons without bi-temporal carrier relaxation (exhibiting only fast carrier relaxation).
We emphasize that the description for FIG. 19 and FIG. 20 is to serve as an example in controlling 1) the fast time constant, 2) the slow time constant, 3) the ratio of the fast and slow time constants, 4) the amplitude of the fast response, 5) the amplitude of the slow response, and finally 6) the combination of all of the above by ion implantation in a saturable absorber. Thus, the concept depicted hereby can be applicable for any type of laser modelocked with a saturable absorber. Specifically, in the presence of un-avoidable large spurious intra-cavity reflections such as in fiber lasers or thin disk lasers (F. Brunner et al., Sub-50 fs pulses with 24 W average power from a passively modelocked thin disk Yb:YAG laser with nonlinear fiber compression, Conf. on Advanced Solid State Photonics, ASSP, 2003, paper No.: TuAl), the disclosed engineerable bi-temporal saturable absorbers can greatly simplify and stabilize short pulse formation.
The preferred implantation parameters for H+ ions in GaAs or InP related materials including MQW absorbers are as follows: The doses and the implantation energies can be selected from 10 12 cm −2 to 10 17 cm −2 and from 5 keV to 200 keV, respectively, for an optically absorbing layer thickness between 50 nm and 2000 nm. For MQW absorbers, the selective ion-implantation depth is rather difficult to measure because the shallow MQW falls into the implantation peak in FIG. 19 . However, with the separation of MQW sections with spacers 209 - 212 (as shown in FIG. 18 ) it is feasible to employ depth selective ion implantation. For arsenic implantation, the implantation parameters for 50-2000 nm absorbing layer spans from 10 12 cm −2 to 10 17 cm −2 for the dosage and an implantation energy range of 100 keV to 1000 keV. In case of MQW saturable absorbers, the implantation range is preferably selected within the total thickness of the semiconductor layer structure containing MQW sections and spacers. In addition to H + and arsenic, any other ions such as for example Be can be implanted with controlled penetration depth by adjusting the above recipes according to the stability requirements of the desired laser.
FIG. 21 a illustrates an alternative implementation of the fiber end and SAM coupling in FIG. 17 . Here cavity 300 comprises an angle-polished thermal-diffusion expanded core (TEC) 301 . Fiber end 302 is brought into close contact with SAM 303 and fiber 304 is rotated inside ferrule 305 to maximize the back reflection from SAM 303 . Ferrule 305 is further angle-polished and SAM 303 is attached to the angle-polished surface of ferrule 305 . As shown in FIG. 21 a , fiber 304 is conveniently glued to the left-hand side of ferrule 305 . A wedge-shaped area between the fiber surface 302 and SAM 303 greatly reduces the finesse of the etalon between the two surfaces, which is required for optimum modelocked laser operation.
Instead of TEC cores, more conventional lenses or graded index lenses can be incorporated between the fiber end and the SAM to optimize the beam diameter on the SAM. Generally, two lenses are required. A first lens collimates the beam emerging from the fiber end, and a second lens focuses the beam onto the SAM. According to present technology, even conventional lenses allow the construction of a very compact package for the second fiber end. An implementation with two separate collimation and focusing lenses is not separately shown. To minimize unwanted back reflections into the fiber cavity and to minimize the number of components, a single lens can be directly fused to the fiber end as depicted in FIG. 21 b . As shown in FIG. 21 b , assembly 306 contains SAM 303 and fiber 304 as well as lens 307 , which focuses the optical beam onto the SAM. Lens 307 can also include a graded index lens.
To minimize aberrations in assembly 306 , an additional lens can also be incorporated between lens 307 and SAM 303 . Such an assembly is not separately shown. Alternatively, a lens can be directly polished onto fiber 304 ; however, such an arrangement has the disadvantage that it only allows a beam size on the SAM which is smaller than the beam size inside the optical fiber, thereby somewhat restricting the design parameters of the laser. To circumvent this problem, a lens surface can be directly polished onto the surface of a TEC; such an implementation is not separately shown. Another alternative is to exploit a graded-index lens design attached directly onto the fiber tip to vary the beam size on the SAM. In the presence of air-gaps inside the oscillator a bandpass filter 308 can be incorporated into the cavity, allowing for wavelength tuning by angular rotation as shown, for example, in FIG. 21 b.
Passive modelocking of laser cavity 100 ( FIG. 17 ) is obtained when the pump power exceeds a certain threshold power. In a specific, exemplary, implementation, polarization-maintaining fiber 101 was doped with Yb with a doping level of 2 weight %; the doped fiber had a length of 1.0 m; the core diameter was 8 um and the cladding diameter was 125 um. An additional 1.0 m length of undoped polarization-maintaining fiber was also present in the cavity. The overall (summed) dispersion of the two intra-cavity fibers was approximately +0.09 ps 2 . In contrast, the fiber grating 106 had a dispersion of −0.5 ps 2 , a spectral bandwidth of 10 nm and a reflectivity of 50%. The grating was manufactured with a phase mask with a chirp rate of 80 nm/cm.
When pumping with an optical power of 1.0 W at a wavelength of 910 nm, the laser produced short chirped optical pulses with a full width half maximum width of 1.5 ps at a repetition rate of 50 MHz. The average output power was as high as 10 mW. The pulse bandwidth was around 2 nm and hence the pulses were more than two times longer than the bandwidth-limit which corresponds to around 800 fs.
Alternatively, a fiber grating 106 with a dispersion of −0.1 ps 2 , closely matching the dispersion of the intra-cavity fiber, was implemented. The fiber grating had a reflectivity of 9% and a spectral bandwidth of 22 nm centered at 1050 nm. The grating was manufactured with a phase mask with a chirp rate of 320 nm/cm. The laser then produced chirped optical pulses with a full-width half maximum width of 1.0 ps at a repetition rate of 50 MHz with an average power of 25 mW. The pulse spectral bandwidth was around 20 nm and thus the pulses were around 10 times longer than the bandwidth limit, which corresponds to around 100 fs. The generation of pulses with a pulse width corresponding to the bandwidth limit was enabled by the insertion of a pulse compressing element; such elements are well known in the state of the art and are not further discussed here. The generation of even shorter pulses can be generated with fiber gratings with a bandwidth of 40 nm (and more) corresponding to (or exceeding) the spectral gain bandwidth of Yb fibers.
Shorter pulses or pulses with a larger bandwidth can be conveniently obtained by coupling the fiber output into another length of nonlinear fiber as shown in FIG. 22 . Here, assembly 400 contains the integrated fiber laser 401 with pig-tail 402 . Pig-tail 402 is spliced (or connected) to the nonlinear fiber 403 via fiber splice (or connector) 404 . Any type of nonlinear fiber can be implemented. Moreover, fiber 403 can also comprise a fiber amplifier to further increase the overall output power.
In addition to cladding pumped fiber lasers, core-pumped fiber lasers can be constructed in an integrated fashion. Such an assembly is shown in FIG. 23 . The construction of cavity 500 is very similar to the cavity shown in FIG. 17 . Cavity 500 contains polarization-maintaining fiber 501 and integrated fiber polarizer 502 . Fiber 501 is preferably single-clad, though double-clad fiber can also be implemented. The chirped fiber grating 503 again controls the dispersion inside the cavity and is also used as the output coupler. Fiber 501 , fiber polarizer 502 , fiber grating 503 and the polarization-maintaining output fiber are connected via splices 504 - 506 . The output from the cavity is extracted at angle-cleaved fiber end 507 . SAM 508 contains anti-reflection coated fiber end 509 , located at the output of the TEC 510 . Fiber 501 and SAM 508 are fixed to each other using ferrule 511 . The fiber laser is pumped with pump laser 512 , which is injected into the fiber via wavelength-division multiplexing coupler 513 .
In addition to chirped fiber gratings, unchirped fiber gratings can also be used as output couplers. Such cavity designs are particularly interesting for the construction of compact Er fiber lasers. Cavity designs as discussed with respect to FIGS. 17 and 23 can be implemented and are not separately shown. In the presence of fiber gratings as shown in FIGS. 17 and 23 , the fiber gratings can also be used as wavelength tuning elements. In this, the fiber gratings can be heated, compressed or stretched to change their resonance condition, leading to a change in center wavelength of the laser output. Techniques for heating, compressing and stretching the fiber gratings are well known. Accordingly, separate cavity implementations for wavelength tuning via a manipulation of the fiber grating resonance wavelength are not separately shown.
In the absence of a fiber grating, a mirror can be deposited or attached to one end of the fiber cavity. The corresponding cavity design 600 is shown in FIG. 24 . Here, it is assumed that the fiber 601 is core pumped. The cavity comprises an intra-cavity all-fiber polarizer 602 spliced to fiber 601 via splice 603 . Another splice 604 is used to couple WDM 605 to polarizer 602 . Polarization maintaining WDM 605 is connected to pump laser 606 , which is used to pump the fiber laser assembly. Saturable absorber mirror assembly 607 , as described previously with respect to FIGS. 17 and 23 , terminates one cavity end and is also used as the passive modelocking element.
A second fiber polarizer 608 is spliced between WDM 605 and polarization-maintaining output coupler 609 to minimize the formation of satellite pulses, which can occur when splicing sections of polarization maintaining fiber together without perfect alignment of their respective polarization axes, as discussed in U.S. patent application Ser. No. 09/809,248. Typically, coupler 609 has a coupling ratio of 90/10 to 50/50, i.e., coupler 609 couples about 90-50% of the intra-cavity signal out to fiber pig-tail 610 . Pig-tail 610 can be spliced to a fiber isolator or additional fiber amplifiers to increase the pulse power. The second cavity end is terminated by mirror 611 . Mirror 611 can be directly coated onto the fiber end face or, alternatively, mirror 611 can be butt-coupled to the adjacent fiber end.
The increase in stability of cavity 600 compared to a cavity where the output coupler fiber, the WDM fiber and gain fiber 601 are directly concatenated without intra-fiber polarizing stages, can be calculated using a Jones matrix formalism even when coherent interaction between the polarization axes of each fiber section occurs.
Briefly, due to the environmental sensitivity of the phase delay between the polarization eigenmodes of each fiber section, for N directly concatenated polarization-maintaining fibers the reflectivity of a fiber Fabry-Perot cavity can vary between R=1 and R=1−(N×α) 2 , where α is the angular misalignment between each fiber section. Further, it is assumed that α is small (i.e., α<<10°) and identical between each pair of fiber sections. Also, any cavity losses are neglected. In fact, it is advantageous to analyze the possible leakage L into the unwanted polarization state at the output of the fiber cavity. L is simply given by L=1−R. For the case of N concatenated fiber sections, the maximum leakage is thus (N×α) 2 .
In contrast, a cavity containing N−1 polarizers in-between N sections of polarization-maintaining fiber is more stable, and the maximum leakage is L=2×(N−1)α 2 . Here, any depolarization in the fiber polarizers itself is neglected. For instance, in a case where N=3, as in cavity 600 , the leakage L into the wrong polarization axis is 2×(3−1)/3 3 =4/9 times smaller compared to a cavity with three directly concatenated fiber sections. This increase in stability is very important in manufacturing yield as well as in more reproducible modelocked operation in general.
In constructing a stable laser, it is also important to consider the construction of WDM 605 as well as output coupler 609 . Various vendors offer different implementations. An adequate optical representation of such general polarization-maintaining fiber elements is shown in FIG. 25 . It is sufficient to assume that a general coupler 700 comprises two polarization-maintaining fiber sections (pig-tails) 701 , 702 with a coupling point 703 in the middle, where the two polarization axes of the fiber are approximately aligned with respect to each other.
In order to ensure pulse stability inside a passively modelocked laser, the group-velocity walk-off along the two polarization axes of fiber sections 701 , 702 should then be longer than the full-width half maximum (FWHM) pulse width of the pulses generated in the cavity. For example, assuming a birefringent fiber operating at a wavelength of 1550 nm with a birefringence of 3×10 −4 corresponding to a polarization beat length of 5 mm at 1550 nm, the stable oscillation of soliton pulses with a FWHM width of 300 fs requires pig-tails with a length greater than 29 cm. For 500 fs pulses, the pig-tail length should be increased to around 50 cm.
Referring back to FIG. 24 , if a fiber pig-tailed output is not required, mirror 611 as well as output coupler 609 can be omitted, and the 4% reflection from the fiber end adjacent to mirror 611 can be used as an effective output mirror. Such an implementation is not separately shown.
Alternatively, a fiber-pig-tail can be butt-coupled to mirror 611 and also be used as an output fiber pigtail. Such an implementation is shown in FIG. 26 . Here, cavity 800 comprises core-pumped fiber 801 , fiber polarizer 802 and SAM assembly 803 . The laser is pumped via WDM 804 connected to pump laser 805 . An appropriate mirror (or mirror coating) 806 is attached to one end of the cavity to reflect a part of the intra-cavity light back to the cavity and to also serve as an output mirror element. Fiber pig-tail 807 is butt-coupled to the fiber laser output mirror 806 and an additional ferrule 808 can be used to stabilize the whole assembly. The polarization axes of fiber 807 and 801 can be aligned to provide a linearly polarized output polarization. Again, applying a Jones matrix analysis, cavity 800 is more stable than cavity 600 , because it comprises only one intra-fiber polarizing section. The maximum leakage in cavity 800 compared to a cavity comprising directly concatenated WDM and gain fiber sections is 50% smaller.
Similarly, a cladding pumped version of cavity 600 can be constructed. Cavity 900 shown in FIG. 27 displays such a cavity design. Fiber 901 is pumped via pump laser 902 , which is coupled to fiber 901 via lens assembly 903 and 904 as well as V-groove 905 . Alternatively, polarization-maintaining multi-mode fiber couplers or star-couplers could be used for pump power coupling. Such implementations are not separately shown. One end of the laser cavity is terminated with SAM assembly 906 (as discussed in regard to FIGS. 17 , 23 and 24 , which is also used as the modelocking element. A single-polarization inside the laser is selected via all-fiber polarizer 907 , which is spliced into the cavity via splices 908 and 909 . Polarization-maintaining output coupler 910 is used for output coupling. The laser output is extracted via fiber end 911 , which can further be spliced to additional amplifiers. Cavity mirror 912 terminates the second cavity end. Output coupler 910 can further be omitted and the laser output can be obtained via a butt-coupled fiber pig-tail as explained with reference to FIG. 30 .
The cavity designs discussed with respect to FIGS. 17 , 23 , 24 , 26 and 27 follow general design principles as explained with reference to FIGS. 28 a - 28 c.
FIG. 28 a shows a representative modelocked Fabry-Perot fiber laser cavity 1000 , producing a linear polarization state oscillating inside the cavity containing one (or more) sections of non-polarization maintaining fiber 1001 and one (or more) sections of polarization maintaining fiber 1002 , where the length of fiber section 1001 is sufficiently short so as not to degrade the linear polarization state inside the fiber laser cavity, more generally a predominantly linear polarization state is oscillating everywhere within the intracavity fiber. The fiber laser output can be obtained from cavity end mirrors 1003 or 1004 on either side of the cavity. To suppress the oscillation of one over the other linear polarization state inside the cavity, either fiber 1001 or 1002 has a polarization dependent loss at the emission wavelength.
FIG. 28 b shows a representative modelocked Fabry-Perot fiber laser cavity 1005 , producing a linear polarization state oscillating inside the cavity containing two (or more) sections of polarization maintaining fibers 1006 , 1007 , where the length of fiber sections 1006 , 1007 is sufficiently long so as to prevent coherent interaction of short optical pulses oscillating inside the cavity and propagating along the birefringent axes of fibers 1006 , 1007 . Specifically, for an oscillating pulse with a FWHM width of τ, the group delay of the oscillating pulses along the two polarization axes of each fiber should be larger than τ. For oscillating chirped pulses τ represents the bandwidth-limited pulse width that corresponds to the oscillating pulse spectrum. Cavity 1005 also contains end mirrors 1008 and 1009 and can further contain sufficiently short sections of non-polarization maintaining fiber as discussed with reference to FIG. 28 a.
FIG. 28 c shows a representative modelocked Fabry-Perot fiber laser cavity 1010 , producing a linear polarization state oscillating inside the cavity containing one (or more) sections of polarization maintaining fiber 1011 , 1012 and one (or more) sections of polarizing fiber (or all-fiber polarizer) 1013 , where the length of fiber sections 1011 , 1013 is not sufficient to prevent coherent interaction of short optical pulses oscillating inside the cavity and propagating along the birefringent axes of fibers 1011 , 1013 , where the polarizing fiber is sandwiched between the sections of short polarization maintaining fiber. Cavity 1010 further contains cavity end mirror 1014 and 1015 and can further contain short sections of non-polarization maintaining fiber as discussed with reference to FIG. 28 a . Moreover, cavity 1010 (as well as 1000 and 1005 ) can contain bulk optic elements 1016 , 1017 (or any larger number) randomly positioned inside the cavity to provide additional pulse control such as wavelength tuning or dispersion compensation. Note that the fibers discussed here can be single-clad, double-clad; the fibers can comprise also holey fibers or multi-mode fibers according to the system requirement. For example polarization maintaining holey fibers can be used for dispersion compensation, whereas multi-mode fibers can be used for maximizing the output pulse energy. Cavity mirrors 1014 , 1015 , 1003 , 1004 and 1008 , 1009 can further comprise bulk mirrors, bulk gratings or fiber gratings, where the fiber gratings can be written in short sections of non-polarization maintaining fiber that is short enough so as not to perturb the linear polarization state oscillating inside the cavity.
FIG. 29 serves as an example of a passively modelocked linear polarization cavity containing holey fiber for dispersion compensation. Cavity 1100 contains fiber 1101 , side-pumping assembly 1102 (directing the pump light either into the cladding or the core of fiber 1101 as explained before), saturable absorber mirror assembly 1103 , all fiber polarizer 1104 and fiber output coupler 1105 providing an output at fiber end 1106 . All the above components were already discussed. In addition, a length of polarization maintaining holey fiber 1006 is spliced to the cavity for dispersion compensation and the cavity is terminated on the left hand side by mirror 1107 .
FIG. 30 serves as another example of a passively modelocked linear polarization cavity containing a fiber grating for dispersion compensation as applied to the generation of ultra-stable spectral continua. System 1400 comprises a small modification of the cavity explained with respect to FIG. 23 . System 1400 contains a fiber laser 1401 generating pulses with a bandwidth comparable to the spectral bandwidth of the fiber gain medium 1402 . Fiber laser 1401 further comprises saturable absorber mirror assembly 1403 , wide bandwidth fiber grating 1404 , polarization maintaining wavelength division multiplexing (WDM) coupler 1405 , which is used to direct pump laser 1406 into fiber gain medium 1402 . Pump laser 1406 is preferably single-mode to generate the least amount of noise.
To enable the oscillation of short pulses with a bandwidth comparable to the bandwidth of the gain medium 1402 , saturable absorber mirror 1403 contains a bi-temporal saturable absorber, constructed with a bi-temporal life-time comprising a 1 st short life-time of <5 ps and a 2 nd long life-time of >50 ps. More preferable is a first life-time of <1 ps, to allow pulse shaping of pulses as short as 100 fs and shorter. By selecting the penetration depth of the implanted ions into the saturable absorber, even tri-temporal saturable absorbers can be constructed.
The wide-bandwidth grating is preferably selected to approximately match the dispersion of the intra-cavity fibers. The wide-bandwidth grating can be made in short non-polarization maintaining fibers and it can be made also in polarization maintaining fibers. In order to suppress detrimental effects from cross coupling between the two polarization axes of the fiber grating, coupling to cladding modes in such large bandwidth fiber gratings should be suppressed. Gratings with suppressed coupling to cladding modes can be made in optical fibers with photosensitive core and cladding area, where the photosensitive cladding area is index-matched to the rest of the cladding. Such fiber designs are well known in the state of the art and can for example be manufactured with an appropriate selection of germania and fluorine doping in the core and cladding regions and such fiber designs are not further discussed here. Because of the large generated bandwidth, splicing of such polarization maintaining gratings to the rest of the cavity without coherent coupling between the linear polarization eigenmodes is no problem. Alternatively, the fiber gratings can be written directly into the photosensitive gain fiber, with an index and dopant profile that suppresses coupling to cladding modes in the fiber grating.
To sustain large spectral bandwidth, fiber grating 1404 has preferably a spectral bandwidth>20 nm. A splice 1407 (or an equivalent bulk optic lens assembly) is used to connect the output of fiber laser 1401 to nonlinear fiber 1408 to be used for additional spectral broadening of the output of the fiber laser. For example fiber 1408 can comprise a highly nonlinear dispersion-flattened holy fiber. In conjunction with such fiber, smooth broad-bandwidth spectral profiles with bandwidths exceeding 100 nm can be generated. These spectral outputs can be used directly in high precision optical coherence tomography.
The pulses at the output of fiber 1408 are generally chirped and a dispersion compensation module 1409 can be inserted after the output from fiber 1408 for additional pulse compression. The dispersion compensation module can be spliced directly to fiber end 1408 when optical fiber is used for dispersion compensation. Alternatively, the dispersion compensation module can comprise two (or one) bulk grating (or prism) pair(s). Such bulk optic elements for dispersion compensation are well known in the state of the art and are not further discussed here. Coupling into and out of a bulk dispersion compensating module is obtained via lenses 1410 and 1411 . The output can also be from the other end of the cavity. The pulses generated after pulse compression can be as short as 20-200 fs. As mentioned previously this pulse compression module is optional and the dispersion compensation needed for this oscillator can be compensated by the pulse stretcher before and pulse compressor after the regenerative amplifier.
A fiber amplifier 1412 can also be added if further pulse energy is necessary.
Note that the discussion with respect to FIG. 30 serves only as an example of the use of bi- or multi-temporal saturable absorbers in the generation of mass producible ultra-broad band, low noise spectral sources. Other modifications are obvious to anyone skilled in the art. These modifications can comprise for example the construction of an integrated all-fiber assembly substituting elements 1408 , 1409 - 1411 and 1412 .
Though the discussion of the laser system with respect to FIG. 30 was based on the use of polarization maintaining fiber, non polarization maintaining fiber can also be used to produce pulses with bandwidth comparable to the bandwidth of the gain medium. In this case, saturable absorbers with depth controlled ion implantation are also of great value. Essentially, any of the prior art modelocked fiber laser systems described above (that were using saturable absorbers) can be improved with engineered bi- and multi-temporal saturable absorbers. Specifically, any of the cavity designs described in U.S. Pat. Nos. 5,450,427 and 5,627,848 to Fermann et al. can be used for the generation of ultra broadband optical pulses in conjunction with bi- or multi-temporal saturable absorbers and wide-bandwidth fiber Bragg gratings.
An embodiment with the fewest bulk optic components in the optical path is shown in FIG. 31 . The source of ultrashort pulses is a fiber-based MOPA 100 . This source is described in detail in Ser. No. 10/814,502 which is incorporated herein. A polarization-maintaining gain fiber 101 has a core 102 and cladding region 103 . The fiber core 102 is doped with rare-earth ions, preferably Yb, to produce gain at a signal wavelength when the laser is pumped with diode laser 104 . The pump diode is coupled into the cladding region 103 of fiber 101 using for example two lenses 105 and 106 and V-groove 107 , though coupling systems comprising more than two lenses can be used. Alternatively a WDM and a single mode laser diode can be used for in core optical pumping. The fiber core can be single-mode or multi-mode. The multi-mode fiber is designed to propagate single mode as is described in U.S. application Ser. No. 09/785,944 (incorporated by reference herein). The multi-mode fiber can also be multi-mode photonic crystal fiber as is described in Ser. No. 10/844,943 (incorporated herein). The fiber laser cavity 100 further contains a fiber Bragg grating 108 , written in polarization maintaining fiber, an optional polarizer (fiber or bulk) 109 and a saturable absorber assembly 110 . A bulk polarizer such as a cube polarizer is preferred. Fiber grating 108 can be chirped or un-chirped, where the polarization cross talk between the two polarization axes of the polarization maintaining fiber containing the fiber gratings is preferably less than 15 dB. Fiber end face 111 completes the basic MOPA system. The fiber Bragg grating can be written directly into fiber 101 or it can be spliced into the MOPA system at splice positions 112 and 113 , where the polarization axes of all involved fibers are aligned with respect to each other. The MOPA comprises an oscillator assembly 114 and an amplifier assembly 115 . The oscillator assembly 114 is bounded on the left hand side by fiber grating 108 and on the right hand side by saturable absorber assembly 110 . The amplifier assembly 115 is bounded by fiber grating 108 and fiber end 111 on the two opposite distal ends. In the present example fiber 101 is used both in the amplifier section and in the amplifier section. In general, however, different fibers can be used in the oscillator and amplifier, though to avoid feedback from the amplifier into the oscillator, the refractive index of both oscillator and amplifier fiber should be closely matched. The chirp of the output pulses can be conveniently compensated with the delivery fiber 118 , where lenses 116 and 117 are used to couple the output from the MOPA into the delivery fiber. Other pulse modification elements can be placed between the lenses such as an isolator, tunable filter or fiber gratings. The delivery fiber can comprise standard silica step-index fiber, holey fiber or photonic crystal fiber. The use of photonic crystal for dispersion compensation and pulse delivery was previously disclosed in Ser. No. 10/608,233. The delivery fiber 118 can also be spliced directly to fiber end face 111 , enabling a further integration of the laser assembly. The delivery fiber can also be sufficiently long to stretch the pulse sufficiently for amplification in the regenerative amplifier. The need for a compressor depends on the exact design of the regenerative amplifier.
The embodiment in FIG. 31 may be the simplest design, however the pulse conditioning shown in FIG. 1 and described in Ser. No. 10/960,923 are often necessary to obtain the needed specifications from the ultrafast source. Ser. No. 10/814,319 (incorporated by reference herein) teaches how to utilize various modules for pulse conditioning for a fiber laser source. Ser. No. 10/813,163 (incorporated by reference herein) describes utilizing some of these methods in a fiber chirped pulse amplification system. These pulse conditioning methods can be utilized in a regenerative amplifier system. FIG. 32 illustrates one embodiment of a laser system 550 having a monitoring and feedback control capability. In one embodiment of the laser system, monitoring the performance such as output power at some point(s) of the system and providing feedback to the diode pump drivers for active control can achieve a stable operation. FIG. 10 illustrates one embodiment of a laser system 550 having such a monitoring and feedback feature. The exemplary laser system 550 comprises an oscillator 552 coupled to an attenuator 556 via an isolator 554 . The output from the attenuator 556 is fed into a bandpass filter 558 whose output is then directed to a stretcher 561 and then an amplifier 560 . The output from the amplifier 560 is fed into the regenerative amplifier 563 and then a compressor 564 via an isolator 562 . It should be noted that the use of the attenuator 556 and the bandpass filter 558 are exemplary, and that either of these components may be excluded and any other modular components, including those disclosed herein, may be used in the laser system having feedback.
As shown in FIG. 32 , the laser system 550 further comprises a first monitor component 570 that monitors a performance parameter of the system after the oscillator 552 . The monitor 570 may comprise a sensor and controller. The monitor 570 may issue adjustment commands to a first driver 572 that implements those adjustment commands at the oscillator 552 .
The exemplary laser system 550 is shown to further comprise a second monitor component 574 that monitors a performance parameter of the system after the amplifier 560 . The monitor 574 may similarly comprise a sensor and controller. The monitor 574 can then issue adjustment commands to a second driver 576 that implements those adjustment commands at the amplifier 560 .
The monitoring of the system performed by the exemplary monitors 570 and/or 574 may comprise for example an optical detector and electronics that monitors optical intensity or power or other relevant parameter such as, e.g., frequency and spectrum. In response to such measurement, the monitor and the driver may induce changes in the oscillator and/or the amplifier by for example adjusting the pump intensity and/or rate, or adjusting the operating temperature. Temperature control of the oscillator can stabilize the gain dynamics as well as frequency fluctuations. Temperature control of the amplifier can also be used to stabilize the gain dynamics.
Other configurations for providing feedback to control the operation of the laser system may also be employed. For example, more or less feedback loops may be included. The electronics associated with these feedback loops are further described in Ser. No. 10/813,173 (incorporated by reference herein). A particularly important electronic control is to control the gain of the fiber amplifier. At 1 KHz repetition rate and lower, the gain of the fiber amplifier could be reduced between pulses to conserve the lifetime of the laser diode. Also the gain needs to be reduced on the fiber amplifier if a signal is lost from the short pulse source to protect from optical damage to the fiber amplifier or subsequent optical elements. The loops may involve electronics that perform operations such as calculations to determine suitable adjustments to be introduced. Examples are the mode-lock start-up and search algorithms that are disclosed in Attorney Docket No. A8828 (incorporated by reference herein). The start-up algorithm is shown in FIG. 37 . The feedback may be obtained from other locations in the system and may be used to adjust other components as well. The embodiments described in connection with FIG. 32 should not be construed to limit the possibilities.
A good Polarization Extinction Ratio (PER) is an important factor in maintaining good temporal pulse quality in a fiber-based ultrafast source for a regenerative amplifier. Poor polarization extinction creates ripple on the spectrum and on the chirped pulse. In various preferred embodiments, the light in the laser is linearly polarized. The degree of the linear polarization may be expressed by the polarization extinction ratio (PER), which corresponds to a measure of the maximum intensity ratio between two orthogonal polarization component. In certain embodiments, the polarization state of the source light may be maintained by using polarization-maintaining single-mode fiber. For example, the pigtail of the individual modular device may be fabricated with a polarization-maintaining fiber pigtail. In such cases, the PER of each modular stage may be higher than about 23 dB. Ensuring a high polarization extinction ratio throughout a series of modules is challenging despite the use of single mode polarization maintaining fiber. Degradation of the PER can occur at the fiber ferrule, fiber holder, or fusion splice in the series of modules.
Levels of PER above 23 dB may be obtained in a system by utilizing linear-polarizing optical components in the modules. Use of linear-polarizing components in the modules within systems that contain polarization degrading elements such as a fiber ferrule, fiber holder, or fusion splice is advantageous. The linear polarizers counter the superposition of the phase shift from each polarization degrading element. A superposed phase shift of 10 degrees may reduce the PER to about 15 dB in which case intensity fluctuation through a linear polarizer might be more than about 4%. In contrast, by embedding linear polarizers throughout the series of modules, the PER of the aggregate system can be substantially controlled such that the intensity fluctuation is below about 1%, provided that the PER of the individual module and splice is above about 20 dB.
FIG. 33 a illustrates one embodiment of a module that can be utilized for polarization correction or as variable attenuation. It is a variable attenuator module 730 comprising a housing 732 that contains optical components for providing a controllable amount of optical attenuation. The housing 732 may be sealed and thermally insulated as well. A first optical fiber connector 734 comprising an optical fiber 736 having an angle polished or cleaved end face passes through one sidewall of the housing 732 into an inner region of the housing containing the plurality of optical components. These optical components include a first lens 738 for collecting and preferably collimating light output from the optical fiber 736 , a variable wave plate 740 and a polarization selective optical element 742 . A second optical fiber connector 744 comprising an optical fiber 745 having an angle polished or cleaved end face passes through another sidewall of the housing 732 into the inner region containing the optical components. The variable waveplate 740 comprises a rotatable waveplate mounted on a rotatable wheel 746 and the polarization selective optical element 742 comprises a polarization beamsplitter such as a MacNeille prism. A second lens 748 disposed between the polarization selective optical element 742 couples light between the polarization beamsplitter 742 and the second optical fiber 745 . An optical path is formed from the first optical fiber 736 through the waveplate 740 and prism 742 to the second optical fiber connector 744 .
The waveplate 740 can be rotated to vary the distribution of light into orthogonal polarizations. The polarization beamsplitter 742 can be used to direct a portion of the light out of the optical path between the first and second fiber connectors 734 , 744 , depending on the state of the waveplate 740 . Accordingly, a user, by rotating the waveplate 740 and altering the polarization of light can control the amount of light coupled between the first and second optical fiber connectors 734 , 744 and thereby adjust the level of attenuation.
Preferably, the optical elements such as the first and second lenses 738 , 748 , the rotatable waveplate 740 and the MacNeille polarizer 742 comprise micro-optics or are sufficiently small to provide for a compact module. The elements in the housing 732 may be laser welded or otherwise securely fastened to a base of the housing. The housing 732 may be sealed and thermally insulated as well. In various preferred embodiments, these modules conform to Telcordia standards and specifications.
A particularly preferred embodiment for a fiber solid-state regenerative amplifier system ( 2000 ) is shown in FIG. 33 b . The mode-locked Yb oscillator ( 2100 ) operates at near 50 MHz with a chirped pulse width after the fiber stretcher ( 2200 ) between 2-100 ps. The mode-locking means is a saturable absorber mirror ( 2001 ). The gain is provided by a Yb: doped fiber ( 2002 ). The other output coupler is a chirped fiber grating ( 2003 ) that also provides for dispersion compensation. The center wavelength is between 1030-1040 nm with a bandwidth between 5-20 nm. The pulse is compressible to 100-300 fs. It is pumped in core by a conventional laser diode ( 2005 ) through a polarization maintaining WDM ( 2004 ). Side pumping the cladding is also suitable. The pulse energy is nearly 1 nJ after amplification. The fiber amplifier ( 2300 ) is slightly nonlinear. The spectral broadening is negligible but is dependent on the input power to the fiber amplifier. The Yb: fiber ( 2011 ) is approximately 3 meters long. It is also polarization preserving fiber. The Yb: fiber amplifier gain shapes and frequency shifts slightly the output. It is pumped co propagating by a conventional single mode laser diode ( 2009 ) through a polarization maintaining WDM ( 2010 ). Counterpropagating pumping and cladding pumping are also suitable. The output from the fiber amplifier is through a bulk collimator ( 2012 ) and a bulk isolator ( 2013 ). More than one isolator may be necessary at this point. Alternatively, an AOM pulse selector can be added to the end of the amplifier for isolation. A Faraday rotator and polarizer can be used at this point to separate the input of the regenerative amplifier ( 2400 ) from the output to the bulk grating compressor ( 2500 ). In addition there is an isolator ( 2007 ) between the fiber stretcher and fiber amplifier that includes an optical tap. The tap ( 2007 ) provides an optical sync output ( 2008 ) that is converted to an electrical signal by means of a photodiode. This signal is used to synchronize the regenerative amplifier pulse selector to the mode-locked fiber laser.
In this next embodiment an alternative source of the ultrafast pulses is a laser-diode or microchip laser. This embodiment is shown in FIGS. 34 and 35 . In FIG. 34 , the microchip laser is a single longitudinal Nd:vanadate source that provides a smooth temporal profile. The pulse width is 250 picoseconds. One solution for the compression fiber 62 is a standard single mode fiber with a mode field diameter of 5.9 μm and a NA of 0.12. The length of this compression fiber would be about 2 meters to create sufficient spectrum for a compression ratio of around 50. The output energy from microchip lasers can be 10 microjoules. In this case, the light intensity at the entrance face of the fiber will be near the damage threshold. A coreless end cap (not shown) can be used on the fiber so the mode can expand before the surface of the fiber. Otherwise, an amplifier with a larger mode field diameter can be used, such as a multimode fiber that propagates a single mode or a holey fiber amplifier as was used in (Furusawa et al “Cladding pumped Ytterbium-doped fiber laser with holey inner and outer cladding”, Optics Express 9, pp. 714-720, (2001)). If a fiber with an order of magnitude higher mode area (mode field diameter of 19.5 μm) is used, then the parameters in the fiber will be the same as in the case with 1 microjoule input. So the fiber length would again be 2 meters.
Since there is no interplay between dispersion and self-phase modulation in this design, the pulse width stays the same as the original pulse width. The nearly linear chirp is created by the shape of the pulse. Such a fiber is normally called a “compression fiber”. We propose to replace this “compression fiber” with an amplifier fiber. The output of the amplifier will be a chirped pulse that can be compressed in a compressor. This saves the need of a stretcher.
For pulse energies significantly greater than 1 microjoule, the single mode beam should be further amplified in a multimode fiber. This chirped pulse source is ideal for amplification of ultrashort pulses by chirped pulse amplification in a regenerative amplifier. The pulse is then compressed after amplification. In this case the microchip 71 was operated at 0.5 μJ, and produced 250 ps, pulses and operating at the repetition rate of the regenerative amplifier. The compression fiber 62 is now a multimode amplifier fiber that amplified a single mode with a mode-field diameter of 17 μm. The pulse was then amplified to 30 microjoules where Raman limited the amplification. This pulse is now a chirped 250 ps pulse. It is further amplified in a solid state regenerative amplifier and compressed in a bulk grating compressor to typically less than 1 ps. FIG. 35 illustrates the source generally described in FIG. 3 of US Published Application 20040240037A1, incorporated by reference herein, with modification made to the chirped fiber grating at the end of the source to further stretch the pulses prior to amplification in the regenerative amplifier.
FIG. 36 illustrates a chirped pulse amplification system that utilizes conventional fiber stretchers, fiber amplifiers, bulk regenerative amplifiers and bulk grating compressors. In order to obtain high quality pulses from such systems, the control of higher-order dispersion and self-phase modulation is critical. A chirped pulse amplification system allowing for independent control of second- and third order dispersion is shown in FIG. 36 . In an exemplary embodiment, a seed source 101 based on a passively modelocked Yb fiber laser was used. Such passively modelocked Yb fiber lasers were previously described in application Ser. No. 10/627,069 and are not further described here. The seed source 101 produces positively chirped optical pulses with a bandwidth of 16 nanometers at a repetition rate of 43 megahertz with an average power of 16 milliwatts. The peak emission wavelength of the oscillator was 1053 nanometers. The pulses from the seed source were compressible to a pulse width of less than 150 femtoseconds, demonstrating that the chirp from the seed source was approximately linear. The output from the seed laser passed through an isolator (not shown) and a tunable bandpass filter 119 with a 15 nanometer bandwidth.
After the bandpass filter 119 , an output power of 5 milliwatts was obtained and a fiber stretcher 120 was used to stretch the pulses to a width of approximately 100 picoseconds. The fiber stretcher employed for producing stretched pulses had a length of approximately 200 meters and was based on conventional polarization maintaining single-mode step-index fiber. In FIG. 36 , the tunable bandpass filter 119 is shown inserted before the fiber stretcher 120 ; alternatively, the tunable bandpass filter 119 can also be inserted after the fiber stretcher 120 (system implementation is not separately shown).
A subsequent Yb-based polarization maintaining pre-amplifier 121 amplifies the stretched pulses to an average power of 500 milliwatts. A pulse picker 122 , based on an acousto-optic modulator and pig-tailed with polarization maintaining fiber, reduces the repetition rate of the pulses to 200 kilohertz, resulting in an average power of 1 milliwatt. The pulses from the pulse picker 122 were subsequently injected into a large-mode polarization maintaining Yb fiber power amplifier 123 and amplified to an average power of 950 milliwatts. The Yb power amplifier had a length of 3 meters and the fundamental mode spot size in the Yb power amplifier was around 25 micrometers. All fibers were either spliced together with their polarization axes aligned or connected to each other (with their polarization axes aligned) with appropriate mode-matching optics (not shown). The power amplifier 123 was cladding pumped via a lens 124 with a pump source 125 , delivering a pump power of about 10 watts at a wavelength of 980 nanometers. A beam splitting mirror 126 was implemented to separate the pump light from the amplified signal light. The amplified and stretched pulses from the power amplifier 123 are further amplified in a bulk solid state regenerative amplifier 129 . The output pulses from the regenerative amplifier 129 were compressed in a conventional bulk optics compressor 127 based on a single diffraction grating with a groove density of 1200 lines/mm, operating near the Littrow angle. Such bulk optics compressors are well known in the state of the art and are not further explained here. After the bulk optics compressor 127 , the output 128 will contain pulses with a full-width half-maximum (FWHM) width of around 330 femtoseconds and pulse energies around 1 millijoule. Alternative designs should be feasible including a system without the power amplifier. However, in this case the power amplifier is operating as the nonlinear fiber amplifier that is able to correct for higher order dispersion mismatch between the fiber stretcher and the bulk compressor.
Because stretched pulses can accumulate significant levels of third-order dispersion in the presence of self-phase modulation, gain-narrowing, gain-pulling and gain depletion, we refer to such pulses as cubicons. More generally, we can define a cubicon as a pulse that produces controllable levels of at least linear and quadratic pulse chirp in the presence of at least substantial levels of self-phase modulation (corresponding to a nonlinear phase delay>1) that can be at least partially compensated by dispersive delay lines that produce significant levels of second and third-order dispersion as well as higher-order dispersion. (Please note that for the compensation of linear pulse chirp, a dispersive delay line with second order dispersion is required, whereas for the compensation of quadratic pulse chirp, a dispersive delay line with third order dispersion is required and so on for higher orders of pulse chirp.) For a dispersive delay line to produce a significant level of 2 nd and 3 rd as well as possibly higher-order dispersion, the stretched pulses are typically compressed by more than a factor of 30. In addition cubicons can also be formed in the presence of resonant amplifier dispersion, gain narrowing, gain pulling as well as gain depletion, where we refer to gain depletion as an appreciable reduction in gain due to a single pulse. If a high power mode-locked oscillator an undoped fiber can be utilized to create the self-phase modulation. Spectral filtering will most likely be necessary to obtain the appropriate pulse shape to the chirped pulse. The chirped pulse width will need to be further expanded before amplification in the regenerative amplifier.
The importance of the pulse picker 122 has been described in Ser. No. 10/960,923 in that it alleviates the specifications on the optical switch in the regenerative amplifier. A further advantage is that it can be utilized as a variable attenuator for controlling the buildup time in the regenerative amplifier. An AO switch can be used here, however EO switches and EA switches are available in modules that conform to Telcordia standards and specifications. As pointed out in Ser. Nos. 10/437,057 and 10/606,829, it often takes two switches since the standard on off discrimination is 30 db while for lowering the rep rate from 30 MHz to 1 KHz requires an on off discrimination of more than 50 db for the majority of the energy to be in the one pulse operating at the lower repetition rate. Another use of the pulse picker is as a variable attenuator to control the nonlinearities in the fiber for dispersion correction. In cubicon amplification the nonlinearities are critical for dispersion control and the variable attenuation feature of the pulse pickers is a means for controlling the nonlinear affects in the fibers. Other variable attenuators can be used such as described in Ser. No. 10/814,319. Other means of controlling the nonlinearities of the fiber amplifier are utilizing the control of the fiber amplifier output as described above. These include varying the gain or temperature of the fiber amplifier by measuring the spectrum and or the output intensity from the fiber amplifier. Controlling the spectrum and the intensity accurately for cubicon amplification can be implemented.
The embodiment of a short pulse source in the picosecond and nanosecond range amplified in a fiber amplifier and amplified in a bulk amplifier is disclosed in application Ser. No. 10/927,374 (incorporated by reference herein) This system in some cases will have better performance when the bulk amplifier is utilized as a regenerative amplifier. This embodiment is shown in FIG. 38 . Fiber amplifier system 501 is described in detail in Ser. No. 10/927,374. The output pulse of the fiber amplifier system 501 is mode-matched by beam conditioning optics 506 to the fundamental mode of the solid state regenerative amplifier 505 . The regenerative amplifier 505 utilizes a bulk crystal gain material which is preferably directly diode pumped. The embodiment displayed in FIG. 38 has the advantage that the gain bandwidth of the regenerative amplifier can be matched to the fiber amplifier system. For example 1 ns pulses with a spectral bandwidth of 0.6 nm and a pulse energy exceeding 100 μJ, centered at a wavelength of 1064 nm can be generated in a fiber amplifier chain in conjunction with a diode seed laser, for injection into a Nd:YVO 4 amplifier, which has a spectral bandwidth of approximately 0.9 nm. As another example a modelocked Yb-fiber oscillator with center wavelength of 1064 nm and a bandwidth of several nm can be amplified and spectrally narrowed and matched to the gain bandwidth of the Nd:YVO 4 solid state amplifier. Thus 100 ps pulses with an energy of around 100 μJ and higher can be generated in a fiber amplifier chain and efficiently amplified in the regenerative amplifier. Without exploitation of spectral narrowing, the pulse energies from fiber amplifier chains designed for the amplification of 100 ps pulses in bulk Nd:YVO 4 amplifiers has to be reduced to avoid spectral clipping in the bulk amplifiers. Spectral narrowing is indeed universally applicable to provide high energy seed pulses for narrow line-width solid state amplifiers. For the example of bulk Nd:YVO 4 amplifiers, spectral narrowing is preferably implemented for pulse widths in the range of 20 ps-1000 ps.
Bulk solid-state regenerative amplifiers are also useful to increase the energy of pulses generated with fiber based chirped pulse amplification systems. Chirped pulse amplification is generally employed to reduce nonlinearities in optical amplifiers. The implementation of chirped pulse amplification is most useful for the generation of pulses with a width<50 ps. Due to the limited amount of pulse stretching and compression that can be achieved with chirped pulse amplification schemes, stretched pulses with an initial pulse width exceeding 1-5 ns are generally not implemented. Hence optical damage limits the achievable pulse energies from state of the art fiber based chirped pulse amplification systems (assuming fiber power amplifiers with a core diameter of 30 μm) to around 1 mJ. Single stage bulk solid state amplifiers can increase the achievable pulse energies normally by a factor of 10 while a regenerative amplifier has a gain of 10 6 . Therefore a regenerative amplifier can be preferable and give flexibility at a cost of complexity. One advantage is significantly lower pulse energies can be utilized from the fiber amplifier. A generic scheme 500 for the amplification of the output of a fiber based chirped pulse amplification system in a bulk optical amplifier is shown in FIG. 39 . Here short fs-ps pulses with pulse energies of a few nJ are generated in fiber oscillator 501 . The pulses from the oscillator are stretched in pulse stretcher 502 to a width of 100 ps−5 ns. The pulse stretcher is preferably constructed from a chirped fiber grating pulse stretcher as discussed with respect to FIG. 1 and can also be constructed from bulk optical gratings as well known in the state of the art. A pulse picker 503 reduces the repetition rate of the oscillator to the 1 kHz-1 MHz range to increase the pulse energy of the amplified pulses. A fiber amplifier chain represented by a single fiber 504 is further used to increase the pulse energy to the μJ-mJ level. Appropriate mode matching optics 506 is then used to couple the output of amplifier chain 504 into the bulk solid state amplifier 505 . Here bulk solid state amplifiers based on rods, slabs as well as thin disk concepts can be implemented. Appropriate bulk amplifier material are based for example on Yb:YAG, Nd:YAG, Nd:YLF or Nd:YVO 4 , Nd:glass, Yb, glass, Nd:KGW and others. Appropriate bulk amplifier materials and designs are well known in the state of the art and not further discussed here. A collimation lens 507 directs the output of the bulk solid state amplifier to the input of the compressor assembly. To minimize the size of a chirped pulse amplification system employing narrow bandwidth Nd-based crystals such as Nd:YAG, Nd:YLF, Nd:YVO 4 or Nd:KGW the use of a grism based compressor is preferred. The optical beam is directed to via mirror 508 to the grism 509 and an additional folding prism 510 is used to minimize the size of the compressor. Mirror 511 completes the compressor assembly. Such compressor assemblies have previously been used to compensate for third-order dispersion in wide-bandwidth chirped pulse amplification systems (i.e. chirped pulse amplification systems with a bandwidth>5 nm); no prior art exists applying grism technology to narrow bandwidth chirped pulse amplification systems (i.e. chirped pulse amplification systems comprising amplifiers with a spectral bandwidth<5 nm).
In an exemplary embodiment, fiber oscillator 501 generates 5 ps pulses, which are stretched by a chirped fiber grating stretcher to a width of 1 ns. After amplification in the fiber amplifier chain a pulse energy of 50 μJ is obtained at a repetition rate of 10 kHz. Further amplification in a Nd:YVO 4 solid state booster amplifier generates a pulse energy of 2 mJ. After recompression in the bulk grating compressor 10 ps pulses with an energy of 1 mJ are obtained. To ensure a compact design for the bulk grating compressor, preferably grisms with a groove density of 2800 l/mm are implemented. The whole compressor can then fit into an area of about 0.6×0.2 m by folding the optical beam path only once.
As discussed above, a burst of multiple pulses with different wavelengths, different pulse widths and different temporal delays may be desired. Referring to FIG. 40 , an embodiment of the laser means 51 is illustrated, which increasing the increasing the possible energy and average power from ultrafast fiber lasers. A longer pulse envelope can be obtained by utilizing a series of chirped gratings that reflect at different wavelengths. After amplification, a similar series of gratings can be placed to recombine/compress the pulses. In FIG. 40 , pulses from a femtosecond pulse source are passed through an acousto-optic modulator, a polarized beam-splitter and a Faraday rotator, and are then supplied to a series of chirped fiber stretcher gratings that operate on different portions of the input pulse spectrum. The spacings between the stretcher gratings can be 1 1 , 1 2 , 1 3 . . . In order to reconstruct the pulses after amplification in the fiber amplifier and the regenerative amplifier the spacings between a series of complementary bulk glass Bragg grating compressors are set to n 1 1 , n 1 2 , n 1 3 , . . . , where n is the refractive index of the fiber between the stretcher fiber gratings, assuming that the bulk Bragg compression gratings are separated by air. The reconstructed pulse is output via a second beam splitter. As previously mentioned, the reconstructed pulse is generally the result of incoherent addition of the separately amplified spectral components of the input pulse.
If the distances between the compression and stretcher gratings are not equalized as described above, then multiple pulses will appear at the output. If the distances are not equal between the different sections than the temporal delays will not be equal. This can be beneficial for applications such as micro-machining. By varying the stretching and compression ratios, pulses with different pulse widths can be generated. A single broadband compression grating can be used when generating multiple pulses.
The utilization of the regenerative amplifier is not as flexible as an all fiber amplifier system for modification of the pulse shape. For example, long pulse widths are limited to repetitive features equal to the round trip time of the regenerative amplifier, e.g., approximately 10 nanoseconds. For a regenerative amplifier, the pulse train created by the gratings needs to be less than the round trip time of the regenerative amplifier.
Another embodiment of a multiple pulse source is shown in FIG. 41 . This source is utilized in the laser system shown in FIG. 42 . The Ytterbium amplifier is normally needed for the pulse intensity to be sufficient for amplification in the regenerative amplifier. The pulse compressor is optional. The multiple pulse source is a laser diode and multiple electronic drivers. In this case there are three sources with a delay generator that allows different delays to each electronic driver. A long pulse is generated by a conventional pulse driver for a laser diode. The shorter pulses are derived from short pulse laser diode drivers such as are available from Avtech. These signals are added through electronic mixers. The output is shown in FIG. 43 a . This is an oscilloscope screen measured with a sufficiently fast photodiode. There are three peaks observable. The output for one of the short pulses is shown in FIG. 43 b . The pulse width is approximately 100 ps. FIG. 43 c illustrates a three peak pulse that is formed by changing the delay between the pulses so the electronic signals overlap. The short pulses can also be chirped and then recompressed to femtosecond pulses by the final compressor as described in Ser. No. 08/312,912 and U.S. Pat. No. 5,400,350 (incorporated by reference herein). By appropriately choosing the chirp rates and frequency ranges a single bulk grating can compress a plurality of pulses.
Another embodiment of this is to utilize laser diodes at different wavelengths or polarization states and then combine these optically either with wavelength fiber combiners such as the wavelength router utilized in multiple wavelength telecomm systems or by fiber splitters as shown in FIG. 44 . It is also possible to utilize conventional mode-locked sources to give multiple pulses. The methods for utilizing fiber gratings and etalons as disclosed in U.S. Pat. No. 5,627,848 (incorporated by reference herein) as a source of multiple calibration pulses can be utilized here. Another method is to use fiber splitters with different path lengths as shown in FIG. 45 . Four pulses are output for each pulse from the Ultrashort pulse source. The four pulses are sequentially, temporally delayed by:
1. c(2L N +L 1 +L 4 ) 2. c(2L N +L 1 +L 3 ) 3. c(2L N +L 2 +L 4 ) 4. c(2L N +L 2 +L 3 ) | The invention describes classes of robust fiber laser systems usable as pulse sources for Nd: or Yb: based regenerative amplifiers intended for industrial settings. The invention modifies adapts and incorporates several recent advances in FCPA systems to use as the input source for this new class of regenerative amplifier. | 7 |
FIELD OF THE INVENTION
This invention pertains generally to microfabricated fluidic devices (e.g. vane pumps, centrifugal pumps, gear pumps, flow sensors, piston pumps, piston valves, nozzles, connectors, etc.), and methods of their fabrication.
BACKGROUND AND SUMMARY OF THE INVENTION
Since their advent, micromechanical devices have been the subject of extensive investigation. (See, e.g., Stix, "Micron Machinations," Scientific American, November, 1992:106-117. "From Microchips to MEMS," Microlithography World, Spring 1994, pp. 15-20.) In view the fascinatingly small scale and extreme precision of these devices, substantial interest has arisen in their possible applications, including use as pumps. Unfortunately, applying pump-design principles to machinery having the dimensional scale of micro mechanical devices poses substantial problems, such as overcoming the effects of viscous drag and friction on movement of dynamic members, achieving sufficient minimal clearances between dynamic members and the internal walls of pump cavities, and sealing pump cavities from the external environment.
Work to date on microelectronic pumps has been focused on various types of diaphragm pumps. The main reasons are because diaphragm pumps can be made using bulk silicon micromachining; i.e., certain diaphragm pump designs are readily extrapolated from various microelectronic pressure transducer technology. Also, diaphragm pumps usually do not require any dynamic seals.
Much work has been done in the application of microfabrication techniques to motors (resulting in so-called "micromotors"). However, adapting micromotors for pumping applications presents many new technological challenges that generally defy conventional solutions. Work to date with micromotors has been performed by persons who were mainly concerned with simply getting the rotors to turn. With the exception of certain diaphragm pump embodiments, the known prior art has not revealed a successful utilization of micromotors or other micromachinery devices for pumping applications.
In accordance with a preferred embodiment of the present invention, the above-mentioned and other problems that have rendered fluidic devices unsuitable for microfabrication have been overcome, enabling--for the first time--the realization of a wide variety of practical micromachined fluidic devices.
The need for such devices enabled by the present invention is long-felt. The biomedical field is but one example.
Representative biomedical applications of micromachined pumps include, but are not limited to:
(a) implantable devices for actively infusing a drug or agent from a reservoir into a patient's body;
(b) withdrawal of microscopic amounts of fluid from a subject's body for analysis;
(c) microchemical instrumentation that can be used in vivo or in vitro, such as instrumentation utilizing microsensors; and
(d) sequence analysis and/or synthesis of polypeptides or nucleic acids.
There is also great demand for micromachined fluidic devices in other fields--a demand that is finally met by devices according to the present invention.
The foregoing and additional features and advantages of the present invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a representative embodiment of a rotor, that can be adapted for use as a pump rotor in a miniature pump according to the present invention, actuated by stator pole pieces provided in the pump body.
FIGS. 2A-2C are views of magnetic-rotor devices, and associated stator coil arrangements.
FIGS. 3A and 3B are schematic plan and elevational views, respectively, of a gear pump embodiment according to the present invention.
FIG. 4 is a plan view of intermeshed driving and driven gears of a gear pump according to the present invention.
FIG. 5 is a schematic plan view of a representative rotary piston pump embodiment according to the present invention.
FIG. 6 is a schematic plan view of a representative rotary lobe pump embodiment according to the present invention.
FIG. 7 is a schematic plan view of a representative rotary centrifugal pump embodiment according to the present invention.
FIG. 8 is a schematic plan view of a representative dual-piston linearly actuated pump embodiment according to the present invention.
FIG. 9 is a schematic plan view of an alternative linearly actuated pump embodiment according to the present invention having a single piston and a spool valve.
DETAILED DESCRIPTION
The present invention is illustrated with reference to a variety of fluidic devices (i.e. devices useful with liquid or gas), including rotary devices (e.g. vane pumps, centrifugal pumps, gear pumps, flow sensors, etc.) and linear devices (e.g. piston pumps, piston valves, etc.). However, it should be recognized that the invention is not so limited; the principles thereof can be applied to virtually any other fluidic device or component.
In the following discussion, reference is sometimes made to fluidic devices being "active" or "passive." An "active" device is one in which a dynamic member(s) causes fluid to pass from an inlet to an outlet, typically requiring input of energy (such as via an actuator). Active devices include, but are not limited to miniature pumps and valves.
A "passive" device is one in which a dynamic member(s) moves in response to passage of fluid through the cavity. Passive devices include, but are not limited to, flow sensors and hydraulic motors.
Devices according to a preferred embodiment of the invention are fabricated, in part, using a technique called LIGA ("Lithographie, Galvanoformung, Abformung"). This technique has been known for at least eight years (see, e.g. Becker et al., "Fabrication of Microstructures With High Aspect Ratios and Great Structural Heights by Synchrotron Radiation Lithography, Galvanoformung, and Plastic Moulding (LIGA Process)," Microelectronic Engineering4:35-56 (1986)). However, despite the widespread recognition of LIGA techniques, and the long-felt, unmet need for microminiature fluidic devices, others working in this field have failed to successfully implement fluidic devices other than simple diaphragm pumps.
LIGA
Before proceeding further, LIGA technology is briefly reviewed. Additional details can be obtained from the above-cited Becker article, and from U.S. Pat. Nos. 5,190,637, 5,206,983 to Guckel et al (incorporated-herein by reference).
LIGA exploits deep X-ray lithography to create structures characterized by very steep walls and very tight tolerances. Dimensionally, such structures can range from a few micrometers in size up to about 5 centimeters. In the preferred embodiments of the present invention, the LIGA-fabricated structures generally have a thickness of at least 50 micrometers. The steepness of the walls can be measured in terms of their slope, i.e. the change in vertical height of a structure over a horizontal distance. LIGA devices typically have a slope in excess of 500 (i.e. a wall may rise 50 microns in the span of a 0.1 micron horizontal distance). In some LIGA processes, a slope of 1000 or more can be obtained.
LIGA techniques also provide great flexibility in choice of materials, such as photoresist, plated metals (e.g. noble, magnetic, non-magnetic), and molded materials (e.g. plastics, ceramics).
X-ray lithography is well suited for high precision micromachining because x-ray photons have shorter wavelengths and typically higher energies than optical photons. The shorter wavelengths of x-ray photons substantially reduces diffraction and other undesirable optical effects.
X-ray photons are preferably generated using a synchrotron or analogous device, which yields x-ray photons at high flux densities (several watts/cm 2 ) with excellent collimation. As a result of their high energy, these x-rays are capable of penetrating thick (e.g., hundreds of micrometers) layers of polymeric photoresist. Conventional methods employing visible or U.V. light, in contrast, offer much more limited penetration into photoresists. It is due to their excellent collimation that x-ray photons penetrate thick photoresists with extremely low horizontal runout (less than 0.1 μm per 100 μm thickness), thereby producing the substantially vertical walls for which LIGA structures are well known. ("Runout" may be considered the reciprocal of slope.)
Microstructures manufactured using LIGA are produced on a suitable rigid substrate that is usually in wafer form ("wafer" as used herein generally denotes the substrate and any layers previously applied thereto, but is not intended to be specifically limited to wafer-shaped substrates). Since LIGA processes can be performed at low temperatures (e.g., less than about 200° C.), a number of different substrates can be used without degradation or destruction of the substrate. Candidate substrates include, but are not limited to: silicon, ceramic, gallium arsenide, glass and other vitreous materials, germanium, organic polymeric materials, and metals.
With certain substrates, such as semiconductor or non-metallic substrates, a plating base of a material such as chromium or titanium, is first applied to the substrate at the beginning of the LIGA process. Metal substrates may not require a plating base. The plating base facilitates adhesion of a subsequent metal layer applied to the wafer by electroplating whenever the substrate is not metallic or is otherwise incompatible with the subsequently applied metal layer. Typically, the plating base is applied by a sputtering technique, but other techniques may be more suitable for certain applications. If required, the plating base can be overlaid with a thin layer of a metal similar or identical to the metal to be subsequently applied by electroplating.
LIGA methods employ photoresists in order to achieve application of layers of metal or other suitable material to the wafer in a desired pattern. Whereas certain steps may permit use of thin (thicknesses generally several μm) photoresists, other LIGA steps require the use of photoresist applied thickly to the wafer (i.e., photoresist layer thickness up to about 1 cm or more). After application to the wafer, the photoresist is cured if required. The wafer is then exposed to x-rays, preferably high-energy and substantially collimated x-rays, passing through a mask pattern placed over the photoresist. Exposed portions of the photoresist are removed using a suitable developer chemical, thereby leaving voids in the remaining photoresist. A substance such as a metal, metal alloy, ceramic, or polymeric material is then applied to the wafer to fill the voids in the photoresist (metals and metal alloys are usually applied by electroplating methods). Unwanted photoresist can then be removed, followed by another electroplating step if indicated or required. The steps of applying photoresist, regio-selective exposure to x-rays, electroplating, casting, developing, and etching can be performed one or more times in various combinations to ultimately produce the desired structural shape ("superstructure") on the wafer.
Voids in the photoresist left after developing can be completely filled by an electroplatable substance (Galvanoformung), thereby forming either a structural element or a molding master. Molding masters formed using LIGA can be used multiple times to form microminiature parts having a particular desired shape. In addition, because of the extremely small dimensional scale of parts and structures made using LIGA, thousands of LIGA structures, including thousands of identical LIGA structures, can be made on a single wafer.
One or more layers applied to the wafer can be "sacrificial." A sacrificial layer is intended to be partially or completely removed, such as by dissolution or etching, after formation of all or part of the superstructure atop the sacrificial layer, thereby permitting formation of undercuts and other complex voids in the superstructure, as well as removal, if desired, of all or a portion of the superstructure from the substrate. For example, if the superstructure to be formed on the substrate is intended to be removed from the substrate afterward, a plating base can be applied over a sacrificial layer applied directly to the substrate, with the superstructure built up from the plating base.
Use of sacrificial layers permits the formation of suspended or movable superstructures on the substrate. For example, as disclosed in Dr. Guckel's U.S. Pat. No. 5,206,983, LIGA can be used to fabricate a high aspect ratio micromotor wherein the rotor is rotatably mounted on an axle or spindle attached to the substrate or formed on the substrate using LIGA. The rotor can be formed in situ inside a pump cavity formed on a single substrate. Preferably, however, the rotor is formed on a separate substrate over a sacrificial layer, subsequently removed, then rotatably mounted in a pump cavity defined in superstructure formed on a different substrate.
The LIGA photoresist is any material that: (a) can be applied as a layer at the desired thickness to the substrate or to a layer on the substrate, (b) is permeable to x-rays, and (c) after exposure to x-ray photons, forms a substance that is differentially capable of being removed using a suitable developer, depending upon whether or not the substance was actually exposed to x-ray photons.
A particularly suitable photoresist material for LIGA is poly(methyl methacrylate), abbreviated "PMMA", which can be developed (i.e., cured) using an aqueous developing system. Guckel et al., "Deep X-ray and UV Lithographies for Micromechanics," Technical Digest, Solid State Sensor and Actuator Workshop, Hilton Head, S.C. Jun. 4-7, 1990, pp. 118-122. PMMA can be applied by in situ casting of liquid PMMA resin on the wafer followed by a curing reaction to cross-link the PMMA resin. Since in situ cross-linking of thick PMMA films can result in the generation of stresses in the PMMA film, which can result in warping and other undesirable consequences, PMMA can be applied directly as a preformed sheet by solvent bonding the sheet to a wafer that had been previously spin-coated, for example, with a single layer of PMMA. (See Guckel patents.)
The maximum permissible thickness of photoresist such as PMMA that can be used is dependent upon the characteristics of the synchrotron or analogous device used to produce the x-ray photons. For example, a 1 GeV machine filtered with 250 μm beryllium has a critical energy of 3000 eV, at which energy the PMMA absorption length is 100 μm; this implies an exposure depth of about 300 μm within a reasonable time. A 2.6 GeV synchrotron having a critical energy of about 20,000 eV when used with a 1 mm beryllium filter has a corresponding PMMA absorption length of about 1 cm. Thus, exposures up to several centimeters in depth in PMMA are feasible. PMMA thicknesses greater than about 1 cm allow the PMMA photoresist to be free-standing, if desired, and permit the manufacture of structures, using LIGA, having thickness dimensions of 1 cm or greater while maintaining submicron tolerances in runout.
Any of various configurations of active fluidic devices in which the dynamic component(s) are rotary-actuated or linear-actuated are encompassed by the present invention. Representative embodiments of miniature pumps, as well as flow sensors and hydraulic motors according to the present invention, which embodiments are not intended to be limiting in any way, are disclosed below.
In part because of the small size of fluidic devices according to the present invention, it is possible to provide multiple such devices (such as thousands of complete miniature pumps) on a single substrate. All the fluidic devices on a single substrate can be either the same or different as requirements dictate. For example, multiple miniature pumps can be provided on a single substrate and used individually for different tasks or used collectively to achieve flowrates that are substantially higher than achievable using a single miniature pump. When used collectively, multiple miniature pumps can be hydraulically connected together in series or parallel, or in any conceivable combination of series and parallel. Fluid conduits interconnecting individual fluidic devices on a substrate can be integral with the devices and formed on the substrate simultaneously with forming the devices themselves.
Actuation of Pump Rotors of Rotary Miniature Pumps
Rotary miniature pumps according to the present invention all have at least one pump rotor that must be "actuated" (i.e., caused to rotate about a fixed axis) in order to derive useful work from the miniature pump. Even though different types of rotary miniature pumps are distinguishable from one another by, inter alia, the different radial profile(s) of the pump rotor(s), virtually all pump rotors requiring actuation can be actuated in substantially the same ways. Thus, it will be understood that the following general discussion is applicable to any of various types of pump rotors.
Direct actuation of the pump rotor is preferably performed by having the pump rotor serve as both a pump rotor and the rotor of a micromotor employed to drive the miniature pump. It is also possible to couple, such as magnetically, the pump rotor to an external prime mover. Both general methods of rotor actuation avoid the need to provide a rotary seal through the pump body.
In instances wherein a pump rotor also serves as a micromotor rotor, the rotor can be actuated either magnetically or electrostatically. An example of magnetic actuation can be found in conventional stepper motors and other variable-reluctance motors. In electrostatic actuation, the force applied to the rotor is proportional to a change in capacitance which is a function of the rotor angle relative to a stationary element on which is imposed an electrostatic charge.
A first embodiment for directly actuating a rotor is shown generally in FIG. 1 (with a portion of the rotor and surrounding superstructure cut away for clarity). A rotor 10 is situated in a cavity 12 defined by the superstructure 14 formed on a substrate 16 using LIGA methods. The rotor 10, shown with a generally cylindrical profile, has a diametrically oriented magnetic portion 18 made of a ferromagnetic material such as nickel or nickel alloy. (More poles, not shown, can also be provided on the rotor if necessary.) The rotor 10 is mounted on a fixed axle 20 defining a rotational axis so as to allow the rotor 10 to rotate about the axis. The cavity 12 has a bottom 22 from which the rotor 10 can be elevated by a sleeve 24 or analogous feature (optional) provided either on the rotor or the bottom 22 to minimize frictional interaction of the rotor 10 with the bottom 22. At least one pair of diametrically opposing stator pole pieces (e.g., 26a, 26b) is provided adjacent the cavity 12 in a manner allowing magnetic interaction of the rotor 10 with the pole pieces. (Four stator pole pieces 26a, 26b, 28a, 28b are provided in the embodiment of FIG. 1, each oriented at a right angle to adjacent stator pole pieces, but one (28b) has been cut away to reveal other detail.) It will be immediately recognized that energization of an opposing pair of pole pieces in a manner generating a magnetic field therebetween will urge an orientation of the rotor 10 relative to the energized pole pieces. Thus, sequential energization of the pole pieces will cause corresponding rotation of the rotor 10 about its axis.
In any embodiment as described above in which the rotor is magnetic and is intended to contact the fluid to be pumped, the rotor can be made of a magnetic material that is chemically compatible with the fluid to be pumped. Alternatively, the rotor can have an external "skin" of a material that is inert to the fluid to be pumped. Such a skin can be of, for example, an inert metal (such as gold) applied to the rotor by, e.g., electroplating, evaporative sputtering, or CVD; a metal oxide, nitride or other inert metal compound; a glass material; or an inert organic polymer. Alternately, a surface modification technique, such as ion nitridization, can be used to change the properties of the rotor without changing its thickness.
Energization of the stator pole pieces 26a, 26b, 28a, 28b can be performed in a variety of ways. For example, the stator pole pieces can be magnetically coupled to an external permanent magnet provided beneath the substrate outside the cavity (not shown). Rotation of the magnet imposes a corresponding periodic magnetization of the pole pieces sufficient to cause a corresponding rotation of the rotor (see FIG. 8 of Dr. Guckel's U.S. Pat. No. 5,206,983). It is also possible to use this scheme to effect magnetic coupling directly from the external magnet to the rotor, thereby eliminating the need for a stator (see FIG. 3B).
Alternatively, opposing stator pole pieces can be magnetically energized using a stationary electromagnet, situated outside the cavity in a manner allowing magnetic coupling to the stator pole pieces, that is subjected to two-phase electrical energization (not shown; but see FIG. 11 of U.S. Pat. No. 5,206,983, incorporated herein by reference). In such a scheme, each opposing pair of pole pieces can be energized by a separate electromagnet. This scheme can also be used to effect magnetic coupling directly from the external electromagnet to the rotor, thereby eliminating the need for a stator.
Alternatively, the stator pole pieces can be magnetized by electrically energizing them directly, thereby eliminating the need to magnetically couple them to an outside magnetic field. For example, as shown in FIGS. 2A and 2B, stator pole pieces 30a, 30b can be formed on the substrate 16 along with electrical "coils" surrounding each pole piece to make each pole piece into an electromagnet, all using LIGA techniques. The pole pieces 30a, 30b are made of a magnetizable material, such as a nickel-iron alloy, that can be electroplated at a high aspect ratio on the substrate 16. A layer 32 of sputtered nickel is applied to the substrate, which is subsequently patterned using an electrically conductive metal to form coil "cross unders" 34a, 34b (i.e., sections of electrically conductive coils that will underlie the pole pieces 30a, 30b, respectively, yet to be formed on the substrate). The "cross unders" are covered with a dielectric film 36 deposited using, for example, a chemical vapor deposition technique. The termini of the "cross unders" are left uncoated with the dielectric (or can be etched off). LIGA is then employed to form the pole pieces 30a, 30b and the vertical sections 38a, 38b of the coils surrounding each pole piece. The vertical sections of the coil are plated directly on the uncoated termini of the "cross unders" 34a, 34b so as to be electrically contiguous with the "cross unders". After application of another patterned dielectric film 40, a subsequent patterned plating of electrically conductive metal atop the pole pieces can be performed to form "cross overs" 42a, 42b which complete the coils around each pole piece. Alternatively, "cross overs" can be made using small wires (not shown) bonded to the tops of the vertical coil sections 38a, 38b. Coils surrounding diametrically opposing pole pieces 30a, 30b can be electrically connected to each other and to a source of electrical current using wires 44a, 44b. Sequential electrical energization of the coils surrounding diametrically opposed pole pieces produces a "revolving" magnetic flux urging the rotor 10 to rotate about its axis.
Instead of forming coils by plated conductors and crossovers, a conventional wound coil can be used instead, as shown in FIG. 2C. Here a coil 21 is wound on a structure 23 of LIGA-fabricated parts (e.g. form 25, secured on posts 27) on the wafer. This arrangement allows coils of hundreds of turns, producing a commensurate increase in the magnetic force.
Still further, the rotor can be electrostatically actuated. Electrostatic actuation, according to conventional methods, usually requires that the rotary member be electrically grounded. Stator pole pieces are provided radially around the rotary member as described above. In electrostatic actuation, the pole pieces are electrically charged at an appropriate instant relative to the rotational orientation of the rotor, wherein the resulting force applied to the rotor by the pole pieces changes in proportion to a change in capacitance, which is a function of the angle of the rotary member relative to a particular opposing pair of pole pieces.
In any of the foregoing schemes, the stator can be located either in the same plane as the rotor, as discussed above, or in a separate axially displaced plane. When the stator is located in a separate plane, the rotor is typically axially extended to provide a portion that can interact with the stator.
It is also possible to drive two or more rotors in a pump simultaneously from a single stator by interconnecting the rotors using microminiature gears. Such gears can also be manufactured using LIGA methods. (See. e.g., FIG. 9 of Dr. Guckel's U.S. Pat. No. 5,206,983.)
It will be appreciated that stator pole pieces need not be situated radially relative to the rotor. Rather, in certain embodiments, it may be more advantageous or necessary for the pole pieces to extend in a plane through which passes the axis of the rotor, thereby orienting the magnetic flux lines from the pole pieces to the rotor in a direction substantially parallel to the axis of the rotor. In addition, even if the stator pole pieces are situated radially relative to the rotor, they need not be situated in the same plane as the rotor.
Gear Pump Embodiments
Gear pumps that can be produced using LIGA include external and internal gear types. According to conventional principles, in an external gear pump, the center of rotation of each driving gear is external to the major diameter of the driven gear, and vice versa; and both the driving and driven gears are of the external tooth type. In an internal gear pump, according to conventional principles, the center of rotation of one of the gears is inside the major diameter of the other gear, and at least one of the gears is an internal-tooth type or crown-tooth type.
A representative external gear-pump embodiment is shown in FIGS. 3A-3B, which comprises first and second rotary members 50a, 50b, respectively. The first rotary member 50a serves as a first pump gear (radially arranged gear teeth around the circumference are not shown); the second rotary member 50b serves as a second pump gear (again, gear teeth are not shown) enmeshed with the first pump gear. Reflective of their function, the first and second rotary members 50a, 50b, respectively, are termed the driving and driven gears, respectively.
The meshed driving and driven gears 50a, 50b are situated in a pump cavity 52 defined by a pump body 54 applied in one or more layers to a substrate 56 via a LIGA process. The pump body 54 can be formed of any of various materials such as, but not limited to, copper or PMMA. Because the pump body 54 is normally left attached to the substrate 56, the LIGA process used to form the pump body 54 on the substrate 56 is termed an "anchored" LIGA process.
The driving gear 50a and the driven gear 50b are rotatable about respective axes such as by mounting the gears on respective axles 58a, 58b or pins which can be integral with the substrate 56 or a with layer on the substrate. The cavity 52 circumferentially conforms to the driving and driven gears with sufficient radial clearance to permit rotation of the driving and driven gears 50a, 50b, in the cavity.
The driving and driven gears 50a, 50b can be formed in situ using the LIGA sacrificial layer technique (see, U.S. Pat. No. 5,206,983). However, forming the gears in situ can result in excessive clearance between each gear and the walls of the cavity as well as excessive clearance between the teeth of the driving gear and the teeth of the driven gear. Hence, the driving and driven gears are preferably constructed separately on another substrate (using the "sacrificial" LIGA technique), then assembled on the respective axles 58a, 58b. This ensures the closest possible tolerances between the driving and driven gears and the closest possible radial tolerances between the gears and the walls of the pump cavity 52.
The driven gear 50b can be made of any of various materials such as, but not limited to, PMMA or copper. Because the driving gear 50a preferably magnetically interacts with a separate rotor or other rotary actuator located outside the pump cavity 52, the driving gear 50a is made of a magnetic material, such as, but not limited to, permalloy or nickel, or at least includes a magnetic dipole therein made of a magnetic material or a permanent magnetic material.
The driving and driven gears preferably have intermeshing teeth having an involute profile (FIG. 4). However, other tooth profiles may be more suitable for certain pumping applications. Tooth width should be minimally about 20 μm to ensure adequate tooth strength. The diameter of gears made using the LIGA process would typically range from 100 μm to about 1 mm, and the height of the gears would typically range from about 100 μm to about 1 cm. Also, space permitting, the driving gear can be meshed with more than one driven gear.
The pump cavity 52 must be provided with a means for conducting fluid into the pump cavity upstream of the meshed gears and a means for conducting fluid from the pump cavity downstream of the meshed gears. Normally, these criteria are met by providing the pump cavity 52 with an inlet 60 and an outlet 62. As shown in FIG. 3A, the inlet 60 and outlet 62 can be configured as separate flow channels formed in the pump body 54 using LIGA methods. See, e.g., U.S. Pat. No. 5,190,637 to Guckel. The inlet and outlet channels 60, 62, respectively, can be made of the same material as the pump body 54. The channels can be covered using a cover plate 64 attached to the pump body 54 (FIG. 3B). Alternatively, use of sacrificial-layer LIGA techniques permits the formation of covered channels without having to use a cover plate. According to the particular pattern on the photomask, inlet and outlet channels can be made extending away from the pump cavity, as shown in FIG. 3A. Alternatively, anisotropic apertures can be formed in the pump body, cover plate, or in the underlying substrate, again using LIGA methods, to serve as inlet and outlet ports for the pump cavity 52 (see FIG. 4). Fluid conduits can be attached to the inlet and outlet channels using conventional methods, if required.
Gears made using LIGA methods have sufficiently high aspect ratios to be useful in gear pumps according to the present invention. Such gear pumps are capable of delivering flow rates of about 1 μL/min to about 5 mL/min. Also, gears individually produced apart from the pump body can have exceptionally tight tolerances of 0.1 μm or less, which are much tighter than achievable by other known methods. Such tight tolerances make possible the manufacture of miniature pumps that are substantially "positive displacement."
It is important that the gears not encounter excessive rotational friction during operation. Examples of ways in which friction can be reduced are use of fluted axles for mounting the gears and ensuring that the inside walls of the pump cavity are smooth. Also, any portion of the gears that actually contact an interior surface of the pump cavity should be configured so as to contact the surface with as low a friction as possible. For example, a gear can be provided with an integral collar or the like to minimize the contact area of any surface of the gear that contacts a cavity wall.
Rotary Piston Pump Embodiments
Many of the principles by which rotary gear pumps are made using LIGA can also be applied to making any of various rotary piston pump embodiments.
In a rotary piston pump embodiment according to the present invention, piston-like rotary elements (rotors) are provided, using LIGA technology, in a pump cavity. In an external circumferential piston pump as shown in FIG. 5, at least two rotors 70, 72 are used, each typically having two lobes 70a, 70b, 72a, 72b with a radial surface and each rotatable about a respective axis 73, 75. The rotors are driven simultaneously; thus, it is possible to use a gear (not shown), but see FIG. 10 of U.S. Pat. No. 5,206,983) to rotationally link the rotors 70, 72 together and drive them simultaneously using a single stator or other rotary actuator as described above. The rotors 70, 72 are disposed in the pump cavity 74 which has walls 76 radially conforming to the radial surfaces of the lobes on the rotors. The lobes 70a, 70b, 72a, 72b on the rotors 70, 72 do not touch each other during operation. The clearance between the radial surfaces of the lobes and the radial walls of the pump cavity is kept as small as possible to ensure positive displacement of pumped fluid as the rotors rotate, while avoiding excessive friction. The pump cavity 74 is provided with an inlet 77 and an outlet 78.
As with gear pumps, "internal" embodiments of rotary piston pumps are also possible, in which the center of rotation of one of the rotors is inside the major diameter of the other rotor.
Rotary Lobe Pump Embodiments
Lobe pumps share a number of similarities with other rotary pumps; thus, LIGA technology can be used to make rotary lobe pump embodiments according to the present invention in a manner similar to that described above with respect to, for example, gear pumps. Actuation of the rotors of rotary lobe pump embodiments can be effected in the same manner as described above with respect to gear pumps and rotary piston pumps.
As shown in FIG. 6, an "external" lobe pump has rotors 80, 82 with rounded lobes 80a, 80b, 82a, 82b that interdigitate with and remain in contact with each other as the rotors 80, 82 rotate about respective axes 83, 84. Also, neither rotor drives the other; rather, the rotors are simultaneously driven. Each rotor can have one or multiple lobes, but three lobes per rotor is usually the maximum practical number of lobes.
According to the present invention, the rotors 80, 82 can be made in situ in a pump cavity 85 and on a substrate using LIGA technology. Alternatively, to ensure the tightest possible tolerances, the rotors 80, 82 can be made separately from the pump cavity 85 using sacrificial layer LIGA methods, then assembled into the pump cavity 85. The pump cavity is provided with an inlet 86 and an outlet 87.
"Internal" lobe pump embodiments are also possible, wherein a single rotor is provided having a lobelike peripheral shape that interdigitates with lobes provided in the radial walls of a pump cavity. The rotor is rotated in a manner providing a combination of rotation and gyration of the rotor center in the pump cavity in such a way that the rotor always radially touches the lobe-shaped contours of the pump cavity, thereby providing positive displacement pumping action.
Rotary Centrifugal Pump Embodiments
A representative embodiment of a centrifugal miniature pump according to the present invention is shown in FIG. 7. The centrifugal pump comprises a pump cavity 92 defined by a pump body 94 that is superstructured on a rigid substrate. The pump body 94 can be made from a suitable metal electroplated onto the substrate or from a polymeric or other castable material adhered to the substrate using LIGA methods. A vaned rotor 95 is mounted in the cavity 92 on a fixed axle 96, and can be actuated by a micromotor rotor (not shown) coaxially affixed to the pump rotor 95 but displaced above or below the plane of the pump rotor.
Fluid enters the pump cavity 92 through an aperture 97 defined by, for example, a cover layer (not shown) adhered to the pump body 94. Fluid exits the pump cavity 92 through an outlet 98 defined in the pump body 94.
In contrast with, for example, rotary gear pumps or rotary lobe pumps, centrifugal pumps according to the present invention are generally not considered "positive displacement" pumps.
Linear-Actuated Pump Embodiments
A first representative embodiment of a linear-actuated miniature pump according to the present invention is shown in FIG. 8, depicting a two-piston pump 100 wherein each piston is actuated by a separate linear actuator (preferably a "variable-reluctance" type). The pump 100 comprises a pump cavity 102 defined by a pump body 104 adhered to a rigid substrate. Communicating with the pump cavity 102 are an inlet port 103 and an outlet port 104 also defined by the pump body. Situated inside the pump cavity 102 are a first piston 105 and a second piston 106. The first and second pistons can be made, using LIGA methods, from a ferromagnetic material responsive to a magnetic field. Each piston 105, 106 extends into a corresponding "actuator" region 107, 108, respectively, of the pump cavity surrounded by actuator "coils" embedded in the pump body. The actuator coils can be made using LIGA methods in the same manner as described above in section 2.
The first and second pistons 105, 106 are actuated in a periodic, coordinated sequence comprising multiple "cycles." In each cycle, the first piston 105 "pushes" while the second piston 106 "pulls", then the first piston 105 "pulls" while the second piston 106 "pushes". This cyclical operation changes the volume of region 109 which, in cooperation with the alternating positive and negative pressure changes caused by movement of the pistons 105 and 106, effects a pumping operation. Completion of each such cycle results in the delivery of a volume 109 of fluid, aspirated into the pump cavity 102 from the inlet port 103 to the outlet port 104.
To ensure sufficiently tight clearance between the pistons and the interior walls of the pump cavity, the pistons can be produced on a separate substrate using sacrificial layer LIGA methods. After removal from the separate substrate, the pistons are assembled in the pump cavity, after which the pump cavity is closed using a cover plate or the like as discussed above. A suitably tight clearance ensures that the pump is "positive displacement."
A second representative embodiment of a linear actuated pump according to the present invention is shown in FIG. 9, depicting a pump 110 comprising a piston 111 actuated by a first linear actuator 112 and a spool valve (piston) 113 actuated by a second linear actuator 114. The spool valve 113 is situated in a pump cavity 115 defined by a pump body 116 formed on a rigid substrate, and defines a channel 117 for routing fluid. An inlet port 118 and outlet port 119, also defined by the pump body 116, communicate with the pump cavity 115. Also communicating with the pump cavity 115 is a side cavity 120 defined by the pump body 116 in which is situated the piston 111.
Operation of the pump of FIG. 9 is cyclical. At the beginning of a cycle, wherein the piston 111 and spool valve 113 are situated as shown in FIG. 9, the piston 111 is moved, as urged by the first actuator 112, in a manner urging intake of fluid from the inlet port 118, through the channel 117 on the spool valve 113, and into the side cavity 120. Then, the spool valve 113 shifts, as urged by the second actuator 114, so as to allow passage of fluid from the side cavity 120 to the outlet port 119; such passage of fluid is effected by movement of the piston 111, as urged by the first actuator 112, so as to expel the fluid from the side cavity 120 via the channel 117. Next, the spool valve 113 shifts again, as urged by the second actuator 114, to allow fluid passage from the inlet port 118 to the side cavity 120 via the channel 117, thus beginning another cycle.
It is to be understood that the spool valve in the miniature pump embodiment shown in FIG. 9 can be replaced with a rotary valve that is rotatably actuated by any of various means as discussed above.
It will also be appreciated that the spool valve embodiments described above can be made without a piston to permit the spool valve to be used for valving purposes.
Covering the Pump Cavity
As shown generally in FIG. 3B, the pump cavity can be isolated from the external environment by attaching a cover plate 64 over the pump cavity 52 to the pump body 54. Sealing the cover plate to the pump body can be performed by any of various methods such as by solvent bonding or eutectic (heat) bonding of the cover plate to the pump body, or clamping a cover plate to the pump body with an elastomeric seal interposed between the cover plate and the pump body. Alternatively, if the cover plate is inherently capable of sealing to the pump body with application of a clamping force (such as a cover plate made from PMMA), it is possible to attach a cover plate to the pump body by clamping without an elastomeric seal.
Flow Sensors
The present invention is also extended to flow sensors. In a representative flow sensor according to the present invention, a toothed or vaned rotor is rotatably mounted in a cavity in a manner not unlike that described above for a centrifugal pump. For example, referring to FIG. 7, if fluid entered the pump cavity 92 through the port labeled 98 (i.e., in a direction opposite to the arrow shown in said port, and exited through the port labeled 97, the rotor 95 would be caused to rotate in response to passage of fluid through the pump cavity.
Sensing of rotation of the rotor can be performed optoelectronically, such as by placing a light-emitting diode (LED) and a photo-transistor on opposing sides of the pump cavity such that light passing from the LED to the photo-transistor is interrupted each time a vane of the rotor 95 passes between the LED and the photo-transistor (not shown). Alternatively, the rotor can be configured as a magnetic dipole magnetically coupled to a magnetic field-sensing transducer located outside the pump cavity; as the rotor rotates, its rotation is magnetically sensed by the transducer and electronically converted to, for example, rpm data. Capacitative coupling, rather than magnetic coupling described above, can also be used between the rotor and a suitable capacitance-sensing transducer to sense the rotation of the rotor.
Fluid Motors
It will be appreciated that a rotor mounted inside a pump cavity as described above can also be utilized as a hydraulic motor. Referring again to the embodiment shown in FIG. 7 used as described above as a flow sensor, it will be appreciated that fluid passing through the pump cavity from the port labeled 98 to the port labeled 97 will urge rotation of the rotor 95. The energy of the rotating rotor 95 can be utilized to perform work. For example, the rotor 95 can be magnetically or capacitively coupled to an extraneous rotor (not shown) that, as the rotor 95 urges the extraneous rotor to rotate, generates an electrical current. In another representative embodiment (not shown), the rotor 95 can be mechanically linked to another rotor ("driven rotor") by one or more gears, wherein the driven rotor can be used to perform work on a fluid, such as by pumping the fluid.
Representative Uses
Miniature pumps according to the present invention can be used for a variety of uses, and the following is not to be construed as limiting in any way with respect to the variety of possible uses.
A first arena in which the miniature pumps can be used is in biomedical applications. Representative biomedical applications include, but are not limited to: (a) an implantable device comprising a reservoir of a drug or diagnostic agent capable of actively infusing the drug or agent from the reservoir into a subject's body; (b) withdrawal of a microscopic amount of fluid from a subject's body or from an environment external to the body for analysis; (c) flow-injection analysis of a medicament administered to a subject or of natural movement of a fluid in a subject's body; (d) microchemical instrumentation that can be used in vivo or in vitro, such as instrumentation utilizing microsensors; and (e) sequence analysis and/or synthesis of polypeptides or nucleic acids.
Another field in which miniature pumps according to the present invention have particular utility is in ink-jet printing and similar uses in which minute quantities of fluid must be accurately delivered to a point of use.
Yet another field is in cooling of semiconductor devices, wherein a conventional semiconductor device, such as a high-density integrated circuit or microprocessor, is provided with an on-board fluidic circulation system including a heat exchanger and at least one miniature pump according to the present invention for circulating fluid coolant from the circuit to the heat exchanger and back again. Such cooling would be of particular value in, for example, laser diodes.
When used with most types of miniature pumps according to the present invention, fluids are preferably suitably filtered to remove particulate material that could cause a moving part of the miniature pump to jam. Such filtration can be readily performed using a commercially available sub-micron filter that is compatible with the fluid.
Whereas the invention has been described in connection with various preferred and alternative embodiments, it will be understood that the invention is not limited to those embodiments. On the contrary, the present invention is intended to encompass all alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. | A microfabricated, remotely actuated fluid pump includes a LIGA-fabricated movable member disposed within a cavity. The LIGA-fabricated movable member and the cavity cooperate to (a) define a sufficiently small clearance therebetween to achieve effective pumping action while (b) presenting a sufficiently low-friction fit to enable remote actuation. Such a pump can take the form of a piston pump, a vane pump, a centrifugal pump, a gear pump, etc. Other fluidic devices including flow sensors, piston valves, hydraulic motors, nozzles, and connectors can be fabricated using similar principles. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of PCT Application PCT/EP2015/073024, filed Oct. 6, 2015, which claims priority to German Application DE 10 2014 220 420.8, filed Oct. 8, 2014. The disclosures of the above applications are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to a sealing compound, to a housing for an electronic control unit, and to an electronic control unit for a motor vehicle.
BACKGROUND
[0003] Housings for electronic control units may have a plurality of housing parts that are connected to one another in a fluid-impervious manner in order to protect a circuit board that is disposed in an interior space of the housing and is populated with electronic components.
[0004] Aging effects may be detrimental to the imperviousness of the connection, allowing moisture to penetrate to the interior space and damage the circuit board and the componentry.
SUMMARY
[0005] It is therefore an object of the present disclosure to enable a particularly aging-stable seal. It is a further object of the present disclosure to specify a housing for an electronic control unit that can be given a particularly long-lived seal.
[0006] One aspect of the disclosure provides a sealing compound and a housing. In particular, the sealing compound can be applied wet. The sealing compound can be cured to give an elastic seal.
[0007] Another aspect of the disclosure provides a housing for an electronic control unit. The housing has a first, metallic housing part and a further housing part. The further housing part may likewise be manufactured of a metallic material. For example, the first housing part is a main housing body composed of an aluminum alloy that includes, in particular, silicon and/or copper. In some examples, the first housing part is a pressure-cast component.
[0008] In some implementations, the further housing part may be a housing cover, such as a metal-sheet cover, for example. In some examples, the further housing part is manufactured from a metal sheet—an iron sheet, for example. In some implementations, the further housing part is formed of a metal sheet which is coated at least in the region of the sealing joint. For example, the metal sheet is coated with a layer that comprises or consists of zinc and/or aluminum. In some examples, the layer further includes magnesium, such as a zinc-magnesium alloy.
[0009] Formed between the first housing part and the further housing part is a sealing joint which, in the completed state of the housing, is filled with an elastic seal. The elastic seal includes the cured sealing compound. In other words, the gap formed by the sealing joint between the housing parts is sealed, more particularly in a manner impervious to fluid, by means of the elastic seal.
[0010] Another aspect of the disclosure provides an electronic control unit for a motor vehicle, including the housing.
[0011] The statement that the sealing compound “can be applied wet” is understood to mean that after application to one of the housing parts to be sealed by means of the sealing compound, the sealing compound is plastically deformable, to produce the shape of the elastic seal during the production of the housing. For example, the sealing compound is plastically deformed when the further housing part is pressed onto the first housing part, in order for the sealing joint between the two housing parts to be filled in a manner impervious to fluid. A sealing compound which can be applied wet is occasionally also termed a sealing putty. The elastic seal is also referred to by the skilled person as an FIP seal (“formed in place” seal) or CIP seal (“cured in place” seal). It is, in particular, not a preformed profile seal and also not a coating material.
[0012] The sealing compound includes a matrix material. The matrix material may usefully—at any rate in an uncured state of the sealing compound—be plastically deformable and curable to give an elastic material. The matrix material may be an elastomer material. The matrix material includes, for example, a silicone material, as for example a silicone resin, or a polyurethane material, more particularly a synthetic PU resin. An epoxy resin material as well is conceivable as matrix material.
[0013] In some examples, the sealing compound additionally includes a corrosion-inhibiting additive. With advantage, owing to the corrosion-inhibiting additive in the sealing compound, there is a particularly low risk of formation, in the region of the sealing joint between the elastic seal and the metallic housing part or metallic housing parts, of corrosion pathways through which unwanted substances—moisture in particular—can penetrate into an interior space of the housing. More particularly, there is a particularly low risk of the seal being undermined by corrosion of the housing part in question at the interface with the metallic housing part(s). With conventional housings, this risk is particularly great, since corrosion is able to progress particularly quickly in the comparatively small gap between seal and metallic housing part.
[0014] Utilizing low-corrosion materials for metallic housing parts, or a specific coating of the housing parts before application of the sealing compound, is not absolutely necessary in the case of the present housing—with the advantageous benefit of saving costs—in order to achieve a high level of corrosion resistance on the part of the sealing joint. The cross section of the seal can be kept particularly low.
[0015] The corrosion-inhibiting additive is, for example, distributed in the matrix material. The corrosion-inhibiting additive may usefully have been added to the matrix material in the form of a multiplicity of particles—in other words, in particular, in the form of powder or dust. The median of the equivalent diameter of the particles—also referred to by the skilled person as d50 or as average particle size—has a value, for example, of 500 μm or less and/or of 1 μm or more. It is preferably between 2 μm and 100 μm, for example between 5 μm and 60 μm, the limits being included in each case. The equivalent diameter can be determined, for example, based on a polished section of the cured sealing compound.
[0016] In some implementations, the particles are bead-shaped, more particularly spherical, and preferably have the same diameter. The statement that the bead-shaped particles have the same diameter is understood presently to mean that the diameters of any two particles differ from one another by less than 10%, preferably by less than 5%. In some examples, the diameter of the bead-shaped particles has a value of 0.1 mm or more, for example 0.4 mm or less. It has, for example, a value of about 0.3 mm. In this way, it is possible by means of the particles to establish an advantageous minimum distance of the housing parts in the region of the sealing joint—i.e., a minimum height of the sealing joint. Accordingly, the risk of inadequate sealing effect or of unsatisfactory long-term stability of the seal because of a seal height which is locally too small is particularly low.
[0017] In some implementations, the sealing compound includes a thixotropic agent for uniform distribution of the corrosion-inhibiting additive in the sealing compound. The thixotropic agent may be, for example, silica gel. In this way, the corrosion-inhibiting additive is able to gain access easily to all locations on the interfaces between the housing parts and the sealing compound.
[0018] In some examples, the corrosion-inhibiting additive is designed as a sacrificial anode for a corrosion reaction with the metallic housing part or metallic housing parts. For this purpose, in particular, the sealing compound includes particles of a non-noble metal as corrosion-inhibiting additive. With advantage, instead of the respective housing part, the corrosion-inhibiting additive gives off electrons and is oxidized. The matrix material in this case is able to remain in consistently sealing contact with the housing part. The risk of oxidation of housing material and hence of the formation of a gap between the housing part and the matrix material is particularly low.
[0019] The sealing compound may include zinc particles as corrosion-inhibiting additive. Additives of the sealing compound that are designed as a sacrificial anode may alternatively or additionally include or consist of at least one of the following materials: Be, Mg, Ca, a lanthanoid such as Sc or Y or La, an actinoid such as Ac, Ti, Zr, Hf, V, Nb, Ta, Cr, Mn, Zn, Cd, Al, Ga, In, Ti, Pb. These materials are highly suitable as sacrificial anode in the case, for example, of a housing part including iron. In some examples, the corrosion-inhibiting additive is designed to bind intermediate products of a corrosion reaction. The intermediate products may be, for example, Fe3+ or OH— or FeOOH. Fe3+, for example, may be bound by an anionic corrosion-inhibiting additive to form a salt of low solubility. OH—, for example, may be bound by a cationic corrosion-inhibiting additive. In some examples, the sealing compound includes zinc phosphate particles as corrosion-inhibiting additive.
[0020] In some implementations, the sealing compound includes particles of a pH-buffering material as corrosion-inhibiting additive. In this way, with advantage, at least one housing part can be passivated—especially if it is formed of an aluminum alloy—or the reaction rate of the corrosion reaction is particularly low.
[0021] The corrosion-inhibiting additive is formed, for example, by a mixture of sodium dihydrogenphosphate with disodium hydrogenphosphate or with sodium hydroxide solution. The additive in that case is, for example, a phosphate buffer. In this way, in particular, a mandated pH value, in the 6-8 pH range, for example, can be achieved. Alternatively, the corrosion-inhibiting additive may be a barbital-acetate buffer of Michaelis, an acetic acid-acetate buffer, a carbonic acid-silicate buffer, 2-(N-morpholino)ethanesulfonic acid, a carbonic acid-bicarbonate system, 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid, tris(hydroxymethyl)aminomethane, 4-(2-hydroxyethyl)piperazine-1-propanesulfonic acid, an ammonia buffer, a citric acid buffer or a citrate buffer.
[0022] In some implementations, the metallic housing part is formed, at least in the region of the sealing joint, of a first metallic material, and the sealing compound includes particles of a second metallic material as corrosion-inhibiting additive, the electronegativity of the second metallic material being greater than that of the first metallic material. In some examples, the further housing part, at least in the region of the sealing joint, is formed of the first metallic material or of a further metallic material, the electronegativity of the second metallic material being greater than that of the further metallic material. With an additive of this kind it is possible—in particular by means of a substitution reaction—for atoms of the metallic housing parts to be replaced, allowing a coating of high corrosion resistance to form in the region of the interfaces between seal and the respective housing part.
[0023] The corrosion-inhibiting additive may have, for example, an electronegativity that is greater than 1.83. In some examples, it is greater than 1.9. In these cases, it is greater than the electronegativity of the materials specified above for the further housing part or for the first housing part, respectively.
[0024] The electronegativity of the corrosion-inhibiting additive may usefully be less than 2.6. In this way, the additive is particularly stable chemically.
[0025] The corrosion-inhibiting additive may include particles which include or consist of silver and/or nickel, examples being silver particles and/or particles of a silver salt and/or nickel particles and/or particles of a nickel salt. Further materials with suitable electronegativity of which the additive may include or consist of one or more of are as follows: Mo, W, Ru, Os, Rh, Ir, Pd, Pt, Au, B, Ge, Sn, P, As, Sb, S, Se, Te, Po, At.
[0026] In some examples, the sealing compound includes two or more different corrosion-inhibiting additives of those described above—for example, an additive designed as a sacrificial anode, and a material designed as a pH buffer. As a result of the different modes of action, it is possible to reduce the risk of corrosion pathways forming in the region of the sealing joint, in a particularly effective way.
[0027] In some implementations, the volume fraction of the corrosion-inhibiting additive as a proportion of the volume of the sealing compound is greater than or equal to 10%. In this way, satisfactory inhibition of corrosion may be achieved. In some examples, the volume fraction is less than or equal to 70%, more particularly less than or equal to 50%. In this way, there is particularly low risk of the additive giving rise to leakage pathways which penetrate the elastic seal. A volume fraction of 70% corresponds here, in particular, to the percolation limit.
[0028] For the inhibition of corrosion, it is advantageous if the sealing compound has high electron mobility and/or ion mobility. If the matrix material, for example, is a silicone material, satisfactory ion mobility may be achieved through the hygroscopic properties of the matrix material. In some examples, the sealing compound includes a plasticizer, such as a heavy metal, for example. As such, it is possible to achieve a low degree of crosslinking of the cured sealing compound and/or a low glass transition temperature of the sealing compound, with advantageous consequences for the electron and/or ion mobility. Alternatively or additionally, the chain length of the elastomers in the matrix material may be selected appropriately for this purpose.
[0029] The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0030] FIG. 1 shows a schematic sectional representation of a detail of a conventional housing,
[0031] FIG. 2 shows a schematic sectional representation of a detail of a housing for a control unit according to a first example,
[0032] FIG. 3 shows a schematic sectional representation of a detail of a housing for a control unit according to a second example, and
[0033] FIG. 4 shows a schematic sectional representation of a detail of a housing for a control unit according to a third example.
[0034] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0035] Elements which are the same, which are of the same kind or which have the same effect are given the same reference symbols in the figures. In certain figures, individual reference symbols may be omitted in order to improve clarity. The figures and the size ratios of the elements shown in the figures to one another should not be considered as being to scale. Instead, for improved representation and/or for greater ease of understanding, individual elements may be shown with exaggerated size.
[0036] FIG. 1 shows a housing 20 of an electronic control unit with a conventional elastic seal 1 , which is disposed in a sealing joint 26 between a first metallic housing part 22 and a further metallic housing part 24 . By means of the seal 1 extending along the sealing joint 26 , an interior space 28 of the housing 20 is sealed with respect, for example, to penetrating moisture.
[0037] Over the lifetime of the control unit, the metallic housing parts 22 , 24 may suffer corrosion. In that case, corrosion pathways 32 , 34 may form, which undermine the seal 1 . For instance, moisture may penetrate through the sealing joint 26 into the interior space 28 of the housing (see, for example, the corrosion pathway 34 in FIG. 1 ). The penetrating moisture may adversely affect the functional capacity of the control unit.
[0038] FIG. 2 shows a schematic sectional view of a detail of a housing 20 according to the disclosure. More precisely, FIG. 2 shows a marginal region of the housing 20 . In some examples, the housing 20 is a housing 20 of an electronic control unit, such as of a motor vehicle control unit, for example. The control unit is, for example, an engine control unit.
[0039] The housing 20 has a first, metallic housing part 22 . This part is, for example, a pressure casting made of an aluminum alloy, more particularly of an alloy familiar to the skilled person as AlSiCu. The first housing part is, for example, a main housing body into which a circuit board populated with electronic components can be inserted—and, in the completed control unit, is inserted.
[0040] The housing 20 has a further housing part 24 . The further housing part 24 , for example, is a cover that seals an assembly aperture in the first housing part 22 . In the present case, the further housing part 24 is formed from an iron sheet, by means of embossing, deep drawing or the like, for example.
[0041] The further housing part 24 is mounted in the region of the assembly aperture onto the first housing part 22 in such a way that a sealing joint 26 is formed along a peripheral marginal region, this sealing joint 26 producing a fluid-impervious connection between the housing parts 22 , 24 .
[0042] The fluid-impervious connection is obtained by means of an elastic seal 1 which is disposed in the sealing joint 26 in a gap-filling manner, and which therefore borders both the first housing part 22 and the further housing part 24 in order to seal the sealing joint 26 . By means of the elastic seal 1 , an interior space 28 in the housing 20 is given fluid-impervious closure with respect to the surroundings of the housing 20 .
[0043] To produce the elastic seal 1 , a sealing compound is applied wet to one of the housing parts 22 , 24 —in the form of a sealing bead, for example—and subsequently the other housing part 22 , 24 is pressed onto the sealing compound. In this process, the sealing compound becomes plastically deformed and thus acquires its ultimate form. The sealing compound is subsequently cured to give the elastic seal 1 . For this purpose, depending on the material involved, the sealing compound may be subjected, for example, to light, such as UV light, or to heat.
[0044] In some examples, the sealing compound—and hence also the elastic seal 1 after the curing of the sealing compound—includes a silicone material or a polyurethane material as matrix material 11 . In the case of polyurethane material, for example, a heavy metal plasticizer may have been added to the matrix material 11 .
[0045] Embedded into the matrix material are zinc particles with a volume fraction of 10% or more, such as of 30%, for example, as corrosion-inhibiting additive 12 . The sealing compound may further include silica gel as thixotropic agent in order to distribute the zinc particles uniformly within the silicone material.
[0046] Because of moisture in the region of the sealing joint 26 , for example, there may be a corrosion reaction with the metallic housing parts 22 , 24 . In that case, the zinc particles present as corrosion-inhibiting additive 12 in the seal 1 act as sacrificial anodes, which give up electrons and in the process are oxidized. The giving-up of electrons by the housing parts 22 , 24 is thereby advantageously reduced or prevented entirely in the region of the sealing joint 26 , meaning that at that location the housing parts 22 , 24 do not undergo corrosion. The volume fraction of the corrosion-inhibiting additive 12 is below the percolation limit, and so, even if the additive is corroded, a reliably sealing contact between the seal 1 and the housing parts 22 , 24 is ensured by means of the matrix material 11 . The risk of moisture penetrating into the interior space 28 of the housing 20 through the sealing joint 26 is therefore particularly low.
[0047] Instead of the zinc particles or in addition to them, the sealing compound may have a different corrosion-inhibiting additive 12 selected from those described earlier on above.
[0048] FIG. 3 shows a schematic sectional representation of a marginal section of a housing 20 according to a second example. The housing 20 of the second example corresponds essentially to that of the first example shown in FIG. 2 .
[0049] As shown in FIG. 3 , however, the further housing part 24 has a main body 242 formed of an iron sheet. This body is provided, on its side facing the sealing joint 26 , with a coating 244 . In the present case, the coating 244 is formed of a zinc layer or of a zinc-magnesium layer, which is applied on the main body 242 . By means of the coating 244 , corrosion protection of the further housing part 24 can be achieved even at locations not covered by the seal 1 . Alternatively or additionally, the main body 242 may have been provided with the coating 244 on its side facing away from the sealing joint 26 .
[0050] Moreover, the first housing part 22 is provided with a groove 222 extending along the sealing joint 26 . At production, the sealing compound is applied, preferably as a sealing bead, along the groove 222 to the first housing part 22 . In this case, by means of the groove 222 , the sealing compound can be positioned with particular accuracy.
[0051] FIG. 4 shows a schematic sectional representation of a marginal section of a housing 20 according to a third example. The housing 20 of the third example corresponds essentially to that of the first example shown in FIG. 2 .
[0052] As shown in FIG. 4 , however, spherical zinc particles, rather than zinc dust, have been added as corrosion-inhibiting additive 12 to the matrix material 11 . All particles have the same diameter of 0.3 mm.
[0053] The spherical zinc particles set the minimum height of the sealing joint 26 . For this purpose, at production, the housing parts 22 , 24 are pressed against one another—with plastic deformation of the sealing compound applied to at least one of the housing parts 22 , 24 —until the zinc particles make contact with both the first housing part 22 and the second housing part 24 . The sealing compound is subsequently cured to give the seal 1 .
[0054] The description using examples does not confine the invention to these examples. Instead, the invention encompasses every new feature and also every combination of features, including in particular every combination of features in the examples and the claims. | The disclosure relates to a sealing compound that can be applied wet and is curable to form an elastic seal. The sealing compound contains a matrix material and a corrosion-inhibiting additive. In addition, a housing having the elastic seal as well as an electronic control device with the housing are disclosed. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to wireline instruments for measuring temperature and pressure in oil and gas wells and in particular to a latching mechanism for use with such instruments to prevent upward movement of the instrument in flowing oil and gas wells.
2. Description of the Prior Art
Pressure and temperature measurements are commonly taken downhole in flowing oil and gas wells in order to determine reservoir conditions. A typical manner in which the measurements are taken is by lowering temperature and pressure instruments into the well to a depth slightly abovethe zone desired to be measured. Conductor cable is frequently used to lower the instruments into the well so that a concurrent surface indication is displayed at the surface.
Since a flowing well is under pressure, a sealing apparatus is placed on top of the christmas tree of the type that seals against the internal pressure but allows the line to move. Normally the flow from the well is shut off at the surface while the instrument is being lowered. Because of the pressure, there is a tendency for the cable to be pushed out of the sealing apparatus, thus lead weights are attached to the instrument to cause it to sink. The well is allowed to flow once the tool is at the desired place. In very high flow rate wells, the fluid flow may cause the instrument to move upward, even though sufficient weights were used to lower the instrument into the well. This can cause the cable to knot and kink, making it difficult to retrieve the instrument through the sealing apparatus.
SUMMARY OF THE INVENTION
It is accordingly a general object of this invention to provide an improved apparatus that prevents upward movement of a wireline instrument while measuring conditions in flowing oil and gas wells.
It is a further object of this invention to provide an improved method of preventing upward movement of a wireline instrument while measuring temperature and pressure in flowing oil and gas wells.
In accordance with these objects, a latching apparatus is provided for connection to the temperature and pressure sensing instrument. The latching apparatus has a tubular body with arms pivotally mounted to it from their lower ends. An electrically driven actuating mechanism selectively moves the arms from a closed position flush with the tool body to an open position with their upper ends protruding upward and outward. Landing means is located or placed in the well tubing at the depth where measurements are desired to be taken. The landing means has a downwardly facing shoulder that is engaged by the upper ends of the arms to prevent upward movement of the instrument. The line is preferably tensioned after the arms are opened to prevent whipping of the line by the fluid flow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a 120° vertical sectional view of a latching apparatus constructed in accordance with this invention.
FIG. 2 is a vertical sectional view of the motorized section of the actuating mechanism for the latching apparatus of FIG. 1.
FIG. 3 is a 120° vertical sectional view of the latching apparatus of FIG. 1 with the arms in the closed position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a latching apparatus 11 is shown in open position. The latching apparatus 11 has a tubular body 13 with the upper end 15 threaded for connection to the electrical actuator 17, shown in FIG. 2. The lower end 19 is threaded for connection to the temperature and pressure instruments, designated in phantom as numeral 21.
A hollow shaft 23 extends axially through the tubular body 13, protruding from the upper end and having threads 25 for engagement with the electrical actuator 17. An electrical wire (not shown) extends through shaft 23 and terminates at a pin 27 at the lower end of the latching apparatus. Pin 27 mates in a receptacle (not shown) in instrument 21 for supplying power and transmitting signals from the temperature and pressure measuring instruments 21.
A first mounting member or arm carrier 29 has a central bore for receiving shaft 23 and is rigidly connected to shaft 23 by three shear screws 31. Shear screws 31 have a reduced portion 33 on the end threaded into shaft 23 that is sized to shear at a predetermined tension for the fail safe mechanism, explained hereinafter. Arm carrier 29 has three vertical slots 35 spaced 120° apart. The lower end of an arm 37 is pivotally mounted within each slot 35 by a pin 39, U-shaped bracket 41 and retaining screws 43. Removal of bracket 41 by screws 39 allows the arm 37 to be lifted upward from pin 41. The upper end 45 of arm 37 is free to move from an open position protruding upwardly and outwardly, as in FIG. 1, to a closed position, flush with the tubular body 13, as in FIG. 3.
A link 47 is pivotally mounted by pin 49 to each arm 37 intermediate its ends approximately at the center. Arm 37 has a recessed area 51 formed in it to allow the link 47 and arm 37 to close, as shown in FIG. 3. The upper end of each link 47 is pivotally mounted by pin 53 to a second mounting member or link carrier 55.
Link carrier 55 is, like arm carrier 29, a cylindrical element having an axial bore for receiving shaft 23 and having three vertical slots 56 spaced 120° apart. A link 47 is inserted into each slot 56. Link carrier 55, however, is independently movable of shaft 23, being free to slide axially. A coil spring 57 is received over shaft 23 above the link carrier 55. A washer 59 is fitted over spring 57, to prevent upward movement of spring 57. An internal shoulder (not shown) in tubular body 15 prevents downward movement of link carrier 55 toward arm carrier 29, while spring 57 biases against upward movement.
Second and third coil springs 61 and 63 are received over shaft 23 between the upper side of the arm carrier 29 and a shoulder 65 on the shaft 23. A washer 67 separates the two springs 61, 63 and is movable independently of shaft 23. The two springs 61, 63 function as a single spring and are retained in position under compression.
Three fins 69 spaced 120° apart are attached to the lower end of the tubular body 13. Fins 69 are larger in diameter than the tubular body 13 and have an axial passage 71 for receiving shaft 23 and the electrical wire (not shown).
Referring to FIG. 2, the electrical actuator means includes a tubular housing 73 within which an electrical motor 75 is rigidly attached. The electrical motor 75 is controlled from the surface and its output mechanism 77 is rigidly attached to a threaded rod or screw 79. The lower end of screw 79 is threaded into a threaded sleeve 80 that is reciprocable in tubular housing 73. A rotary to linear translator or shaft carrier 81 comprises a tubular member with threads 83 on the upper end for connection to sleeve 80 and threads 85 on the lower end for receiving the threaded end 25 of shaft 23. The bore of shaft carrier 81 is carried vertically, or axially movable in a subhousing 87, but is prevented from rotation by a slot 89 in subhousing 87 and key 91. Limit switches 93, 95 switch the motor 75 off when the shaft carrier 81 is at its uppermost and lowermost positions.
The latching apparatus 11 is adapted for use with landing means located in the well. The landing means includes a downwardly facing shoulder indicated as 97 in FIG. 1, that should be placed in the string of tubing, indicated as 99 in FIG. 1. Preferably a member with a reduced diameter portion 101, known as a "nogo," is located below the shoulder a distance equal to the distance between the fins 69 and upper ends 45 of arms 37. Nogo 101 should be smaller in diameter than fins 69, but larger than the diameter of the instrument 21. Also passages should be provided in the nogo to facilitate flow of the fluid. The landing means may be placed at the desired depth during a time when the tubing 99 is out of the well and will remain in place during normal production.
In operation, the flow from the well is closed off at the top and wireline sealing means installed on the christmas tree. The wireline sealing means is of a type that seals on moving single conductor cable of approximately 3/16 inch diameter. The cable is of the type that contains the conductor wire in the center and is surrounded by a plurality of twisted wires or armour that protect the conductor from damage and add strength. The sealing means may utilize grease pumped around the cable in close fitting tubes to contain the pressure.
The latching apparatus 11 is threaded into the electrical actuator 17, simultaneously connecting shaft 23 to the shaft carrier 81. The arms 37 should be closed at this time. The temperature and pressure instruments 21 are connected to the lower end 19 of the latching apparatus 11. Lead weights to aid in running the tool in, and a collar locator for depth control, may also be connected into the assembly.
The assembly is connected to the cable and lowered into the well while under pressure, but normally not while flowing, until the fins strike the nogo 101. The motor 75 is then energized to rotate screw 79, drawing shaft carrier 81 upward and along with it shaft 23 and arm carrier 29. Since the link carrier 55 is substantially stationary, arms 37 are forced outward, engaging shoulder 97. Springs 61, 63 will be unaffected by this movement, since they are compressed between fixed points on a shaft 23. Coil spring 57 will compress to some extent as the arm 37 and link 47 tend to force the link carrier 55 upward.
The motor 75 is then stopped and the cable drawn upward to a selected tension. Force of the cable will be transmitted through the shaft 23 to the arms 37, drawing them tightly against shoulder 97. This prevents undesirable whipping of the line by the fluid flow. The valves at the surface are then turned on to allow the fluid to flow past the instrument and latching apparatus 11. The instruments are energized by surface control equipment to give a concurrent surface reading of temperature and pressure.
Once the measurements are completed, the fluid flow is closed at the surface, tension is relieved, and the motor is energized to push shaft downward. This draws in arms 37 flush with the tool body 13, as shown in FIG. 3. The combined latching apparatus and instruments may then be retrieved from the well.
Should the actuating means fail to close the arms because of a malfunction, fail-safe means can be employed to close the arms by the use of cable tension. The cable is tensioned until the shear screws 31 shear from their ends 33, this force being calculated to be at a safe value below the cable strength. The tension is then released. This allows springs 61 and 63 to return to the natural state, drawing down with them arm carrier 29, thus closing arms 37. The latching apparatus can then be retrieved from the well.
The latching apparatus is suitable for use without the nogo 101, using simply some type of ledge or shoulder located in the tubing to serve as landing means for the arms to latch against. In this case, since the precise depth of the shoulder may not be known, the arms 37 are opened below where a shoulder is expected, with their ends bearing against the inner wall of the tubing. The latching apparatus is then pulled upward. When the upper ends of the arms come in contact with a recessed shoulder, they will spring further out into the recess due to the compression of spring 57. Upward movement is then stopped and measurements taken.
It should be apparent that an invention having significant improvements has been provided. The latching apparatus and method of use provide positive retention of the instrument, preventing upward movement of the tool due to fluid flow. Whipping and kinking of the line is avoided.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes and modifications without departing from the spirit thereof. | A wireline latching apparatus and method of use with wireline instruments for measuring temperature and pressure downhole in flowing oil and gas wells. The latching apparatus includes a tubular body for connection to the instrument. Three arms are mounted in the tubular body pivotally so that their upper ends open outward. A downwardly facing shoulder is located in the well pipe in the area where the measurements are to be taken. An actuating mechanism is operable to open and close the arms so that their upper ends bear against the shoulder. The instrument with the latching mechanism is lowered into the well and positioned so that the arms are adjacent the shoulder. The arms are opened to engage the shoulder and the wireline tensioned to prevent whipping of the line as fluid flows past. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of manufacturing an ionic conductor to improve oxygen ion conductivity that would otherwise be reduced by the presence of impurities comprising silicon. More particularly, the present invention relates to such a method in which a solution containing a dissolved salt of an alkaline-earth metal is applied to doped ceria, doped zirconia, doped lanthanum gallate or a stoichiometric mixture of precursor salts or oxides thereof and then decomposed to produce the ionic conductor.
BACKGROUND OF THE INVENTION
[0002] Ionic conductors are formed of ceramic materials that are capable of conducting oxygen ions at elevated temperature and that have a low electronic conductivity. They are used to form electrolytes that are typically used within oxygen generators and solid oxide fuel cells. Such electrolytes are employed in a layered structure that has an anode and a cathode sandwiching the electrolyte. There are other uses for such materials known in the art such as steam electrolyzers and the like.
[0003] In case of an oxygen generator, when an electrical potential is applied across the anode and cathode, oxygen, in an oxygen containing feed, ionizes to produce oxygen ions which are transported through the electrolyte. The oxygen ions emerge from the electrolyte and recombine to form molecular oxygen. In a solid oxide fuel cell, the anode and cathode are connected to an electric load. A fuel is combusted using the permeated oxygen as an oxidizer. The electrons released as a result of the oxygen ions exiting the electrolyte at the anode travel to the electric load and then to the cathode to ionize the oxygen in the oxygen containing feed.
[0004] Oxygen generators, solid oxide fuel cells and like devices use elements having layered anode-electrolyte-cathode structures in the form of flat plates or tubes that are fabricated by known techniques such as isostatic pressing and tape casting. In such methods oxygen ion conducting materials such as doped zirconia or gadolinium doped ceria in the form of a powder are mixed with an organic binder and then molded into the desired shape or onto the anode layer. The anode layer can be a conductive metal such as silver supported by an inert structure or a mixed conductor capable of conducting both oxygen ions and electrons. The resultant green form is fired to burn out the binder and to sinter the materials into a coherent mass. Thereafter, the cathode layer is applied.
[0005] As may be appreciated, to be useful in a practical device, such as an oxygen generator or a solid oxide fuel cell, it is important that the oxygen ion conductivity be the maximum obtainable for a particular material as well as its sintered density and therefore the strength thereof. As mentioned in 106 Solid State Ionics, “Properties of La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF) Double Layer Cathodes on Gadolinium-Doped Cerium Oxide (CGO) Electrolytes I. Role of SiO 2 ”, by Bae et al., pp. 247-253 (1998), silicon in the form of silicon oxides has a ubiquitous presence in all oxides. Such silicon can negatively influence the conductivity of an electrolyte formed of gadolinium-doped cerium oxide (hereinafter “CGO”).
[0006] The need to increase the conductivity of CGO electrolytes, particularly at low temperatures, has been identified in the prior art with respect to solid oxide fuel cells. CGO, while having a high conductivity, is not robust in high temperature reducing atmospheres present in solid oxide fuel cells. Hence, it is necessary to use the CGO for such applications at relatively low temperatures of operation in the neighborhood of 500° C. to 700° C. Moreover, the cost of the solid oxide fuel cell is also reduced by operating it at a lower temperature because less temperature critical components are required. However, at such temperatures, the oxygen ion conductivity becomes particularly critical for CGO. Hence, there exists the need in such applications and operations to maximize the conductivity of CGO.
[0007] In 575 Material Research Society Symposium Proceedings, “Improving Gd-Doped Ceria Electrolytes for Low Temperture Solid Oxide Fuel Cells”, by Ralph et al., pp. 309-314 (2000), the conductivity of CGO having impurities such as silicon dioxide is improved by doping the CGO with calcium. It is suggested in this reference that praseodymium and iron dopants would have the same effect. The calcium-doped CGO having impurities is made by using an amorphous citrate route of preparation. Such preparation is an atomic mixing technique that involves mixing cation salts in proper stoichiometric ratios with citric acid and then dissolving the resultant mixture in water to produce an aqueous solution. The solution is then heated and calcined to form the oxide.
[0008] In Ralph et al., it is mentioned that grain boundary conductivities showed an improvement over the standard CGO samples due to formation of a second phase of reasonably good conductivity as compared with the poor conductivity of the impurity oxides such as SiO 2 . In Ralph et al. the SiO 2 concentration is stated to be less than 20 parts per million.
[0009] In 129 Solid State Ionics, “Appraisal of Ce 1-y Gd y O 2-y/2 Electrolytes for IT-SOFC Operation at 500° C.”, by Steele, pp. 95-110 (2000), it is noted that the use of highly purified powders for CGO and doped zirconia electrolytes, that is an SiO 2 content of less than 50 parts per million in order to obtain sufficient conductivity of the electrolyte material at low temperatures of operation.
[0010] It therefore can be understood from the foregoing references that contaminants such as silicon in the form of silicon oxides act to lower ionic conductivity in CGO and doped zirconia electrolyte materials. In order to operate an SOFC employing an electrolyte formed of CGO and other materials at low temperature, it is necessary that the ionic conducting material making up the electrolyte should be as pure as possible, that is contain a minimum amount of silicon. Furthermore, such pure forms of CGO can be doped to provide a further increase in low temperature conductivity with the use of calcium dopants. As may be appreciated, the same criteria for the use of CGO and YSZ in solid oxide fuel cells applies equally to other similar devices such as oxygen generators.
[0011] In U.S. 2001/0007381 A1, a salt solution containing a transition metal dopant, for instance, iron dissolved in a solution, is applied to purified CGO powder in an amount of about 2 mol %. This treatment reduces the sintering temperature so that a sintered ceramic element with small grain size can be produced having superior strength to untreated CGO.
[0012] It is to be also noted that the purer the electrolyte powder, the higher the costs involved in obtaining the electrolyte. For instance, a powder 99 percent pure costs about 75 percent as much as a powder 99.9 percent pure which in turn costs about 60 percent as much as a powder 99.99 percent pure. Hence, while there exists the general need to raise the oxygen ion conductivity of ion conductors having grain boundary impurities such as silicon or silicon containing compounds, such need is particular acute with particularly low purity oxygen ion conducting materials. If such materials can be made useful by enhancing their ion conductivity, they are particularly advantageous due to their low cost.
[0013] As will be discussed, the present invention provides a method of manufacturing ionic conductor materials that are doped with alkaline-earth metals that enhances the oxygen ion conductivity over that obtainable by prior art manufacturing techniques. In this regard, as will be discussed, such prior art techniques, such as disclosed in the Ralph et al. article are not effective in enhancing the conductivity of low purity ionic conductors such as CGO. Furthermore, an added benefit of the present invention is that the strength of the ionic conducting material is also enhanced.
SUMMARY OF THE INVENTION
[0014] The present invention provides a method of manufacturing an ionic conductor to improve oxygen ion conductivity that is otherwise reduced by the presence of deleterious impurities comprising silicon. In accordance with the invention a salt of a dopant is dissolved into a solvent to form a solution. The dopant consists of an alkaline-earth metal. The solution is applied to an oxygen ion conducting material composed of doped ceria, doped zirconia, or doped lanthanum gallate and having the deleterious impurities. The oxygen ion conducting material is a powder having particles of less than about 100 microns in size. The solution is applied such that a molar ratio of the dopant to total cations within said ionic conductor is between about 0.001 and about 0.1. Further, the solution is mixed with the particles so that the solution uniformly covers the particles. The oxygen ion conducting material is heated with the solution applied thereto to evaporate the solvent and to decompose the salt and thereby to form said ionic conductor.
[0015] In another aspect of the present invention, the solution containing the alkaline-earth metal is applied to a mixture of precursor salts that are substantially insoluble in the solvent or oxides of the constituent cations of an oxygen ion conducting material. The oxygen ion conducting material is composed of doped ceria, doped zirconia, or doped lanthanum gallate and has a silicon content of at least 50 parts per million. The precursor salts or oxides are a powder having particles of less than about 100 microns in size. After application and mixing, the precursor salts or oxides are heated with the solution applied thereto to evaporate the solvent and to decompose the salts or oxides and thereby to form said ionic conductor.
[0016] As mentioned above, the low conductivity exhibited by certain batches of ionic conductors is the result of surface impurities at the grain boundaries. A known impurity that has deleterious effects on conductivity is silicon dioxide. In the prior art, calcium doped CGO with a low silicon content increases the conductivity of the CGO. As will be shown hereinafter, the method of the present invention produces such doped materials with a conductivity that is further enhanced over that obtainable by such prior art atomic mixing techniques as amorphous citrate preparation. In fact, such doping has no or little effect in case of materials with high amounts of silicon impurities, such as above 50 parts per million, while unexpectedly, the present invention can produce a measurable ion conductivity enhancement for such materials.
[0017] Without wishing to be held to any specific theory of operation, it is believed by the inventor herein that the addition of the calcium or other alkaline-earth metal by way of a solution applied to the surface of the particles, as opposed to the prior art atomic mixing, acts to further drive the calcium or other alkaline-earth metal towards the grain boundary and hence, to the surface to provide more of such material to interact with impurities. As will be discussed, the method of manufacturing employed in the present invention also enhances the strength of the conductor.
[0018] The oxygen ion conducting material can be doped cerium dioxide having an average composition given by the chemical formula Ce 1-x M x O 2-d . In this formula, M is Sm, Gd, Y, La, Pr, Sc or mixtures thereof, x is between about 0.03 and 0.5, and the value of d is such that the composition is rendered charge neutral. The molar ratio of the alkaline-earth metal can be between about 0.001 and about 0.05. More preferably, such molar ratio lies between about 0.005 and about 0.025. Preferably, x is between about 0.08 and about 0.25.
[0019] The dopant can preferably be calcium and said oxygen ion conducting material can be the doped cerium dioxide discussed above. Preferably, x can be 0.1 and the molar radio can be 0.01.
[0020] The solution can have about 0.05 molar concentration.
[0021] Where the solution is added to the oxygen ion conducting material, advantageously, the oxygen ion conducting material with solution applied can be formed into a desired configuration before heating the same and then heating said oxygen ion conducting material under conditions sufficient to sinter the ionic conductor. Similarly, in case the solution is added to a mixture of salts or oxides of cations, the mixture with said solution applied can be formed into a desired configuration before heating the same and then heating said mixture with said solution applied under conditions sufficient to sinter the ionic conductor.
[0022] As may be appreciated, such configurations can be a layer applied to an anode or an anode supported by an inert material in the form of a plate or tube. Thus, the ionic conductor and electrolyte layer are formed in one step as opposed to prior art techniques in which the ionic conductor is formed into the desired finished configuration.
[0023] The dopant is preferably calcium or strontium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] While the specification concludes with claims distinctly pointing out the subject matter that Applicant regards as his invention, it is believed that the invention will be better understood when taken in connection with the accompanying drawings in which:
[0025] [0025]FIG. 1 is a graph of conductivity versus temperature of doped oxide ionic conductors manufactured in accordance with an embodiment of the present invention compared with those of the prior art;
[0026] [0026]FIG. 2 is a graph of conductivity versus temperature of doped oxide ionic conductors manufactured in accordance with an alternative embodiment of the present invention compared with those of the prior art; and
[0027] [0027]FIG. 3 is a graph of failure probability versus failure strength of doped oxide ionic conductors of the present invention compared with those of the prior art.
DETAILED DESCRIPTION
[0028] As will be discussed, the present invention has application to improvement of conductivity and strength of oxygen ion conducting materials such as doped ceria (Ce 1-x M x O 2-z ), doped zirconia (Zr 1-x M x O 2-z ), and doped lanthanum gallate (La 1-x A x Ga 1-y B y O 3-z ).
[0029] In accordance with the present invention, a salt of an alkaline-earth metal, preferably calcium or strontium, but also possibly barium or magnesium, is dissolved in a suitable solvent such as water or an alcohol. The salt may be a nitrate, an acetate, an oxalate, a sulfate, a chloride. Most preferably the salt is a nitrate, acetate or oxalate.
[0030] The salt solution is then applied to the oxygen ion conducting material in an amount sufficient to produce a desired molar ratio of the dopant. This molar ratio can be anywhere between about 0.001 and about 0.1. Alternatively, the salt solution can be applied to a mixture of cation salts or oxide salts present in the desired stoichiometric ratio. In case of cation salts, the solvent used to dissolve the dopant should not be effective to also dissolve the cation salts. For example, if calcium nitrate were the dopant salt dissolved in water, appropriate cation salts to make CGO would be cerium carbonate and gadolinium carbonate which would not significantly dissolve in water. In case of cation oxides, a calcium nitrate solution could be added to a mixture of cerium dioxide and gadolinium oxide in the desired proportions.
[0031] The oxygen ion conducting materials and the cation salts should be in a powder form having a particle size of no greater than about 100 microns. It is believed that the smaller the particle, the better the results obtainable in accordance with the present invention. The solution and particles are then thoroughly mixed by such conventional mixing techniques as ball milling so that the solution uniformly covers the surface of the particles.
[0032] The oxygen ion conducting material with solution applied or the cation salts or oxides with solution applied is then heated to evaporate the solvent and then decompose the salt of the solvent or in addition, where applicable cation salts and oxides. In this regard, the “heating” can be ambient heating in case of the solvent removal and then added heating for decomposition purposes. The “heating” can be accomplished in one step. The resultant ionic conductor can be ground into a powder and then formed into the desired configuration of the electrolyte. Advantageously, the oxygen ion conducting material or cation salts or oxides thereof with dopant solution applied can be formed into a desired configuration, for instance, a tubular layer or flat plate, and then heated to evaporate the solvent, decompose the dopant salt, the electrolyte cation salt or the cation oxide. If necessary a suitable organic binder can be mixed with the oxygen ion conducting material or cation salts or oxides prior to the formation of the same. Thereafter, further heating can be applied to form a sintered ceramic layer or form of the ionic conductor in a desired shape.
[0033] A particularly preferred ionic conductor in accordance with the present invention is calcium-doped CGO. This can be formed by the addition of calcium nitrate to a doped cerium dioxide having a composition given by the formula Ce 1-x M x O 2-d . where M is one or a mixture of Sm, Gd, Y, La, Pr, Sc, (most preferably Sm, Gd or Y) and x is between about 0.03 and about 0.5 and more preferably, between 0.08 and 0.25. The value of d is such that the composition is rendered charge neutral. A preferred oxygen ion conducting material has a composition given be the chemical formula Ce 0.9 Gd 0.1 O 2-d (the value of d is such that the composition is rendered charge neutral).
[0034] Preferably, 1 cation percent calcium is added to a doped ceria oxygen ion conducting material. Additions of calcium of between about 0.01 cation percent and about 10 cation percent are encompassed within the present invention. A preferred range is between about 0.1 and about 5 cation percent and a particularly preferred range is between about 0.5 cation percent and about 2.5 cation percent. The foregoing is preferably accomplished with a solution of 0.05 molar concentration.
[0035] As mentioned above, after the solution is added to the oxygen ion conducting material, the solvent may be evaporated by ambient heat or by addition of external heat. Thereafter, the calcium nitrate can be decomposed by further heating to a temperature of about 650° C.
[0036] As also mentioned above, the solution-treated electrolyte substance or cation salts or oxides can be heated to sintering after having been formed into a desired shape or configuration. In this regard, the heating conditions can be at a temperature of between about 1250° C. and about 1700° C. that is maintained for between about 5 minutes and about 24 hours, depending upon the thickness and size of the configured ionic conductor. More optimal heating conditions are between about 1350° C. and about 1550° C. for between about 1 and about 10 hours. Heating conditions of between about 1400° C. and about 1500° C. are particularly preferred for most configurations of ionic conductors in accordance with the present invention that are applied to ceramic membrane elements within oxygen generators. In all of the foregoing ranges, temperatures are obtained and cool down is accomplished at heating or cooling rates of about 2° C./minute.
[0037] With reference to FIG. 1, several ionic conductors were tested to illustrate the application of the present invention to doped-CGO oxygen ion conducting materials having a high silicon content, that is between about 100 and 300 parts per million and a low silicon content, less then 50 parts per million. In all tests, testing samples were prepared by first pressing about 2.5 grams of powder into a die to produce a green test pellet form having a diameter of about 13 mm and a thickness of about 5 mm. The green test pellet form was then heated at 2° C. to 1400° C. and held for four hours and then cooled back to ambient temperature at 2° C. per minute to produce a sintered test pellet. The sintered test pellet was then tested for oxygen ion conductivity using an AC impedance spectroscope. Strength testing was accomplished by an electromechanical test apparatus in four point bend configuration according to ASTM Standard C1161.
[0038] In samples prepared in accordance with the present invention, the formation of calcium-doped CGO referred to in FIG. 1 as CGO 5 is illustrative of the preparation in accordance with the present invention. In preparing this particular sample, a gadolinium doped cerium dioxide powder of composition Ce 0.9 Gd 0.1 O 2-d (the value of d is such that the composition is rendered charge neutral) was obtained from Praxair Specialty Chemicals, Seattle, Wash., United States of America. The powder had a high silicon content of between about 100 parts per million and about 300 parts per million.
[0039] Calcium nitrate was dissolved in water to produce an aqueous solution of 0.05 molar concentration. It is to be noted that ethanol is another suitable, preferred solvent. The solution was added to the CGO powder in an amount such that the molar ratio of calcium cation content to total cation content (Ce+M+Ca) was 0.01 (1 cation % calcium).
[0040] The CGO powder with solution applied was then mixed using ball-milling to ensure homogenous distribution of the dissolved calcium salt throughout the suspension of doped cerium dioxide powder.
[0041] After ball-milling, the water was allowed to evaporate to leave a CGO powder that had a coating of the calcium salt homogeneously distributed over the surface of CGO particles. As may be appreciated, solvent removal could be enhanced by heating or possibly filtering. The treated powder was then loaded into the die and formed into the test pellet as described above.
[0042] The data points defined by reference CGO 1 represent tests conducted on commercially available CGO (Ce 0.9 Gd 0.1 O 2-x ) with a high conductivity and therefore, a low silicon content of less than about 50 parts per million.
[0043] The CGO 2 sample is commercially available CGO (Ce 0.9 Gd 0.1 O 2-x ) with a low conductivity produced by a high silicon content of between about 100 parts per million and about 300 part per million. As expected, it exhibits very low conductivity over the temperature range. When CGO 2 is treated in accordance with the present invention by doping it with the use of a strontium nitrate solution in the amount of 1 cation percent, it becomes CGO 3 , a material having a conductivity that is essentially the same as CGO 1 .
[0044] Hence, a treatment in accordance with the present invention increases conductivity of high silicon content CGO to that obtainable in low silicon content CGO. Unexpectedly, a treatment in accordance with the present invention also increases the conductivity of doped CGO having a high silicon content over that obtainable by prior art techniques involving atomic mixing. In this regard, CGO 6 is commercially available CGO having a low conductivity produced by a high silicon content of about 100 parts per million in which strontium is added by atomic mixing prior art techniques, such as combustion synthesis of a solution of dissolved metal salts, to produce (Ce 0.9 Gd 0.1 ) 0.995 Sr 0.005 O 2-x . It has a conductivity near that of sample CGO 2 . This is to be compared with sample CGO 9 which was prepared by treating a sample identical to CGO 2 in accordance with the present invention by the addition of 0.5 cation percent strontium added as strontium nitrate solution. Its conductivity over the temperature range is measurably in excess of CGO 6 .
[0045] Sample CGO 4 was prepared by treating CGO 2 with 0.5 cation percent calcium added in a calcium nitrate solution in accordance with the present invention. Its conductivity is not as great as CGO 5 which is CGO 2 with 1 cation percent calcium added as calcium nitrate solution.
[0046] Sample CGO 7 was prepared by treating CGO 2 with a transition metal, namely cobalt, at a level of 2 cation percent added as cobalt nitrate solution and CGO 8 is CGO 2 treated in accordance with the present invention with 1 cation percent cobalt added as cobalt nitrate solution and 1 cation percent calcium added as a nitrate solution. As is apparent the presence of the alkaline-earth metal demonstrably increases conductivity over the temperature range as compared with the use of a transition metal dopant alone and in greater quantities.
[0047] [0047]FIG. 2 displays the advantages of treating cation oxides used in forming CGO in accordance with the present invention to produce CGO doped with an alkaline-earth metal where such cation oxides contain silicon impurities at a level of about 100 parts per million. Sample CGO 11 is a sintered mixture of commercially available cerium dioxide and gadolinium oxide powders to yield CGO having an average composition given by the chemical formula Ce 0.9 Gd 0.1 O 2-x . It has a high silicon content of between about 100 and about 300 parts per million. As expected, the resultant ionic conductor has the lowest conductivities over the temperature range. Sample CGO 12 is a sintered mixture of commercially available cerium dioxide and gadolinium oxide powders used in the preparation of CGO 11 treated in accordance with the present invention with 1 cation percent calcium added as calcium nitrate solution. This produced a calcium doped CGO having an average composition given by the chemical formula: (Ce 0.9 Gd 0.1 ) 0.99 Ca 0.01 O 2-x . As illustrated, the treated sample has the highest conductivities over the temperature range. This is to be compared with CGO 13 which is a sintered mixture of commercially available cerium dioxide, gadolinium oxide used in the preparation of CGO 11 and strontium carbonate. This yielded a strontium doped CGO having an average composition given by the chemical formula: (Ce 0.9 Gd 0.1 ) 0.99 Sr 0.01 O 2-x . The CGO 11 sample has lower conductivities over the temperature range than CGO 12 which is unexpected given the fact that the 1 percent strontium and calcium-doped CGO in which CGO powder was treated in accordance with the present invention (CGO 3 and CGO 5 ) had similar conductivities. Thus, the treatment in accordance with the present invention increases the conductivity over that which could be expected by the addition of an alkaline-earth metal alone.
[0048] The forgoing samples were examined with the use of an energy dispersive X-ray analysis in a scanning electron microscope. Within the accuracy of measurement it was found that there were no uneven distributions of dopants apart from the interactions found between calcium and strontium species and silicon at the grain boundaries which was expected given the presumptive operative mechanisms of the present invention. As such, the results for CGO 11 of FIG. 2 would be similar for an atomic mixing preparation of such sample that has been disclosed in Ralph et al., discussed above. Moreover, when sample CGO 5 , that utilized a more contaminated CGO than Ralph et al. was compared with the graphically depicted results of this reference, it was also found that CGO 5 had conductivites slightly above those of Ralph et al.
[0049] With reference to FIG. 3, it can be seen that production in accordance with the present invention as evidenced by CGO 5 increases the ultimate failure strength of the ionic conductor as compared with CGO 1 (the high conductivity CGO) and CGO 2 (the low conductivity CGO.) Hence, it can be said that the present invention not only raises the conductivity of high silicon containing ionic conductors but also has the added advantage of increasing their strength.
[0050] While the present invention has been described with reference to preferred embodiment, as will occur to those skilled in the art, numerous changes, additions and omissions can be made without departing from the spirit and scope of the present invention. | A method of manufacturing an ionic conductor to improve oxygen ion conductivity that is otherwise reduced by the presence of deleterious impurities comprising silicon or silicon containing compounds. In accordance with the invention a dissolved salt of a dopant consisting of an alkaline-earth metal is applied to an oxygen ion conducting material composed of doped ceria, doped zirconia, or doped lanthanum gallate and having the impurities. The solution can also be applied with equal success to cation salts and oxides used in making the oxygen ion conducting material. The oxygen ion conducting material with the solution applied thereto is thoroughly mixed and then heated to evaporate the solvent and to decompose the alkaline-earth salt and thereby to form said ionic conductor. | 7 |
RELATED APPLICATION
This application is a continuation of my application Ser. No. 221,554, filed on Dec. 31, 1980 abandoned.
FIELD OF THE INVENTION
This invention relates generally to the production of uranium and more particularly to the regeneration of ion exchange resins which are employed in the recovery of uranium from a pregnant leachate formed in an in situ leaching operation. More specifically yet, the present invention relates to the regeneration of such resins which have become poisoned with polythionate.
BACKGROUND OF THE INVENTION
The leachate from in situ uranium leaching processes most always contains some polythionates. Polythionate concentration is particularly high where the gangue materials are rich in sulfides, such as pyrites. The polythionate concentration is also higher in the early stage of leaching operation. When the leachate is passed over the ion exchange resin for uranium recovery, the polythionates are also adsorbed on the resin strongly. The polythionate adsorption is so strong that they cannot be eluted along with the uranium in the normal elution cycle and become a poison to decrease the uranium loading capacity of the resin in the following loading cycles.
Use of H 2 O 2 or strong caustic solution has been suggested for regeneration of polythionate poisoned resins. However, both procedures attack the resin chemically and physically resulting in shortened resin life.
In application Ser. No. 270,303 abandon filed concurrently herewith by Hans-Peter C. Schmiedel and commonly assigned, there is disclosed and claimed a new process for controlling polythionate poisoning of the ion exchange resin. The process involves treating the poisoned resin with a solution of Na 2 SO 3 , preferably 0.1 M, which may also contain another non-reacting salt, e.g. NaCl. The reaction may be represented as follows:
S.sub.n O.sub.6.sup.= +(n-3)SO.sub.3.sup.= →S.sub.3 O.sub.6.sup.= +(n-3)S.sub.2 O.sub.3.sup.=,
wherein n is typically 4-8, usually 4.
The treated resin is then eluted with acidic or neutral eluant to remove the conversion products, namely, thiosulfate and polythionates with 3 or less sulfur atoms per molecule. The procedure requires interruption of normal operation schedules so that the sulfite treatment can be carried out. It was believed important to avoid contacting sulfite, being a reducing agent, with the uranium complex in order that the uranium at +6 state will not be reduced and precipitated.
The improved process of the Schmiedel application offers a number of important advantages, however, including avoidance of undesirable physical and chemical degradation of the resin as had been associated with previous attempts to reduce polythionate poisoning. The entire disclosure of that application is incorporated herein by reference.
DESCRIPTION OF THE INVENTION
The present invention is an improvement on the above-discussed process of Schmiedel and is based on the discovery that polythionate accumulation can be prevented by adding sulfite ion directly to the eluant or, alternatively, directly to the leachate without reducing the uranium from its soluble hexavalent to its insoluble tetravalent state. This finding is totally unexpected in view of the known reducing properties of sulfite ion. Thus, surprisingly, I have discovered that:
(1) Sulfite does not reduce and precipitate the uranium complexes both on the resin and in the leachate solution, and
(2) Sulfite is a good eluting agent, perhaps as good as carbonate ion.
This invention therefore provides a process for the regeneration of polythionate poisoned ion exchange resins which does not damage the resins chemically and physically and which can be carried out intermittently or continuously in-line without disrupting the operation schedules and adding new operational steps. Moreover, the process permits regenerating resin without producing hazardous wastes requiring disposal.
The present invention is based on this discovery and includes processes for regenerating polythionate poisoned resin in situ, continuously or intermittently, by adding SO 2 or sulfites to the eluant or to the leachate. Preferably essentially stoichiometric amounts are added. The sulfite can be added as a sulfite salt (e.g. Na 2 SO 3 , etc.) or as SO 2 gas. It can be added uniformly in the eluant, or it can be injected as a slug at the beginning of the elution cycle. If acid elution (HCl/NaCl solution) is used, it is preferred to add SO 3 = as a slug at the start of the elution cycle. If an excess amount of SO 3 = is added, SO 3 = will be present in the eluate and consume extra H 2 O 2 in the subsequent precipitation step. The SO 3 = injection can be carried out as frequently as it is required to keep the resin essentially free of polythionate poisoning.
Similarly, a stoichiometric amount of SO 3 = may be added to the leachate (feed to the ion exchanger) continuously or intermittently as slugs. Injection in the form of a slug is preferred. The slug size can range from 1/100 to 10 bed volumes. The SO 3 = can be in the form of a sulfite salt or as SO 2 . Addition of SO 2 lowers the pH of the leachate, which also improves uranium loading capacity of the resin. Excess amount of SO 3 = injection should be avoided because it can be present in the barren leachate and recycled to the formation or retained in the resin and eluted in the elution cycle. Extra O 2 consumption in the leaching will result for the former case, and extra H 2 O 2 consumption in precipitation will result for the latter case.
The invention offers important industrial advantages by providing an overall more effective uranium recovery process. That is, uranium leakage and loss are minimized, resin loading capacity is increased, ultimate life of the resin is prolonged, and a lower operation cost is achieved.
The foregong description of my invention has been directed to particular details in accordance with the requirements of the Patent Act and for purposes of explanation and illustration. It will be apparent, however, to those skilled in this art that many modifications and changes may be made without departing from the scope and spirit of the invention. It is further apparent that persons of ordinary skill in this art will, on the basis of this disclosure, be able to practice the invention within a broad range of process conditions. It is my intention in the following claims to cover all such equivalent modifications and variations as fall within the true scope and spirit of my invention. | A process is described for minimizing accumulation of undesirable polythionates on an ion exchange resin used to recover uranium values from a leachate from an in situ mining operation by adding sulfite, either as a sulfite salt or as SO 2 , directly to the leachate or to the eluant. | 2 |
BACKGROUND OF THE INVENTION
There are currently serious economic and safety factor problems encountered in procedures for handling the bleaching agent sodium hydrosulfite in certain mills and in related applications. The problem arises especially among textile manufacturers who desire to feed all components automatically to dyeing operations. The use of liquid feeds is essential for computer controlled, fully automated operation. Sodium hydrosulfite is today delivered to a textile mill, for example, in relatively small quantities of liquid, say approximately 4,000 and 6,000 pounds. To maintain the liquid sodium hydrosulfite in such a state, relatively large quantities of caustic soda are now mixed into this solution, say, approximately one weight percent concentration. Even so, the stability and storage life of the solution is on the order of days only since there is significant sodium hydrosulfite reduction. The concentration of solution at use time is now often significantly different from that at the time of mixing or delivery. Close coordination of delivery and stock depletion with mill shut-downs, vacation times, etc., naturally pose significant problems.
SUMMARY OF THE INVENTION
The invention provides a solution to the problems experienced with prior art apparatus and methods for handling sodium hydrosulfite. The pure dry chemical may be stored at the site in large quantities for up to three months. As the aqueous solution is required, the chemical may be metered into a mixing tank with a metered quantity of water and caustic soda solution to provide an essentially pure solution which may be metered out as required for on site use. Due to the purity of the dry chemical, resultant solution contains substantially less stabilizing caustic soda, relative to the amount of water, than found in previously available commercial compositions, yet because of the continuous manufacture of the solution, decomposition of the sodium hydrosulfite is minimized.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE illustrates a schematic of the inventive apparatus used to produce the sodium hydrosulfite solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The system consists of semi-bulk returnable shipping containers and unloading stands, a dry chemical feeder, caustic pump, fluid controls, a densimeter for monitoring and trimming solution strength, a dissolver tank and a vertical storage tank from which the solution is drawn to process. A typical arrangement is shown in the FIGURE.
Referring to the FIGURE, sodium hydrosulfite is delivered to a mill site location in dry or powder form in any bulk quantities desired. For example, 3,500 lb. quantities have been delivered with satisfactory storage and handling results. Sodium hydrosulfite 1 thus delivered is contained at one-site location in commercially available, returnable containers 2. As indicated, the sodium hydrosulfite can be stored in container 2 in its dry state for as long as 3 months. To protect the sodium hydrosulfite in container 2 from air, moisture and other reducing elements, a sliding door 3 is disposed at the bottom of the container and a sealed barrel closure 4 at the top. The door 3 may be open as indicated by the arrow and shut at the termination of use to seal the container 2 airtight.
Dry sodium hydrosulfite 1 delivered to the mill site in container 2 is disposed above motorized conveyor feeder 5. A series of containers 2 can be, of course, placed in a row with a conveyor belt, not shown, thereunder, the belt being controllably operable to deliver the dry sodium hydrosulfite to the feeder 5. From feeder 5, the dry powder is directed to the dissolver tank 6 which then mixes the sodium hydrosulfite with caustic solution by stirring with mixer 7. The dissolver tank is covered except for the openings to admit caustic soda and water, via line 10, sodium hydrosulfite via feeder 5 and sample solution via line 37. This minimizes contact with the atmosphere and resultant reduction of the solution. The mixing operation may be conducted satisfactorily in a temperature range of from 32° to 110°F.
Liquid caustic soda is moved by pump 8 through pipe 9 directly into a steady stream of water flowing in pipe 10. The water flows through meter 11 and valve 12 to mix with the caustic soda at point 13. A level control 14 automatically reads the level in dissolver tank 6 and controls the solution input to the desired level by coaction with valve 12. Meter 15 shows the liquid level.
Meter 11 sends a pulse signal to pre-amplifier 16 and via scaler 17 to the blend ratio controller 18. A signal is also directed from pre-amplifier 16 via processing circuitry 19 to recorder 20. Blend ratio controller 18 produces two outputs, one to the controller 21 for caustic soda pump 8 and one to the controller 22 for conveyor feeder 5. Controller 21 may comprise a driver unit 23 and a relay 24, as shown. Controller 22 may comprise a trim unit 25, pulse to current converter 26 and rectifier 27. Thus the appropriate amounts of caustic soda and sodium hydrosulfite are metered into the dissolver tank 6 in proportion to the amount of water passing meter 11. concentrations to within ± 2.5 weight percent can be maintained in this system. When valve 12 shuts in response to a high level signal from level control 14, no output is produced by blend ratio controller 18, and the feeder 5 stops.
The sodium hydrosulfite in solution may then be delivered via pump 28 and pipe 29 directly to the point of application if desired. However, it is preferred to use a covered and vented storage tank 30 wherein the stabilized sodium hydrosulfite solution is held prior to delivery to the in-plant locations through pipe 31. Tank 30 may be refrigerated if extended storage is anticipated prior to use. A storage tank level control 32 can be placed in connection with the storage tank 30 which by preselected control of valve 33 may control the volume of solution in the tank. Meter 35 shows the level in the storage tank. Obviously, if valve 33 is restricted or switched into a non-flow state, the level in dissolver tank 6 will increase to a point at which level control 14 will adjust valve 12.
In connection with solution flow pipe 29, there is provided a densimeter 36 for sensing the density of the solution. A sample line 37 recycles the sample flow back to the dissolver tank 6. The output from the densimeter is directed via processing circuitry 38 to recorder 20. The output from circuitry 38 is also directed via density alarm 39 to density controller 40. If the density of the mixture leaving tank 6 is at variance with the setpoint of controller 40, a signal is transmitted to trim unit 25 which may be set to adjust the speed of feeder 5 within, say, plus or minus 10% of the setting of blend ratio controller 18. When the density is beyond this range, alarm 39 may be set to actuate and to close valve 33 via solenoid 34, as indicated. At such a time, the operator could perform any necessary trouble shooting operations to return the system to automatic operation, or operate the feeder manually until the problem is rectified.
In practice, the following commercially available components have been found acceptable for use in this system, though one skilled in the art will appreciate that many variations are possible within the scope of this invention:
Element in Figure Available Component______________________________________11 Foxboro M/81SFSC3, 1/2inch 12, 33 Foxboro M/V4A Needle 14, 32 Foxboro M/13FA-MS315 W/1AS-F 15, 35 Foxboro M/43A-A4 W/PC3-1516 Foxboro A2020LA W/A2021BZ17 Foxboro M/99M-100SP18 Foxboro M/99M-21219 Foxboro M/FR316C-5-2, M/FR316C-5 with large capacitor output network20 Foxboro M/6420 HF-023 Foxboro M/99M-73124 Foxboro A9374625 Foxboro M/99M-720H26 Foxboro M/FR316C-5-238 Foxboro M/66BT39 Foxboro M63U-BT-OHEA40 Foxboro M/62H-4E-O______________________________________
This listing is merely representative and components not listed may be selected as needed by one of ordinary skill in the art.
OPERATION
Once a container 2 is placed on the stand and its slide gate 3 removed, feeder 5 will proportion the hydrosulfite into the caustic-water solution, both chemical feed rates being automatically paced with the inlet water flow, as discussed. The solution will then be pumped to storage tank 30 in which a constant level will be maintained. By operating with essentially constant level in the dissolver tank and the storage tank and minimizing flow of air over the surface of the liquids in these tanks, the solution and the samll volume of air essentially trapped under the tank covers interact to form a primarily nitrogen atmosphere over the solution, thus minimizing further reduction of the solution during continued system operation. From the storage tank, the solution will be withdrawn either by gravity or will be pumped through liquid meters to the application points.
Under normal conditions tank 6 is sized so that at the maximum feed rate approximately fifteen minutes are required as a minimum for complete solution of sodium hydrosulfite in caustic to form a solution containing 1% caustic and 15% sodium hydrosulfite by weight. Tank 30 is sized to provide 1 to 2 hour's reserve supply for a particular plant in the event that the feed system is shut down for minor repairs.
Feeder and fluid controls will all meet the specified accuracy over a 10/1 span, i.e., if the normal draw is 100 pounds per hour, the system will supply solutions containing 20 to 200 pounds of dry product without adjustment. Manual resets can be used to move the control range upward on demand. Recorded signals will be the solution density, and the solution flow-rate. Alarms also may be installed on the caustic pump output and holding tank 30 level.
In solutions having a concentration of sodium hydrosulfite varying from between 0.2% to 15% by weight, it is necessary to use only approximately 1% by weight caustic soda. This low caustic soda ingredient is made possible since the sodium hydrosulfite solution is available for use almost immediately after mixing. Thus, no time exposure to air and other reducing elements occurs. The concentration of solution at the use point and in the original mixture is almost identical. Prior known commercial solutions had a maximum of 11% by weight of the sodium hydrosulfite because refrigeration was required and included from 0.9% to 1.1% caustic soda. Concentration of the prior art solutions at the use point is unreliable.
A typical solution which has been found to be highly satisfactory in the practice of the invention is:
Na.sub.2 S.sub.2 O.sub.4 10.0% (by weight)NaOH 1.0%Inerts 0.8%Water 88.2%
With a concentration of 0.2% to 15% by weight of sodium hydrosulfite and approximately 1.0% by weight sodium hydroxide, water from 82.8% to 98.78% by weight and inert from 0.016% to 1.2% by weight may be used with satisfactory results. This solution, which has a saturation temperature of less than 34°F., has a stability factor of less than 2% decomposition in 48 hours at 90°F; with the initial pH factor of 11.7 and the initial specific gravity of 1.0925. Because pure sodium hydrosulfite may be used in this system, the solution has approximately 5% less impurities than known commercial solutions, which do not use the pure chemical due to the instability of the solution and associated problems of shipment and storage. The solution may be used with pH factor in the range of 8.0 to 12, with acceptable results.
Among the advantages achieved through the practice of the invention are the following:
A. The complete system is competitive from a materials handling viewpoint with liquid sodium hydrosulfite, and offers some additional benefits. The inventory and delivery frequency problem resulting from the transportation of small quantities (4000-6000 pounds) liquid sodium hydrosulfite is eliminated, as the mill now may take truckloads in 35,000 pound quantities. Inventory of the dry chemical is stable and can be kept 3 months. Shutdowns for maintenance and/or for vacation periods to not require tight coordination of inventory depletion and quitting time; and start-ups are not dependent upon delivery of a new load of hydrosulfite on the day preceding the beginning of operation. Further, this system may be operated without the use of either a nitrogen blanket or refrigeration as required in the prior art systems. Finally, the on-site prepared hydrosulfite solution is essentially pure sodium hydrosulfite and caustic soda. Because the solution is pure it can be delivered to the point of application in the mill with a loss no greater than 1 percent.
B. Economically, the container 2 contains 3500 pounds net weight, or the equivalent of 14 drums (250-100 pound net) of sodium hydrosulfite. The container may be designed to be handled with a fork-lift truck and, hence, labor for materials handling during unloading and in-plant movement will be reduced to a minimum. Larger containers of up to 5000 pounds net may also be used. At present, savings of 0.4 cents per pound are possible by replacing manual handling with a lift truck operation.
C. The cost of weighing, hand-carrying, and dumping small charges of hydrosulfite can be eliminated. Savings of 0.5 cents a pound are possible in many cases by using fluid meters in place of hand-batching methods.
D. Losses of hydrosulfite through decomposition can be reduced to a negligible value. In many textile mills, batch mixtures of sodium hydrosulfite and caustic soda are prepared. Although initially these solutions are quite stable, during the time between preparation and use, losses of 5 percent may occur as a result of air contamination. This FIGURE will vary in different mills and primarily is a function of the amount and time the solutions are in contact with air. Assuming the 5 percent loss is typical of a batch system and 1 percent in a continuous system, savings of 4 percent or 1.2 cents per pound will be available.
E. Since the solution will be delivered directly to continuous textile mill ranges, the amount of reduction will be constant and end-to-end color matching is better than that obtained with solutions prepared batchwise. | Apparatus and method are disclosed for continuously handling sodium hydrosulfite for use in textile dyeing including means for receiving the pure dry chemical in semi-bulk returnable containers, for dissolving the same in a caustic solution and for storing the resulting solution in low inventory automatic make-up tanks. The novel resulting solution is stabilized against decomposition and may be metered to specified locations in the textile mill. | 3 |
BACKGROUND OF THE INVENTION
Previous bank night depository closures involved rotating or oscillating doors, straight line movable ejectors, and/or complicated lever and cam mechanisms for controlling the same, with and without special mechanisms for preventing unauthorized access and/or reversible movement of such closures.
SUMMARY OF THE INVENTION
Generally speaking, the night depository closure of this invention is for the opening at the upper end of a chute which passes through a wall in a bank and opens into a safe or vault type receptacle that can only be opened by authorized personnel. The closure in the bank wall is manually operable by customers or depositors of the bank, and is journalled in a frame around the opening in the wall. This frame may contain a light source and/or a key lock for illuminating and locking the closure, respectively. This closure comprises a sector shaped door whose axis is pivoted horizontally along the lower edge of the frame, and when opened exposes a pocket in its arcuate side into which parcels and envelopes can be dropped. Separate parallel closures may be provided for parcels and letters. As the door is rocked closed, the parcel dropped therein is ejected into the chute and falls into the safe receptacle. In order to prevent unauthorized access into this safe through the sector shaped door, there are provided means whereby the door cannot be jammed or reversed in its movements and after each closing to scrape off the walls of its pocket into the chute.
A pull type handle is provided on the outer angle side of the sector shaped door and the other angle side of the sector is provided with a pivoted wall which forms the pocket for the parcels to be deposited, which pivoted wall moves to eject and scrape out the contents of the pocket when the door is closed.
The pivots for the door comprise trunnions which may be retracted by cam slots moved by bowden type wires with knobs preferably located inside the safe type receptacle so that access for removing the door can only be had by authorized personnel. Once the trunnions are axially retracted, the door may be pulled out of the opening in the top of the chute by means of its handle thereon, so that easy access may be had to its lever, ratchet and bolt locking mechanisms for maintenance and repairs. Around each of the trunnions are provided hardened freely rotatable rings so that if a saw blade is placed between the frame and the door it cannot get a bite on the trunnions.
The key locking mechanism may comprise a tumbler type lock with a special key so that the tumbler may be removed, and the lock housing unscrewed for access to a double pronged connector for its removal from a pinion that operates a rack type bolt that engages a seat in the side of the sector shaped door.
The arcuate side of the sector shaped door, and of the wall of pocket therein are preferably grooved to mesh with each other and with grooves in the top of the frame, so that as the door is moved there is a type of interfitting combing of the inner surfaces of the pocket walls for scraping out anything that may adhere to the pocket walls.
A lever is pivotally mounted on one or both sector shaped sides of the movable door and is connected by a pin in a slot in the movable wall of the pocket, which lever co-acts with stops mounted in the frame and with a depending spring-urged ratchet pivoted to the frame. Between the pin or shaft on the lever that rides in the slot in the pocket wall and the movable door is an outwardly urged link which may be damped which acts as a toggle for insuring two extreme positions of the pocket wall, namely its open and closed pocket positions. Fixed stops on the frame limit the relative movements of the door and lever to move the pocket wall between its extreme positions only during the movement of the door when the pocket therein is inside the frame and not visible to the customer. An additional pin on the lever engages the spring pressed toothed or notched ratchet to prevent the reverse movement of the door once the pocket is invisible to the customer. This ratchet also has teeth to prevent opening of the door in the event that the toggle and/or ratchet spring is reversed or jammed, such as by a wire being inserted surreptitiously between the grooves of the door and hooking on these mechanisms.
OBJECTS AND ADVANTAGES
Accordingly, it is an object of this invention to produce a simple, efficient, effective, corrosion resistant, easily repairable, and burglar proof night depository closure for banks, and the like.
Another object is to provide such a closure having a mechanism of relatively few moving parts which is strong and resists unauthorized access, and is completely mechanically and manually operable by the customers.
Another object is to provide a depository closure which cannot be reversed once the compartment or pocket for the receptacle has been moved towards its closed position out of view of the depositor or customer, and to provide means for wiping the walls of the pocket before it can be opened again to insure that no parcel from a preceding depositor is stuck in the pocket for a succeeding depositor.
Another object is to provide a night depository closure that will prevent opening thereof if its mechanism has been tampered to move its mechanism out of its normal operative positions.
Still another object is to provide a depository closure which exposes no crevices into which tools may be wedged or pried to try to gain or force unauthorized access to the safe type receptacle below it.
BRIEF DESCRIPTION OF THE VIEWS
The above mentioned and other features, objects and advantages, and a manner of obtaining them are described more specifically below by reference to embodiments of this invention shown in the accompanying drawings wherein:
FIG. I is a left front side perspective view of one embodiment of a night depository according to this invention, showing its attached chute and safe type receptacle, with parts of the walls broken away;
FIG. II is a right front perspective view of the closure shown in FIG. I, with its letter closure open and a letter in dotted lines being inserted therein;
FIG. III is a perspective view similar to FIG. II but of an embodiment without a separate letter closure and showing the parcel closure in its open position and a parcel in dotted lines being inserted therein;
FIG. IV is a vertical sectional view taken along line IV--IV of FIG. I, showing the sector shaped closure door closed with its pocket wall in its parcel ejecting position;
FIG. V is a sectional view similar to FIG. IV, showing the door partially opened, and the ejecting pocket wall being scraped off against the top of the closure frame;
FIG. VI is a sectional view similar to FIGS. IV and V, with the door three-quarters open, and the pocket ejecting wall partially retracted;
FIG. VII is a sectional view similar to FIG. IV but with the door completely opened and a parcel being dropped into the completely opened pocket therein, as also shown in FIG. III;
FIG. VIII is a sectional view similar to FIG. VI in which a parcel has been placed in the pocket in the door and the door has been partly closed to the position where the pocket is invisible and the ratchet engages a pin on a lever to prevent reopening of the door;
FIG. IX is a sectional view similar to FIG. IV in which the door is substantially closed and the pocket wall has moved to eject the parcel from the pocket into the chute;
FIG. X is an enlarged sectional view taken along line X--X of FIG. IV or V showing interfitting scraping grooves of door, frame and pocket wall;
FIG. XI is a rear view taken along line XI--XI of FIG. VI showing the locations of toggle, levers, ratchets and stops with respect to the frame and movable wall of the pocket;
FIG. XII is a sectional view similar to FIG. IV but on a slightly reduced scale, showing the removal of the door from the frame;
FIG. XIII is an enlarged sectional view taken along line XIII--XIII of FIG. I showing the cam mechanism for retracting a trunnion pivot at the side of the door frame, the trunnion being extended to its door supporting and pivoting position;
FIG. XIV is a view similar to FIG. XIII and taken along line XIV--XIV in FIG. XII, showing the cam in its other or trunnion retracted position for the removement of the door;
FIG. XV is an enlarged sectional view along line XV--XV of FIG. XII of the shaft for the letter depository as shown in FIGS. I and II, showing the retractable parcel-pocket trunnion on the left end of the unscrewable shaft for the letter closure;
FIG. XVI is a sectional view taken along line XVI--XVI of FIG. XV showing how the shaft is locked into position;
FIG. XVII is an enlarged front view of the lock shown at the left side of the frame in FIGS. I, II, and III;
FIG. XVIII is a vertical sectional view taken along line XVIII--XVIII of FIG. XVII showing the lock mechanism including the tumbler lock, double pronged connector, and pinion for operating the rack bolt;
FIG. XIX is a horizontal sectional view taken along line XIX--XIX of FIG. XVIII showing how the tumbler lock can be locked into its housing by set screw; and
FIG. XX is a vertical sectional view taken along line XX--XX of FIG. XVIII showing the rack and pinion for operating the bolt lock for the door.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A. Depository in General
Referring first to FIG. I, there is shown a wall 30 of a building such as a bank, inside of which wall may be located a safe type of receptacle 32. The wall 30 is provided with an opening 34 (see FIG. IV) into which is anchored a rectangular frame 40 and from which frame extends a duct or chute 36 completely enclosed and sealed to an opening into the top of the safe or receptacle 32. An electric conduit 38 may be connected to the frame 40 for supplying electricity to a bulb for illuminating the sign "Depository" in the top of the frame 40, and/or also for illuminating the front of openable closures 50 and 52 for parcels P (see FIG. III) and letters L (see FIG. II), respectively. The closure or door 50 may be locked and unlocked by a key K in a tumbler lock 44 mounted in the outside surface of the frame 40.
Thus a customer or a depositor, after banking hours, that has a key K may unlock the larger closure 50 for depositing a large amount of cash or a parcel P by pulling open the door 50 until a pocket appears therein, drop the parcel P in the pocket, and then close the door, and relock it with the key K so the key K can be withdrawn from the lock 44. On the other hand, a customer which only has the letter, envelope or small parcel L to deposit, may open the smaller door 52, which similarly is provided with a pocket into which a letter L may be dropped, and then close the door.
The mechanism of the closure 50 or 52 of this invention prevents the access into the chute 36 and thus into the vault 32, and even access into the pockets in the doors 50 and 52, after the pockets are closed sufficiently to be out of view. It is this mechanism that will now be described in detail in the following sections.
The frame 40 may be faced with a stainless steel or other durable attractive face plate 41. Near the bottom of the frame 40 is an arcuate trough 43 as shown in FIGS. IV through IX, XI and XII concentric with the axis 62 of the sector door 60. This trough 43 is provided with drain holes 45 to prevent rain and weather from getting into the chute 36 and safe 32. As previously stated, the upper part of the frame 40 may be provided with a light such as a flurorescent lamp 46 shown in FIGS. IV through IX energized via the electric cable 38 shown in FIG. I, which lamp 46 may illuminate the front handle-side 64 of the closures 50 and/or 52 as well as the sign "Depository" 47 which may be placed across the upper side of the frame 40. Beneath the lamp 46 is provided a concave grooved door frame member 48 with which a cooperating grooved arcuate surface 68 on the door 60 and correspondingly grooved arcuate surface 98 on the pivoted wall 90 interfit as shown in FIG. X.
B. Closures 50, 52
1. Sector Door 60
Referring primarily to FIG. IV, the closure 50 comprises a sector shaped door pivoted near its apex on an axis 62 into the stationary rectangular frame 40. One and the front angle side 64 of this door 60 comprises a stainless steel handle 65 whereby the customer may manually rock or oscillate the door 60 from its closed to open positions as shown respectively in FIGS. IV and VII. The other angular side of the sector shaped door 60 has pivoted at its other corner near the arcuate edge thereof a movable arcuate wall 90 pivoted at 92 and movable from its pocket ejecting position shown in FIG. IV into its full open pocket position shown in FIG. VII. The control of the movement of this pocket wall 90 is by a lever member 110 also pivoted to the door 60 at 112 near and parallel to its pivoted axis 62. This lever 110 is connected to the pivoted wall 90 by a shaft 114 movable in slot 94. Thus the closure 50, and similarly closure 52, each comprise only three parts, namely: a sector shaped door 60, and movable pocket wall 90, and interconnecting lever 110.
The sector shaped door 60 is provided with an arcuate grooved intermediate radial partition or wall 66, whose arc is concentric with the pivot 92 of the movable pocket door 90. Between the outer end of this partition 66 and the handle 65 is the arcuate grooved door-jam-intermeshing and wiping surface 68. Just below this arcuate surface 68 adjacent the outer side 64 or handle 65 is a bolt locking engaging aperture or seat 69. The outer parallel sector shaped sides 72 and 74 of the door 60 also provide end walls for the pocket formed in the inner half portion of the sector shaped door 60. These sides 72 and 74 are each provided with arcuate notches 75 for bridging the arcuate trough 43 in the bottom portion of the frame 40. Concentric of these arcuate notches 75 there are provided in each wall 72 and 74, apertures for the pivotable bearings 76 into which the retractable trunnions 77 journal the oscillating door 60.
The gap between the vertical sides of the frame 40 of the door jam and the side walls 72 and 74 of the oscillating sector shaped door 60 are bridged by hardened freely rotating rings 78 so that if a saw blade is placed in this gap it cannot cut trunnions 77, nor the protective hardened steel rings or sleeves 78 around them (see FIGS. XI, XIII, XIV and XV). Slots 79 are provided in the outer surfaces of the walls 72 and 74 (see FIGS. XII, XIII, XIV and XV) for the assembly of the door 60 with these rings 78 bridging the space between the side walls 72 and 74 and the jam door 40.
B 2. Movable Pocket Wall 90
The pivoted or movable pocket wall 90 has an outer arcuate grooved surface 98 which also may have an inwardly projecting end flange 96 to restrict the insertion of sharpe instruments between its edge and the other arcuate wall 66 of the door 60. This movable pocket wall 90 has triangular sector shaped side walls 91 and 93 which are parallel and in which the slots 94 are provided for the shaft 114 for connection to the levers 110 between these walls 91 and 93 and the sector door walls 72 and 74, respectively.
On this shaft 114 between these walls 91 and 93 and parallel to the axis 62 of the door 60, there is connected a toggle link 100 pivoted at one end 102 to the inside of the movable wall 98 and at the other end to the bar 114. This link 100 may comprise a pair of telescopic members 104 and 106 urged apart by an interior helical spring 108 (see FIG. IV). The action of this spring 108 may be damped by a friction, pneumatic, or hydraulic mechanism to prevent noise when this spring pushes the movable wall 90 into its two extreme positions shown in FIGS. IV or V and VII or VIII, respectively. It is to be noted that this particular outwardly urged spring link 100 acts as a toggle mechanism in these two most extended positions. In all other positions of the toggle link 100, such as shown in FIGS. VI and IX, the toggle link 100 is more compressed and the rod 114 to which it is connected is at the opposite end of the slots 94 from what it is when the link 100 is in its fully extended positions shown in FIGS. IV and VIII.
B 3. Lever 110
The third part of the closure 50 or 52 that moves both with and relative to the door 60 comprises a lever 110 pivoted to the door 60 on the shaft 112 parallel to and near the pivotal axis 62 of the door 60. Connected to one end of the lever 110 is the shaft 114 that slides back and forth in the slot 94 of the movable pocket wall 90. Near the pivot shaft for this lever 110 is a stop pin or rod 116 and a cam surface 118. It is the abutment of this rod 116 and the cam surface 118 against fixed stops mounted on the inside of the two vertical parallel sides of the door jam frame 40 which moves the lever 110 to control the motion of the movable pocket wall 90. Thus until this lever 110 is engaged by one or the other of these fixed stops, it is held by the resilient expandable toggle link 100 into the position shown in either FIGS. IV and V or FIGS. VII and VIII.
The two fixed stops on the vertical side frame 40 which cooperate with the cam surface 118 and the ends of the rod 116 on the lever 110, are respectively, a cylindrical pin or rod stop 148 and rectangular plate stop 146. These stops 148 and 146 are spaced and to be located for engagement near the ends of the travel of the oscillating door 60 so that the movable pocket wall 90 remains in its ejecting position until the door is opened and remains in its pocket forming position until the door 60 is closed.
A third and herein rectangular shaped stop 147 is provided along the vertical door jam of the frame 40 for limiting the opening movement of said door 60 by abutment against it by the lower end 67 of the front radial side wall of the closure 60, as shown in FIG. VII.
B 4. Ratchet 120
Between the fixed stops 146 and 148 are pivoted beneath the stop 146 is a double sided tooth ratchet 120 pivoted at 122 at its upper end adjacent the stop 146, which ratchet 120 is urged by a coil or leaf spring 124 (see FIGS. VI, VII and XII) into its normal upper position (full line position in FIG. VII) so that its lower free end contacts the under side of the drain trough 43 of the frame 40. The opposite oscillating movement of the ratchet 120 may be limited by a fixed pivot or stop 143 mounted on the vertical wall of the frame 40 in the event the spring 124 is ever broken due to jimmying or wear. The teeth 126 along the upper or left hand side of the ratchet 120 and the bottom notch 127 remote from the pivot 122 are engaged by the ends of the stop rod 116 on the lever 110 to prevent the reverse movement of the door 60 once it has been moved into its pocket closed position as shown in FIG. VIII. The notches 128 along the right or lower side of the ratchet 120 are also provided for engaging the ends of the pin or rod 116 in the event the spring 124 is broken, so that the door 60 cannot be opened. Otherwise the spring 124 maintains the lower notches 128 of the ratchet 120 out of the normal path of the pin or rod ends 116 when the door is being opened as shown between the positions of FIGS. IV and V.
Each closure 50 and 52 may be provided with one or a parallel pair of levers 110 and correspondingly cooperating pivoted ratchets 120 along either or both of its parallel vertical side walls of the frame 40. Generally however, the wider and/or larger closure 50 is provided with a pair of parallel levers 110 and cooperating ratchets 120, while the narrower and smaller closure 52 for the letters L may be provided with only one lever 110 and cooperating pivoted ratchet 120 (see FIG. XI).
C. Operation
Referring now to FIGS. IV through IX, successively, the operation of the closure mechanism for either the parcel P or letter L for closure 50 or 52, will be described, in that both closures operate in the same manner.
First considering the operation of the parcel closure 50, the operator or customer therefor must have a key K which is inserted into the lock 44 as shown in FIG. II and turned as shown in FIG. III in order to release the bolt 200 (see FIGS. IV, XII, XVIII and XX) from the bolt lock aperture or seat 69 in the side wall 74 of the closure door 60. This bolt unlocks the door 60 as long as the key K is turned in the position shown in FIG. III, but the key cannot be removed while in this position. Thus the depositor that has a key K must complete the following operation of completely opening and closing the door 60, once it has been opened further than the position shown in FIG. V, before the key K can be removed by returning the bolt to enter into its seat 69 in door locked position. If the depositor, however, does not have a key K and only is to deposit a letter L as shown in FIG. II, this unlocking step is not necessary.
Thus once the closure is unlocked, the depositor reaches for the handle portion 65 on the front panel 64 and pulls the door outwardly and downwardly as shown in FIG. V to open the door 60. During this door opening operation, the grooves in the door jam 48 wipe the grooves 98 on the movable pocket wall 90 to insure that no parcel or letter from the previous depositor could be adhered to this wall 90. When the door reaches the position shown in FIG. V, the pin ends of rod 116 on the lever 110 have moved from the position shown in FIG. IV up below the teeth 128 of the spring urged ratchet 120 so that the pin or rod ends 116 abut against the rectangular stops 146. Now further movement for opening of the door 60 by pulling down on the handle 65 causes the lever 110 to move or rotate clockwise about its pivot 112 on the door sector 60 into the position as shown in FIG. VI which rocks the movable pocket wall 90 downwardly by the movement of the shaft 114 along the slot 94. Thus, as soon as the pocket begins to appear beyond the edge of the upper door jam 48, the wall 90 has already started to form the pocket, which pocket is completely formed when the door is completely opened as shown in FIG. VII. In this position the pin 114 on the lever 110 is moved to the opposite end of the slot 94 (see FIG. VI) and then back again (see FIG. VII) into its other limited position, and is held in its last position by the spring 108 in the expanded link 100.
At this time the parcel P which is to be deposited by the customer or depositor is dropped into the pocket thus formed in the door 60 as shown in FIG. VII, and the door 60 then may be closed. When the door 60 reaches its half way position shown in FIG. VIII, the ends of the rod or pin 116 on the lever 110 move downwardly, above and along the upper side of the ratchet 120 until the pin 116 has engaged the first notch 126 of the ratchet. This engagement prevents any reverse motion of the door 60 by pulling on the handle 65 by the depositor or any other person. Thus once the pocket in the door 60 has been moved so that the pocket is no longer visible to the depositor as shown in FIG. VIII, reverse action of the door 60 is prevented by the teeth 126 along the ratchet 120. These teeth 126 are engaged successively in steps as the door 60 is continued to be closed until it almost reaches its fully closed position as shown in FIG. IX. Then the pins or rod 116 as well as the axial shaft 112 for the lever 110 have passed below the lower notch 127 of the ratchet 120.
Thus as soon as the partition 66 in the door 60 clears the inside door jam 48, a cam surface 118 of the lever 110 engages the stop 148 to start the ejection of the parcel P into the chute 36 as shown in FIG. IX. Simultaneously the outer arcuate end 96 of the grooved wall 98 of the movable wall 90 scrapes the cooperating grooved partition wall 66 and its side walls 72 and 74 of the pocket to insure that no parcel can be or is stuck thereto. Thus, when the door 60 is completely closed, the movable pocket wall 90 is back into the position shown in FIG. IV from that of FIG. IX and the toggle 100 has been moved into its limiting extended position after its pivot rod 114 has been moved back and forth in the slot 94. Now the key K can then be turned to insert the bolt 200 into its seat 69 in the closed door 60 to lock it, and the key removed and the deposit of the parcel P into the safe 32 has been completed. Similarly for the letter closure 52, the ratchet mechanism 120 engaging the pin 116 and axle 112 for the lever 110 prevents reopening of the door closure 52, until the letter L in the pocket in the door 52 has been completely ejected into the safe 32 as is the parcel P shown in FIG. IX.
In the event an unauthorized person tries to jam or pry into the closure 50 or 52, the only possible access other than completely breaking the wall 30 and/or the frame 40 and closure 50 and 52 out of wall 30, is to try to fish with wire in between the sides of the door and its jam. Thus if a hook on a wire could engage either the lever 110 or one of the shafts or pins 114, or 116 associated therewith to move the toggle link 100, or if the ratchet 120 were moved and/or its spring 124 broken to drop the ratchet 120 into its lower position as shown in dotted lines in FIG. VII, the shaft or rod 116 would engage the teeth 128 of the ratchet 120, and will prevent opening of the door.
Furthermore, the fact that the movable pocket wall 90 has the flange 96 at the outer edge thereof, and this wall starts retracting from its package ejecting position shown in FIG. V into its pocket opening position as shown in FIG. VII before the outer edge of the arcuate wall 66 appears, prevents a tool from being inserted under the movable wall 90 to jam any operation which might further permit access into the chute 36 and safe 32.
D. Disassembly
1. Doors
Referring now to FIGS. I, III, XI, XII, XIII, XIV, and XV, there is shown the mechanism for retracting the trunnions 77 which hold the door 60 into the door jam 40 so that this door 50 can be removed easily from the door jam 40 for repair and/or maintenance thereof, as well as access, repair and/or maintenance of the letter door 52, and their stops and ratchets 120 mounted on the frame 40. The removal of this door 60 is shown in FIG. XII after each trunnion 77 has been retracted into the position shown in FIG. XIV. This retraction is accomplished by pulling the knobs 150 (see FIGS. I and XII) at the far end of the bowden wires 152, which wires extend from the housing 154 (see also FIGS. III and XI) on each vertical outside wall of the frame 40. Inside each housing 154 may be a horizontally slidable rectangular jam plate 160 with a diagonal slot 162 having parallel offset ends. In the slot 162 slides a pin 164 diametrically attached across a slot 165 at the outer end of the trunnion shaft 77. This cam plate 160 may be guided in its horizontal movement between two guide plates 166 (see also FIG. XV), and is pulled or pushed from this one limiting position to the other (see FIGS. XIII and XIV) by the knobs 150 at the end of the bowden wires 152. The offset ends of cam slots 162 prevent axial movement of the trunnions 77 at their two extreme positions. Thus the trunnions cannot be retracted unless the bowden wires 152 and knobs 150 are operated. In order to prevent unauthorized access to these knobs 150 they may be placed inside the safe type container 32 as shown in FIG. I, so that only personnel authorized to enter the same may also permit removal of the closure 50 or 52.
Attention is called to the fact that the retraction of the trunnions 77 into their position shown in FIG. XIV is sufficient to remove the door 50 but still to retain the hardened or loosely rotating sleeves 78, which slide in the grooves 79 in the door sides 72 and 72 as previously described. There is also shown in FIG. XII a pair of plates 168 and 169 which may be bolted or otherwise fastened to the vertical inner parallel walls of the door jam or frame 40 to bridge the normal gap between the outer parallel side walls of the closure and its door jam. These members 168 and 169 are provided with a gap 167 between them so that the outwardly extending ends of shaft or pin 116 that engage the ratchet 120, will not prevent removal of the door 60 and also makes for easy assembly of the closure according to this invention.
Referring now to FIGS. XV and XVI, there is shown a shaft 170 which may extend through the letter closure 52 as shown in FIGS. I and II upon which the side walls 54 of the letter door 52 are journalled. In this combination, the parcel door wall 72 and one letter door wall 54 have a common trunnion 177 through the two closures separating wall 180 in the frame 40. This trunnion 177 is fixedly connected onto one end of the fixed shaft 170, which shaft 170 is threaded at its other end into a sleeve 172 which is slotted 165 and has the pin 164 that rides in the cam slot 162 in plate 160. The sleeve 172 and trunnion 177 are also provided with surrounding freely rotatable hardened rings 78.
Thus the operation of the cam 160 as shown in FIG. XV axially moves the whole shaft 170 to retract the trunnion 177 into the position as shown in FIG. XIV, so that the parcel closure 50 or door 60 can be removed as shown in FIG. XII. Then the shaft 170 may be unscrewed from its extension sleeve 172 by a screw driver placed in the slot 175 at the end of the trunnion 177, which end is now exposed by the removal of the closure 50. This shaft 170 can be axially withdrawn so that the letter closure 52 can be removed from its compartment in the frame 40 separated by partition 180 (see FIG. XV). In order to secure the shaft 170 in position, and prevent it being unscrewed surreptitiously, a key 182 shown in FIGS. XV and XVI is countersunk into the wall 180, and held in place by a countersunk screw 184. The edge of this key 182 fits into a notch 179 in the trunnion section 177 of the shaft 170. Thus the key 182 first must be removed before the shaft 170 can be unscrewed and removed.
D 2. Lock
Referring now to FIGS. XVII through XX, the connection and operation of lock for the rack bolt 200 are shown. Herein the tumbler lock 44 has a tumbler 190 which is rotatable by the key K from the position shown in FIG. XVIII to that shown in FIG. XIX. This tumbler 190 is connected to a pinion shaft 192 carrying a pinion 194 which engages the rack teeth 202 of the lock bolt 200. This shaft 192 has a pair of diametrically spaced axially extending apertures 196 at its end adjacent the lock, which apertures 196 are engaged by corresponding pins 216 which project axially outwardly on both sides of a connector member 210. The other side of the pins 216 from those that engage the apertures 196, engage a similar diametrical pair of apertures 191 in the end of the rotatable tumbler 190. This whole assembly may be located in a housing 220 (see also FIG. 1) which may be anchored to an outside vertical wall of the frame 40. Inside this housing 220 may be provided a V-shaped support 222 (see FIGS. XVIII and XX) for aiding and supporting the shaft 192 for easy assembly and disassembly of this locking mechanism. The far end 195 of the shaft 192 may be journalled in an aperture 224 in the rear wall of the housing 220, opposite from that of the tumbler lock 44.
Easy access and disassembly removal of this lock and bolt mechanism may be had by the use of a special key K which is only held by authorized personnel, which will permit the removal of the tumbler 190 so that access may be had to the set screw 226 (see FIG. XIX) in the side of the tumbler housing, which set screw 226 engages an internally threaded ring 228 mounted in and attached to the housing 220. Thus the whole tumbler lock 44 may be unscrewed from the housing 220, and then by the means of pliers the connector 210, and then the shaft 192 may be withdrawn out through the aperture in the outer end of the housing 220 into which the tumbler lock 44 is normally screwed. Since the bolt 200 is provided with rack teeth 202, longitudinally axial withdrawal of the rack 200 may be had from the inside of the frame 40 after the pinion 194 has been removed, or by rotating the pinion 194 to feed out the rack 202.
It is to be understood that the closures according to this invention may comprise just a letter closure as 52 or just a parcel closure as 50, or both, and either or both which may be provided with lock 44 without departing from the scope of this invention. Furthermore, it is to be understood that the container 32 may or may not be a safe, and the chute 36 connected from the closure and its frame 40 to a container may be of any length, however preferably, it should extend downwardly so that gravity will aid in movement of any deposited letter or parcel L or P, respectively, after it has been ejected by the movable wall 90 of the closure of this invention.
While there is described above the principles of this invention in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of this invention. | A rockable customer operated door for a chute to a safe type receptacle as in a bank for receiving parcels and/or envelopes, which door may be unlocked by a key, and when opened exposes a pocket into which a parcel or letter may be dropped, and which during the manual closing of the door, a pivoted wall of the pocket ejects the contents thereof into the chute. Spring urged lever and ratchet means control the movement of the pocket wall to not only eject its contents but to scrape the walls thereof as well as to prevent reversing movement of the door intermediate the ends of its travel. Movable trunnion pivots for the door are provided for removing the door for repairs to its mechanism. The lever means pivoted to the door is provided with pins that cooperate with the ratchet means which is pivoted to the frame for the door that is rigidly mounted in the opening of the chute. Stops and toggle means are provided for controlling and limiting the movement of the door, the movable pocket wall, and the lever means. The key lock for the door comprises a pinion for a rack type bolt. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. application Ser. No. 08/803,512, filed Feb. 20, 1997 now U.S. Pat. No. 5,893,415 entitled GAS DIVERSION TOOL.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a multiple function oil well tool for installation in a production tubing string to provide valved communication between the interior of the tubing string and the annulus between the exterior of the tubing string and the interior of the well casing. More specifically, the invention relates to a tubular body, similar to a collar, serially connected in a well tubing string, and includes valved passageways for the passage of gas from the annulus between the well casing and the exterior of the tubing string into the interior of the tubing string for movement of the gas along with the oil being produced up the tubing string to the well head at ground surface.
In one function of the tool, it performs as a gas diversion tool to enable a well to be pumped with the tool being oriented below a packer to seal off a hole, crack or other leak in the casing. In another function of the tool, the efficiency of the down hole rod pump can be improved by introducing gas above the pump to cause a gas lift effect on the fluid being pumped and enable the pump to operate at higher pump capacity. In a further function of the tool, it is placed above the packer and a gas compressor at ground surface injects gas down the annulus between the tubing string and the casing with the pressurized gas entering the tool through the valved passageways to lift the fluid out of the well to produce a gas lift effect. A still further function of the tool is use as a pump assist tool in which the tool is installed in the tubing string above the pump to assist the pump by eliminating gas locking of the pump thereby lightening the load on the pump, pump rods and pump jack.
2. Description of Related Art
With regard to the function of the tool as a gas diversion tool, it is well known that oil and gas wells with cracked casings present problems to economical removal of the oil and gas. Typically, the crack or hole in the casing permits contaminating materials, such as water and mud, to enter the well and flood out the productive oil and gas zone, thereby rendering a marginal well uneconomical to pump the oil to the surface. The conventional solution is to repair the casing at the crack or hole by the "cement squeeze" process; however, this is very costly and is not economically feasible in marginal wells. Further, there is no assurance a "cement squeeze" repair will hold. Thus, there is a great demand for a simple and inexpensive tool which can be utilized in wells having a cracked or leaking casing, especially marginal wells, to make the wells productive.
The U.S. patent art includes various prior patents which disclose excess gas pressure diversion and venting structures as well as sealing and fluid bypass structures that pertain to improvements in well production. For example, Mack U.S. Pat. No. 1,536,348 discloses a gas venting tool disposed in a tubing string below a packer and capable of enabling the flow of gas from the exterior of the tubing string into the interior of the latter. However, the Mack gas venting tool is made as part of the packer and is designed to be used in conjunction with, and sealed relative to, the upper end of a "bottom casing". However, installation of the Mack device requires stabbing of the tool into the upper open end of a casing string and lowering the tool down onto the casing to create a seal.
Lynn U.S. Pat. No. 1,238,165 also discloses a gas venting tool, but the Lynn tool is interposed between two laterally offset tubing sections and therefore prevents the passage of various repair and/or service tools downwardly through the tubing string past the venting tool. Also, it would appear that the Lynn tool would not provide sufficient clearance for a pump rod. Carlton et al. U.S. Pat. No. 5,507,343 discloses an apparatus for repairing a damaged well casing and employs two packers with gas vents.
Ames U.S. Pat. No. 1,139,745 is directed toward an apparatus for evacuating gas from a closed well to permit the continuing flow of oil into the well casing. Roeder U.S. Pat. No. 3,625,288 discloses a pump assembly providing a plurality of passageways to accommodate oil, gas and power fluid flow as well as a structure for alternately using the various passageways. Jacobi U.S. Pat. No. 5,390,737 discloses a packer assembly with a sliding valve to be opened or closed manually, and Renfroe U.S. Pat. No. 4,834,176 discloses a device for opening a valve to communicate the exterior and interior of the tool. The patents to Pistole et al., U.S. Pat. No. 2,804,147, and to Koster, U.S. Pat. No. 5,046,558, disclose structures for sealing leaks in casings. Finally, Falk U.S. Pat. No. 2,913,054 discloses a device for closing a connection in the tubing string between different zones separated by a packer, and Hesh U.S. Pat. No. 4,844,156 discloses a method for promoting increased formation flow.
The above prior art does not disclose a simple and inexpensive tool that can be readily inserted into a tubing string below or above a packer, or without a packer, and that provides valved communication between the interior of the tubing string and the annulus between the casing and the exterior of the tubing string which will (1) divert gas buildup which occurs outside of the tubing string below a packer into the tubing string to flow to the surface along with the oil being pumped up the tubing string, (2) increase the effective pump capacity of the down hole pump, (3) function as a gas lift device when compressed gas is pumped down the annulus from ground surface by a compressor and the tool is placed above a packer, and (4) eliminate gas locking of the pump when the tool is installed above the pump to reduce the load on the pump, pump rod and pump jack.
SUMMARY OF THE INVENTION
To overcome the deficiencies of the prior art, the present invention when functioning as a gas diversion tool can be readily installed in an existing tubing string with a conventional tension packer positioned above the tool. The packer location places the packer and tool below a crack or hole in the casing when the system is completely installed. Once the tool and packer are in place, the packer is activated to seal off the casing below the crack and thereby prevent migration of the contaminating materials from the crack to the bottom of the well. The sealing of the casing also prohibits the upward flow of gases from below the packer and outside the tubing string to the surface. As the oil and gas enter the well, the oil falls to the bottom, where it can be pumped to the surface, and the gas flows upward. When there is a gas pressure buildup inside the casing, the tool automatically diverts this gas into the tubing string, where it can then flow to the surface along with the oil being pumped.
When the tool is used to increase the effective pump capacity of the down hole pump, the tool is installed in the same manner as described above, when it functions as a gas diversion tool. In this arrangement, the effective capacity of the down hole pump is increased. More specifically, a rod pump when obtained and installed in an operating mode, such as an oil well pump, is typically provided with a delivery capability when the pump is functioning at 100% efficiency. However, in practical use, due to the load on the pump, pump rod and pump jack, and due to gas locking, the maximum efficiency usually ranges between 70 and 80%, that is, the pump produces oil at the well head at about 70 to 80% of its capacity. By utilization of the tool of this invention to introduce the gas through the tool into the tubing string, the gas produces a gas lift effect on the fluid being produced up the tubing string. Accordingly, the reduction of the load and the gas lift effect enables the pump capacity to be increased to approximately 100%.
When the tool of the present invention functions as a gas lift tool, the tool is placed above the packer which is positioned just above the perforations. A gas compressor is used at ground surface and injects compressed gas down the annulus between the casing and the tubing string with the compressed gas passing inwardly through the tool into the interior of the tubing string to lift the production fluid or oil out of the well.
When the tool functions as a pump assist tool which prevents the pump from gas locking, the tool is installed in the tubing string above the pump without a packer. The cylindrical body or collar of the tool preferably has a larger diameter in order to cause the gas to more readily enter the tool and pass to the interior of the tubing string. This passage of the gas into the tubing string assists the pump by eliminating gas locking of the pump and also by lightening the load on the pump, rods and pump jack.
The oil well tool in accordance with the present invention has a simple thick walled cylindrical body, similar to a collar, with appropriate threads, top and bottom, for serial connection within a tubing string. The tool preferably includes a plurality of substantially vertical gas passageways having bottom inlets peripherally around the tool body. These passageways each lead to a check valve which permits the gas to enter the interior of the tool responsive to a specific differential in the pressure of the gas in the annulus between the outside of the tubing string and the inside of the casing above the pressure of fluid within the tubing string. The interior of the tool is generally in line with the interior of the tubing string so that the gas entering the interior of the tool can then pass up the tubing with the oil that is being pumped up the tubing to the surface. Further, this in line alignment of the interior of the tool with the interior of the tubing eliminates obstruction to the passage of various tools therethrough for performing repair or maintenance functions within an associated well below the tool.
The gas passageway inlets and check valves consist of a plurality of circumferentially spaced longitudinal bores in the thick wall of the cylindrical body with each bore being provided with an upwardly opening valve seat. The bores are preferably vertical and straight in the thick wall of the cylindrical body. A ball check valve and cylindrical hold down and wiper rod are movably received in each bore and the ball valve is engaged with the valve seat and the rod is engaged with the ball valve. The interior of the thick walled tubular body includes a circumferentially extending undercut portion opening slightly into the adjacent sides of the bores appreciably above the lower ends thereof. Hence, when the gas pressure outside the tool and inside the casing exceeds the fluid pressure within the tubing string by a predetermined amount, the gas pressure causes the ball check valves and cylindrical hold down and wiper rods to move upwardly to a point which permits the higher pressure gas to enter into the interior of the tool through openings in the sides of the bores. The gas then passes into the interior of the tool and passes upwardly through the interior of the tubing string along with the oil being produced. The combined weight of the ball check valve and wiper rod counters the pressure of the inlet gas until it reaches the design opening minimum pressure differential. In accordance with the present invention, it has been found that the design minimum pressure differential for initial opening of the check valves in accordance with the tool of the present invention should be about 2 psi and that full opening of the check valves should be at about 7 psi.
In accordance with the foregoing, an object of this invention is to provide an oil well tool serially connected within a tubing string through the use of threaded connections with the tubing string and which communicates the interior of the tubing string with the annulus between the exterior of the tubing string and the casing responsive to a predetermined differential in fluid pressure exteriorly of the tubing string over the fluid pressure interiorally the tubing string.
Another object of this invention is to provide an oil well tool which may be serially connected within a tubing string in a manner to enable all repair and maintenance tools moving downwardly through the tubing string to also pass easily through the tool.
A further object of this invention is to provide an oil well tool of simple construction, which includes inexpensive components and which may be manufactured by inexpensive manufacturing procedures.
Yet another object of this invention is to provide an oil well tool including check valve assemblies which are highly dependable in operation and offer a long life expectancy of operation.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary vertical sectional view of a well casing including a hole or leaking area in an upper portion, a packer installed between a tubing string and the casing with the oil well tool of this invention used as a gas diversion tool serially connected in the tubing string below the packer;
FIG. 2 is an enlarged longitudinal sectional view of the oil well tool of the present invention used as a gas diversion tool shown in FIG. 1;
FIG. 3 is a top plan view of the tool illustrated in FIG. 2;
FIG. 4 is a bottom plan view of the tool illustrated in FIG. 2;
FIG. 5 is a transverse sectional view taken along section line 5--5 of FIG. 2;
FIG. 6 is a schematic view of the oil well tool of the present invention functioning as a gas lift for the oil being pumped;
FIG. 7 is a sectional view of a tubing sub preferably positioned between the packer and the oil well tool of the present invention when functioning as a gas lift pump in order to prevent fluid and gas from entering the tubing string while the packer is being set;
FIG. 8 is a schematic view of the oil well tool of the present invention functioning as a down hole pump assisting device to eliminate gas locking of the pump; and
FIG. 9 is a longitudinal sectional view of a second embodiment of the oil well tool of the present invention functioning as the down hole pump assisting device illustrated in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing the preferred embodiments of the present invention as illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific embodiments illustrated and terms so selected; it being understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Referring now more specifically to FIGS. 1-5 of the drawings, numeral 10 generally designates an in ground well casing including a perforated or leaking area 12, such as caused by corrosive water or the like. The perforated area 12 allows water and mud to enter the casing and to fall downwardly to the bottom of the well contaminating the oil and gas entering the casing through the production zone or zones (not shown). The water and mud interfere with pumping the oil and gas to the surface and the static pressure of such water and mud at the production zone can actually completely stop oil flow from the production zone into the well casing.
When such a condition exists in a "marginal well", the well becomes unprofitable to pump and in many cases the well is so "marginal" that expensive repair of the perforated area 12 is not carried out and the well is shut down. Although it is possible to prevent the downward flow of the water and mud from the perforated area 12 to the bottom of the casing 10 through the utilization of a packer 14 connected in a tubing string 16 extending downwardly through the casing 10, see FIG. 1, in almost all cases the utilization of packer 14 within the casing 10 results in gas pressure within the casing 12 below the packer 14 being elevated to an extent that oil production into the lower end of the casing is either terminated or severely retarded, thereby also rendering oil production from the well uneconomical.
In order to restore or bring back such marginal wells into production, an oil well tool referred to generally by the reference numeral 18 and constructed in accordance with the present invention is serially connected within the tubing string 16 below the packer 14 to serve as a gas diversion tool. The tool 18 includes a thick walled cylindrical body 20, see FIG. 2, having a central longitudinal opening or passageway 22 defined therethrough. The opening 22 includes threaded upper and lower ends 24 and 26 at the top and bottom, respectively, thereof. In this manner, the tubing section 28 above the tool 18 may be threaded downwardly into the threaded upper end 24 of the central longitudinal opening 22, and the tubing section 30 disposed immediately below the tool 18 may have its upper end threaded into the threaded lower end 26 of the opening 22.
In addition to the central longitudinal opening or passageway 22, a series of preferably four longitudinal through bores 32 are formed through the body 20 at points spaced circumferentially thereabout generally intermediate the outer surface 34 of the body 20 and the inner surface 35 of the central longitudinal opening 22. The bores 32 include upper and diametrically enlarged counterbores 36 extending downwardly through generally two thirds the length of the body 20 and defining upwardly facing annular seats 38 at their lower ends. As shown, the through bores 32 and counterbores 36 are preferably straight and vertically aligned in the thick wall forming body 20.
A ball check valve 40 is downwardly received in each counterbore 36 and loosely seated against the corresponding seat 38. In addition, a cylindrical rod 41 which acts as a valve hold down and wiper is also positioned in each counterbore 36 and loosely seats downwardly upon the top of the corresponding ball check valve 40. Typically, the central longitudinal opening or passageway 22 may be about 2 3/8 inches in diameter, the counterbores 36 about 7/16 inch in diameter, the rods 41 about 5/16 inch in diameter and the ball check valves 40 about 3/8 inch in diameter.
The upper ends of the counterbores 36 include threaded second counterbores 42 in which threaded plugs 44 are removably threaded to sealingly close the upper ends of the bores 32. Meanwhile, the lower ends of the bores 32 open downwardly through the lower axial end face 46 of the body 12 to provide inlets 47 for the gas into bores 32.
The approximate longitudinal mid-point of the rods 41 are aligned preferably with the longitudinal midpoint of the body 20 when the ball check valves 40 are seated and the rods 41 engage the valves 40. At approximately the longitudinal midpoint of the body 20, the body has a first undercut zone 48 of appreciable axial extent and a second undercut zone 50 of much shorter axial extent which opens into the adjacent sides of the counterbores 36. The opening of undercut zone 50 into the sides of counterbores 36 defines a short circumferentially extending slot 52 for each counterbore 36. Thus, when the tool includes four bores 32 and counterbores 36, there will be four slots 52. The slots 52 thus communicate the undercut zone 50 and the passageways 22 with the counterbores 36 in which the ball check valve 40 and cylindrical wipers 41 are loosely received.
It will therefore be seen from FIGS. 1 and 2 that the inlets 47 at the lower ends of the bores 32, and the lower ends of the counterbores 36 and slots 50, define passageways communicating the annular zone 56 interiorly of the casing 10 and exteriorly of the tubing string 16 below the packer 14 with the interior of the tool 18 and its central longitudinal opening or passageway 22 and thence to the interior of the tubing string 16. Accordingly, if a gas pressure buildup occurs within the casing 10 below the packer 14 tending to restrict the flow of oil from the surrounding formation (not shown) into the bottom of the casing 10, as soon as that excess pressure reaches a level approximately 2 psi above the fluid pressure within the tubing string 16, the ball check valves 40 and wiper rods 41 are designed to move slightly upwardly within the counterbores 36. When the pressure differential of the gas on the exterior of the tubing string 16 to the fluid pressure within the tubing string reaches about 7 psi, the tool is designed so that the ball check valves 40 and wiper rods 41 have moved to the positions illustrated by the phantom lines in FIG. 2. However, different differential pressures may be utilized depending on the design details of the tool and the pressures encountered in the well. Hence, it is not intended that the present invention be limited to these preferred pressure differentials.
Once the gas starts to flow through the tool 18, the gas within the annular zone then moves upwardly in the general direction of the arrows 57, through the seats 38 and the slots 52 into the central longitudinal opening 22. From there, the gas flows upwardly through the central longitudinal opening 22 with the oil being pumped upwardly through the tubing string 16 from the bottom of the well, generally indicated by arrow 58. The gas is thus diverted by the tool of the present invention until the excess pressure in the casing has been relieved. Of course, once the excess gas pressure is relieved, the ball check valves 40 and wiper rods 41 return to the solid line positions illustrated in FIG. 2.
The longitudinally straight through bores 32 in the body 20, together with the counterbores 36 and the threaded second counterbores 42, may be formed through relatively easy and inexpensive machining procedures. Also, the undercut zones or portions 48 and 50 also may be inexpensively formed. Further, the tool 18 includes only the body 20, four ball valves 40 and four cylindrical rods 41 for the valve assemblies, and four plugs 44 to close the tops of counterbores 36. Hence, the entire tool 18 is very inexpensive to produce. In addition, the wiper rods 41 are provided to maintain the ball check valves 40 clean and the lower portions of the counterbores and the slots 52 free of accumulation of various materials which might otherwise tend to clog the gas pressure bypass passages. Still further, the central longitudinal opening 22 is preferably of a larger diameter than, and aligned with, the inside diameters of the tubing string sections. As such, the tool 18 does not present an obstruction to the passage therethrough of any well bottom repair, maintenance or other tools. Thus, a pump rod may easily pass and work through the central longitudinal opening 22.
The function of the oil well tool illustrated in FIGS. 1-5 as a gas diversion tool also increases the capacity of the down hole rod pump. Actually, the tool enables the pump to operate at or over 100% of rated pump capacity. When a down hole rod pump is obtained for positioning in a well, the supplier is typically provided with the size of the pump, the length of stroke and the number of strokes per minute. The supplier will then provide the pump and indicate the number of barrels of fluid the pump should deliver per minute at 100% efficiency. However, in practical operation, due to various loads, gas locking and the like, a pump usually functions at only 70 to 80% of its capacity. By utilizing the oil well tool 18 in the manner illustrated in FIGS. 1-5, the gas lifting effect and the reduction of the gas locking capability of the gas in relation to a down hole rod pump will enable all of these problems to be avoided so that the pump capacity will be increased substantially, to near or above its theoretical maximum.
When the oil well tool of the present invention is utilized as a gas lift pump, the oil well tool can be installed in a system such as illustrated schematically in FIG. 6 of the drawings. The gas lift system is generally designated by reference numeral 70 and includes an oil well casing 72 having a perforated area 74 at the lower end thereof associated with an oil producing zone 76 which produces oil and gas for movement upwardly through a production tubing string 78. The oil well tool of this embodiment of the invention is generally designated by reference numeral 80 and can be the same structure as that disclosed in FIGS. 1-5. A packer 82 is positioned between the tubing string 78 and the casing 72 above the lower end of the tubing string and above the production zone so that all of the material produced from the formation 76 will pass upwardly through the pump production tubing string 78.
The gas lift system 70 includes a compressor assembly 84, preferably positioned above ground, which has a discharge line 86 extending into the annulus 88 between the casing 72 and the tubing string 78. The compressor 84 provides a supply of compressed gas which is discharged downwardly in the annulus 88 and is prevented from entering the formation of the production zone by packer 82. The pressurized gas is thus forced to enter the bottom of the oil well tool 80 in the same manner as in FIGS. 1-5 and thus enters into and mixes with the oil and other fluids being produced in the production tubing string. The introduction of the compressed gas into the tubing string 78 through the tool 80 causes the driving gas as well as the production fluids to move upwardly in the tubing string to the surface. When the mixture reaches the surface, it is direction into a separator, generally designated by numeral 90, in which the oil and gas are separated with the oil being discharged to a storage tank or the like and the gas being discharged back to the compressor 84 through a supply line 92. The gas passing into the compressor is cleaned or filtered and a portion of the gas may be discharged to a gas sale line 94. The remainder of the gas is then fed back into the annulus 88 for recirculation through the tool 80 so that the driving gas will continuously elevate the production fluids.
Since oil and gas wells have bottom hole pressure, the production fluid will enter the tubing string 78 and move up through the packer 82. The production fluid will mix with the gas that is being pressurized by the gas compressor 84 and continue the upward movement in the tubing string 78. This upward movement will create a vacuum or reduction in pressure on the formation and urge additional fluid into the lower end of tubing string 78 so that it can be brought to the surface.
By putting the oil well tool 80 above the packer 82 which itself is positioned just above the perforations 74, and with the gas compressor 84 injecting gas down into the casing and causing the compressed gas to go through the tool 80 and assist in lifting the fluids out of the well, the tool 80 acts as a gas lift pump. This arrangement of lifting the production fluid provides a very simple and highly efficient gas lift pump for producing fluid from a well. The gas lift pump method to produce the well in accordance with the present invention will eliminate the need of a mechanical pump whether it be a down hole rod pump or other type of pump and of course would also eliminate a pump jack and pump rods if a down hole rod pump has been replaced.
Between the packer 82 and the tool 80, the tubing string 78 is preferably provided with a tubing sub generally designated by reference numeral 96 and illustrated in FIG. 7. Tubing sub 96 includes an upper component 98 and a lower component 100 which are each provided with internal screw threads 102 in order to connect the tubing sub into the tubing string. The upper component 98 is provided with an axially projecting lower end portion 104 that has a reduced external diameter and large external screw threads 106. Screw threads 106 interengage with a similar threaded interior area 108 of the lower component 100 which enables the tubing sub 98 to be made up with a ceramic disk 110 positioned on a shoulder 112 formed on the lower component 100. When the components are assembled, the threaded connections 106 and 108 will retain the ceramic disk 110 in place.
The tubing sub 96 is a tool used to keep fluid and gas from entering the tubing string until the packer 82 has been set. After the packer 82 has been set, the casing and the tubing can be swabbed dry by starting the gas compressor and having the gas move up the tubing string. Then a sinker bar (not shown) can be inserted into the tubing string 78 and lowered to break the ceramic disk 110 so that the fluid and gas from the formation can enter the tubing string and be pumped up the tubing string by the pressurized gas produced by the compressor. By using the oil well tool 80 as a gas lift pump together with the tubing sub 96 and packer 82, the production of oil from the formation can be pumped at a lesser cost initially and less energy since the gas lift pump will produce more production fluid with less cost than a comparable pump jack, sucker rod and down hole pump assembly.
FIGS. 8 and 9 illustrate an embodiment of the oil well tool of the present invention in which the tool is used in the tubing string above a down hole rod pump to assist the pump in preventing gas locking. The oil well system is schematically illustrated in FIG. 8 and is generally designated by reference numeral 120. The system 120 includes the oil well tool 122 which is similar to but slightly different from that illustrated in FIGS. 2-5. In this construction, an oil well casing 124 extends into a production zone 126 which is communicated with the bottom of the casing through a perforated area 128. A tubing string 130 is made up with the tool 122 positioned therein. The tool 122 includes a generally vertical central open passageway 132 with a threaded upper end 134 and a threaded lower end 136 for make up with the tubing string. The tubing string 130 receives a pump rod or sucker rod 138 which extends through the passageway 132 in the tool 122. The pump rod 138 is operatively connected to a down hole rod pump, generally designated by reference numeral 140, which has a screened inlet 142. The upper end of the pump rod 138 is operatively connected to a pump jack (not shown) for reciprocating the rod and operating the down hole pump 140 in a conventional manner.
The tool 122 includes a thick walled body 144 similar to a collar and includes a plurality of longitudinal passageways 146 in the lower portion thereof. Preferably, eight generally cylindrical passageways are employed in this tool although the number may vary. The passageways are also preferably straight and aligned vertically in the tool 122. The lower end of each vertical passageway 146 is provided with a threaded insert 148 forming a valve seat 150 for a ball valve 152 having a wiper rod 154 extending vertically above the ball valve to retain the ball valve 152 in place on the seat and to keep the ball valve and passageways 146 clean during the vertical movement of the ball valve 152 upwardly. The central passageway 132 includes a circumferential undercut portion 158 located somewhere near the midpoint of vertical passageways 146 which forms circumferentially spaced slots 156 to communicate the vertical passageways 146 with the central passageway 132 through body 144.
Pressure buildup in the annulus 159 between the casing 124 and the tubing string 130 below the tool 122 will cause the ball valves 152 and wiper rods 154 to move upwardly away from valve seats 150. Upon upward vertical movement of ball valves 152, gas in annulus 159 is able to pass upwardly through the passageways 146, and then into central passageway 132 through circumferentially spaced slots 156, thereby communicating the annulus 159 with the tubing string 130 and introducing the gas pressure into the tubing string. As illustrated in FIG. 9, the transverse dimension of the body of the tool 122 adjacent its lower end is closer to the diameter of the casing 124 in order to provide a restriction in the annulus 159 so that the gas pressure from the formation will enter the tool 122 for assisting the pump by preventing gas locking of the pump. Introduction of the gas into the tubing string and the production oil passing upwardly therein will reduce the density of the production fluid and lighten the load on the down hole rod pump, the pump rods or sucker rods and the pump jack thereby enabling the pump to operate closer to maximum capacity.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. For example, while four or eight gas inlets and check valve assemblies are shown, more or less could be utilized. Further, the positioning of the inlets, the check valve assemblies and the passageways could be altered so long as the central longitudinal opening or passageway remains unobstructed and the check valve assemblies operate to transmit gas flow from the annulus between the tubing string and the casing to the interior of the tool and then up the tubing string. Accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | An oil well tool for installation in a production tubing string to provide valved gas communication between the interior of the tubing string and the annulus between the tubing string and casing for improving production from the well. The tool includes a thick walled tubular body for in-line threaded connection in a tubing string and includes valved passageways for the automatic transfer of gas from the annulus into the interior of the tubing string when the pressure in the annulus exceeds the pressure in the tubing string by a designed differential. The tool can be installed in the well in various arrangements for improving production of the well. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Prov. Appln. No. 61/043,664 and U.S. Prov. Appln. No. 61/043,675, the contents of both being incorporated by reference herein in their entirety.
FIELD OF TITLE INVENTION
[0002] The present invention relates to solar cells, and more particularly to solar cells with nitrided junctions.
BACKGROUND
[0003] Many types of solar cells have structures that could be improved with better junction and contact properties due to the materials used and/or their fabrication processes.
[0004] For example, polysilicon emitter solar cells were demonstrated in the early '80s. These typically consist of polysilicon deposited on a thin tunnel dielectric such as SiO 2 . The dielectric is supposed to serve two functions. First, it is intended to passivate the interface between the poly and the substrate. Second, it is intended to block diffusion to form a hyperabrupt junction.
[0005] However, these devices were not commercialized. This is partly because it is much easier to obtain long lifetime n-type silicon at low cost. In that case the polysilicon must be boron doped to create a p-type poly, and a thin SiO 2 layer will not stop boron diffusion. This is a problem because the polysilicon is formed in two steps. In the first, it is deposited at a relatively low temperature, typically 650-700° C. The boron diffusion is negligible at this point. However, the poly must then be annealed, typically at >900° C. for about 30 seconds, in order to densify it. The densification reduces the sheet resistance of the layer to useful values (typically <200 ohms/square) and also reduces optical absorption. At the densification time/temperature, the boron diffuses substantially, which results in a conventional p-n junction solar cell without a hyperabrupt junction. Therefore, polysilicon solar cells with hyperabrupt junctions could not be achieved.
[0006] A similar type of high efficiency single-junction solar cells, reaching 24.7% efficiency, use a selective emitter structure such as that shown in FIG. 1 . (See A. Aberle, Crystalline Silicon Solar Cells: Advanced Passivation and Analysis, UNSW Books, Sydney, 1999). The selective emitter consists of a shallow, moderately doped diffusion 106 in the areas between the contacts 102 (on the order of 0.3 μm thick, 10 19 /cm 3 doping), and a deep, highly doped region 108 under the contacts (on the order of 1-3 μm deep and doped 5×10 19 /cm 3 ). The contact openings through coating 104 are 2-3 μm wide, and the metal grid lines 102 are aligned over these small openings. The narrow contacts are needed to minimize the metal contact area with the surface, as this contact region causes high carrier recombination.
[0007] This structure is complex to fabricate for a number of reasons. First, the deep diffusion must be done in a process step separate from the shallow diffusion, and can require several hours diffusion time. Second, the contact holes and contact lines must be lithographically aligned to the deep diffusions. This precise lithography is costly and slow. Third, small contact holes are needed, forcing use of high resolution lithography.
[0008] Another type of known solar cell is the MIS type solar cell (see Sze, Physics of Semiconductor Devices, second edition, Wiley, 1981, page 820). These devices can be combined with polysilicon contacts to provide the proper work function (see Green, Solar Cells: Advanced Principles & Practice, Center for Photovoltaic Devices and Systems, University of New South Wales, Sydney, 1995, pp. 181-186 and 212-214).
[0009] The MIS solar cell structure is shown in FIG. 2A . It consists of a thin tunnel oxide 204 —typically 15 Å thick over a p-type substrate 202 . Front contact fingers 206 are formed over the oxide, using either metal or polysilicon, with the latter preferred to avoid pinning the Fermi level of the surface. The substrate under the tunnel oxide may also be doped in order to provide lateral conductivity and reducing surface recombination. Back contacts 208 are formed to complete the device.
[0010] A problem with this device structure is shown in FIG. 2B , which graphically depicts the junction characteristics. As mentioned above, SiO 2 in layer 204 is a poor diffusion barrier. Consequently, dopant atoms from the polysilicon contact 206 will diffuse into the underlying silicon 202 . For example, if the polysilicon is N-type and doped with phosphorous, then the phosphorous will diffuse through the thin SiO 2 during growth of the polysilicon, causing the underlying silicon to be N-type as well. Consequently, there will be a relatively small field 210 across the SiO 2 as shown in FIG. 2B . As the tunneling current is an exponential function of this field, the thin SiO 2 will thus cause a series resistance that reduces cell fill factor and efficiency.
[0011] Another problem of the prior art MIS cell is that the layers such as the polysilicon and thin SiO 2 were formed in diffusion furnaces, where the wafers are held vertically in slotted boats. This is adequate for thicker wafers (>200 μm thickness), but will result in unacceptable breakage for thinner wafers.
[0012] Therefore, there is an opportunity for improvement to form a tunnel dielectric that prevents diffusion in order to increase the field across the dielectric, and for processes that allow formation of layers with wafers on planar susceptors. Moreover, there remains a need in the art for a less complex structure and technique for forming point contacts in a solar cell. Still further, there remains a need in the art for polysilicon emitter and other types of solar cells with hyperabrupt junctions, and methods for making the same.
SUMMARY
[0013] The present invention relates to polysilicon and shallow emitter solar cells, and more particularly to such types of solar cells with hyperabrupt junctions, and methods for making such solar cells. According to one aspect, a polysilicon emitter solar cell according to the invention includes a nitrided tunnel insulator. The nitridation prevents boron diffusion, enabling a hyperabrupt junction for a p-poly on n-Si device. One favorable result is a very low reverse saturation current device on a low cost substrate. A nitrided oxide is used as a diffusion barrier to enable use of a polysilicon emitter.
[0014] According to another aspect, a nitrided oxide (DPN) is used in a tunnel oxide layer of a MIS solar cell structure. The DPN layer minimizes plasma damage, resulting in improved interface properties. An overlying polysilicon emitter can then provide a low sheet resistance emitter without heavy doping effects in the substrate, excess recombination, or absorption, and is a significant improvement over a conventional diffused emitter or TCO. The films for the MIS structure can be formed using planar processes suitable for thin wafers that could not be stacked in a diffusion tube, as is done conventionally. The combination of a DPN oxide and polysilicon emitter results in a high doping gradient across the DPN oxide, and, therefore, a high field to reduce series resistance. The DPN film may be charged to create surface inversion or control surface carrier concentration, obviating the need for doping the substrate. The substrate surface may be counter doped to increase the tunneling field (and current) across the MIS oxide.
[0015] The present invention further relates to methods and apparatuses for improved emitter contacts for solar cells. According to another aspect, the invention includes a method for making a solar cell structure that is functionally equivalent to a selective emitter, but without the requirement for multiple diffusions, long diffusions, aligned lithography, or fine contact holes.
[0016] In furtherance of these and other aspects, a solar cell according to some embodiments of the invention comprises a substrate, a tunnel dielectric that is nitrided formed over the substrate, and a doped polysilicon layer formed over the nitrided tunnel dielectric.
[0017] In additional furtherance of these and other aspects, a solar cell emitter contact according to some embodiments of the invention comprises a dielectric layer formed over an emitter having an opening formed therein; a nitrided layer formed over the dielectric layer and in the opening; a polysilicon layer overlapping the opening; and metallization in contact with the polysilicon layer.
[0018] In yet additional furtherance of these and other aspects, a MIS solar cell according to some embodiments of the invention comprises a substrate; a polysilicon layer over the substrate; an insulating layer between the substrate and the polysilicon layer that includes a nitrided diffusion barrier to prevent diffusion from the gate into the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures, wherein:
[0020] FIG. 1 shows a selective emitter structure in conventional high efficiency solar cells;
[0021] FIGS. 2A and 2B illustrate certain properties of an emitter structure in conventional high efficiency MIS type solar cells;
[0022] FIG. 3 shows a polysilicon emitter solar cell structure according to embodiments of the invention;
[0023] FIG. 4 shows a process flow for making a polysilicon emitter solar cell having a hyperabrupt junction according to embodiments of the invention;
[0024] FIG. 5 shows an improved emitter contact structure for a solar cell according to embodiments of the invention;
[0025] FIGS. 6A and 6B show process flows for a conventional solar cell structure and a solar cell structure according to embodiments of the invention, respectively; and
[0026] FIGS. 7A and 7B illustrate certain properties of an emitter structure with underlying nitrided layer in MIS type solar cells according to embodiments of the invention.
DETAILED DESCRIPTION
[0027] The present invention will now be described in detail with reference to the drawings, which are provided as illustrative examples of the invention so as to enable those skilled in the art to practice the invention. Notably, the figures and examples below are not meant to limit the scope of the present invention to a single embodiment, but other embodiments are possible by way of interchange of some or all of the described or illustrated elements. Moreover, where certain elements of the present invention can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present invention will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the invention. In the present specification, an embodiment showing a singular component should not be considered limiting; rather, the invention is intended to encompass other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present invention encompasses present and future known equivalents to the known components referred to herein by way of illustration.
[0028] The present invention recognizes that hyperabrupt junctions provide improved efficiency in solar cells because the open circuit voltage is related to the log of the ratio of the light-generated current, J L , to the reverse saturation current, J 0 , as
[0000] V oc =kT/q ln( J L /J 0 +1)
[0000] Where the reverse saturation current is given by
[0000] J 0 =q ( D n n p /L n +D p p n /L p )
[0000] where D is the minority carrier diffusivity, n(p) is the minority carrier concentration, and L is the diffusion length. For example, in the case of p-type poly on a low doped n-type substrate, the poly is heavily doped, so the minority carrier concentration, n p , is essentially zero. Therefore, only the second term contributes to the J 0 . Very low values can be achieved, as the value of L is large.
[0029] The present inventors further recognize that silicon nitride and silicon oxy-nitride layers can be used to block boron diffusion. These can be formed either by growing a silicon dioxide layer and implanting nitrogen to form an oxynitride, or by thermally growing a silicon nitride layer on silicon or on a very thin SiO 2 base.
[0030] Accordingly, in one embodiment, the present invention forms a polysilicon emitter solar cell with improved junction properties, as shown in FIG. 3 . As shown in FIG. 3 , the solar cell consists of a junction formed through deposition of a nitrided gate tunnel insulator 304 under a boron doped polysilicon layer 306 and on top of a p-type substrate 302 . In contrast to the gate stack on an MOS transistor, the nitride layer covers the full surface of the solar cell. Grid lines 308 complete the top surface of the cell.
[0031] An aspect of the invention is the use of the nitrided gate insulator layer 304 instead of silicon dioxide. The nitrided insulator blocks boron diffusion, providing an abrupt junction even with use of a thermal densification step. The densification step is advantageous for two reasons. First, it reduces the resistivity of the polysilicon 306 so that it can be used to conduct current to contact grid lines 308 . Second, it reduces the optical absorption of the polysilicon. Although the polysilicon emitter solar cell and nitrided gate oxide are both known in the art, these elements have existed for over a decade without this combination having appeared in the prior art for the solar cell application. In fact, as recently as 2006 a U.S. application was filed (U.S. Patent Pub. 2007/0256728) explicitly referring to use of a tunnel oxide with no mention of a nitrided tunnel dielectric, and explicitly avoiding high temperature steps in the description of the specification.
[0032] FIG. 4 shows an example process flow according to this embodiment of the invention. After the surface of a silicon substrate is cleaned in step S 402 , a tunnel insulator layer is formed. According to the invention, silicon nitride and silicon oxy-nitride layers for the tunnel insulator can be used to block boron diffusion. As shown in FIG. 4 , these can be formed either by growing a silicon dioxide layer in step S 404 and implanting nitrogen to form an oxynitride in step S 406 , or by thermally growing a silicon nitride layer on silicon or on a very thin SiO 2 base in step S 408 . In either event, the tunnel insulator is preferably on the order of 8-12 Å thick.
[0033] As further shown in FIG. 4 , the polysilicon layer is next formed. Preferably, the polysilicon layer is about 500-1000 Å thick, and the poly doping is in the range of 2 to 20×10 20 /cm 3 , providing a sheet resistance on the order of 50-200 ohms/square. As shown, the deposition preferably takes place in two steps S 410 and S 412 . First, the poly is deposited at 670° C. using conventional CVD decomposition of silane or disiane. Next, the poly is densified with a 30 second 1050° C. anneal.
[0034] It should be apparent that additional processing steps can be performed to form contacts on the front and/or back surface of the cell.
[0035] In accordance with further aspects, embodiments of the present invention use a polysilicon tunnel junction to replace the deep diffusion in a selective emitter type solar cell. This eliminates the deep diffusion and associated patterning step, and enables the remaining patterning to be done without critical alignment or fine features.
[0036] A structure according to these embodiments of the invention is shown in FIG. 5 . As shown, it includes a doped emitter layer 504 formed over a silicon substrate 502 . A buried oxide layer 506 is formed on emitter layer 504 with contact holes etched in it between portions of polysilicon layer 508 and contacts 510 . According to further aspects of the invention, a thin tunnel oxide layer (not shown) is also included between polysilicon layer 508 and emitter layer 504 . Further details regarding this structure will become apparent from the process flow descriptions below.
[0037] To assist in understanding aspects of the invention, a conventional process flow is shown in FIG. 6A and a process flow according to these embodiments of the invention is shown in FIG. 6B .
[0038] As shown in FIG. 6A , in the prior art, the deep diffusion step S 606 must be done in the contact areas, requiring a prior masking oxide formation step S 602 and patterning step S 604 . After the subsequent deep diffusion step S 606 , the masking oxide is stripped in S 608 . The remaining processing steps S 610 to S 620 are then performed, which to the extent are helpful to understanding the invention and are similar to those of the invention, will be described below.
[0039] As shown in FIG. 6B , the first three steps in the conventional process are eliminated in the new process, which begins with the shallow emitter 504 diffusion in step S 652 , and which can be performed in many ways known to those skilled in the solar cell arts. A passivation oxide 506 is then formed in step S 656 , and holes etched in it in step S 658 . Differently from the prior art, this step S 658 can be performed as disclosed in co-pending PCT application No. PCT/US09/31868, as well as other ways known to those skilled in the solar cell arts. Because the contacts themselves are passivated, it is not necessary to restrict the hole size to 2-3 μm, and much larger holes can be formed. This enables the patterning step to be done using screen printing rather than lithography.
[0040] Further different from the conventional process, a thin tunnel oxide is then grown in step S 660 , using processes such as Applied Materials' ISSG. This oxide is on the order of 12 Å thick, and is preferably nitrided to improve diffusion barrier properties. Next, in step S 662 , a thin polysilicon layer 508 is then deposited, which is on the order of 200-500 Å thick. The thin poly is transparent, and absorbs only a very small fraction of the incoming light. The polysilicon, or alternately, the oxide/polysilicon combination, provides contact passivation. Further passivation may be obtained by offsetting the metal conductor lines from the contact holes, so that the underlying oxide isolates the contacts 510 from the emitter 504 .
[0041] The metal contacts 510 are then formed in steps S 664 and S 666 . Note that because the poly is conductive, these need not be aligned over the contact holes, but must only be close to the contact holes. Therefore, fine aligned lithography is not needed in this step.
[0042] According to further aspects, the present inventors recognize that silicon nitride films have been considered for surface passivation in solar cells. These films are often charged in order to invert the surface, reducing the concentration of majority carriers at the surface and thereby suppressing recombination in surface traps. It is thought that films deposited using the most common methods—plasma-enhanced chemical vapor deposition (PE-CVD) and sputtering—may have surface damage due to initiation of the plasma, which somewhat degrades the passivation performance of these films. The issue is that there is no film present to protect the surface when the plasma first turns on.
[0043] In a next preferred embodiment of the invention, therefore, a nitrided gate film is first formed on the solar cell surface. This can be done in a two step process. Following a surface clean and HF etch to remove native oxide, a thin SiO 2 layer is formed, typically 12 to 15 Å thick. This layer is then nitrided in a remote nitrogen plasma. Low energy nitrogen ions from a plasma inject themselves into the oxide, forming a thin top layer of silicon nitride. The interface with the silicon remains silicon dioxide, with good passivation properties. The presence of the silicon dioxide during the nitridation also protects the surface from plasma damage, overcoming the problem of surface plasma damage known in the prior art. This process can be implemented using commercially available technologies, for example, as the DPN process from Applied Materials. Depending on the process parameters, more or less nitrogen can be injected into the oxide. The nitrogen ions are positively charged, so a residual charge may be left in the oxide. This can be used to bias the surface. For example, if the substrate is P-type, the charge can be used to invert the surface, thereby further reducing recombination. However, this must be done in a controlled manner, as inversion will reduce the field across the oxide required to sustain a tunneling current as described later in the invention.
[0044] Next, a polysilicon layer is grown over the DPN layer, typically 2000 Å thick, This layer may be in-situ doped using arsenic or phosphorous for n-type, or boron for p-type. A unique advantage for solar cells is that the nitrided oxide now forms a diffusion barrier to prevent diffusion of the dopant into the underlying silicon. In other cases, the poly may be doped using plasma immersion ion implantation, although a high temperature annealing step is then required to activate dopants. In the preferred embodiment the polysilicon layer is uniformly doped to minimize the resistance of the structure. Contacts are then added on the front and back to complete the structure as in conventional processing.
[0045] FIG. 7A shows the finished MIS solar cell structure using processes described above in accordance with these embodiments of the invention. As shown, it includes a tunnel oxide layer 704 formed over a substrate 702 , a polysilicon layer 706 formed over the tunnel oxide layer 704 , and front and back contacts 708 and 710 , respectively. As discussed above, tunnel oxide layer 704 preferably is nitrided to include a thin DPN layer (not shown). FIG. 7B shows the band structure in this case. It should be noted that the field across the oxide is increased over the prior art case of FIG. 2B due to the nitride composition. The tunneling current will be increased, overcoming the series resistance limitation of prior art MIS solar cells.
[0046] Note that in some cases the poly contacts are formed as localized regions, as in FIG. 2A . However, because a thin polysilicon layer has relatively little light absorption, the polysilicon may be formed over a large region, or even the entire surface of the solar cell. This reduces the sheet resistance of the surface without adding undesired recombination at the interface between the poly and the cell (by virtue of the presence of the tunnel oxide). The benefit is again seen as reduced series resistance of the cell and improved efficiency.
[0047] In some cases, a doped layer can be formed in the top surface of the silicon before formation of the DPN layer. This is of the same conductivity type as the substrate and of lower doping than the polysilicon; for example, 10 17 to mid-10 18 atoms/cm 3 . The purpose is to form a region devoid of minority carriers to minimize recombination at the interface between the DPN layer and the substrate. This layer may be 1000 to 2000 Å thick, and may be formed using gaseous diffusion. However, as noted above, this doping will reduce the field across the dielectric, so a lower doping is preferred if it is used.
[0048] Although the present invention has been particularly described with reference to the preferred embodiments thereof, it should be readily apparent to those of ordinary skill in the art that changes and modifications in the form and details may be made without departing from the spirit and scope of the invention. It is intended that the appended claims encompass such changes and modifications. | The present invention relates to polysilicon emitter solar cells, and more particularly to polysilicon emitter solar cells with hyperabrupt junctions, and methods for making such solar cells. According to one aspect, a polysilicon emitter solar cell according to the invention includes a nitrided tunnel insulator. The nitridation prevents boron diffusion, enabling a hyperabrupt junction for a p-poly on n-Si device. According to another aspect, a nitrided oxide (DPN) is used in a tunnel oxide layer of a MIS solar cell structure. The DPN layer minimizes plasma damage, resulting in improved interface properties. An overlying polysilicon emitter can then provide a low sheet resistance emitter without heavy doping effects in the substrate, excess recombination, or absorption, and is a significant improvement over a conventional diffused emitter or TCO. According to another aspect, the invention includes a method for making a solar cell structure that is functionally equivalent to a selective emitter, but without the requirement for multiple diffusions, long diffusions, aligned lithography, or fine contact holes. | 8 |
BACKGROUND OF THE INVENTION
The term avermectin (previously referred to as C-076) is used to described a series of compounds isolated from the fermentation broth of an avermectin-producing strain of Streptomyces avermitilis and derivatives thereof. The morphological characteristics of the culture are completely described in U.S. Pat. No. 4,310,519. The avermectin compounds are a series of macrolides, each of which is substituted at the 13 position with a 4-(α-L-oleandrosyl)-α-L-oleandrose group. The avermectin compounds and the derivatives of this invention have a very high degree of anthelmintic and anti-parasitic activity.
The avermectin series of compounds isolated from the fermentation broth have the following structure: ##STR1## wherein R 4 is the 4'-(L-oleandrosyl)-α-L-oleandrosyloxygroup of the structure ##STR2## and wherein A at the 22,23 position indicates a single or a double bond; R 1 is a hydrogen or hydroxy and is present only when A indicates a single bond;
R 2 is iso-propyl or sec-butyl; and
R 3 is methoxy or hydroxy.
There are eight different avermectin natural product compounds and they are given the designations A1a, A1b, A2a, A2b, B1a, B1b, B2a, and B2b based upon the structure of the individual compounds. In the foregoing structural formula, the individual avermectin compounds are as set forth below.
______________________________________(The R group is4'α(L-oleandrosyl)α-L-oleandrosyloxy.)(A) R.sub.1 R.sub.2 R.sub.3______________________________________A1a double bond -- sec-butyl --OCH.sub.3A1b double bond -- iso-propyl --OCH.sub.3A2a single bond --OH sec-butyl --OCH.sub.3A2b single bond --OH iso-propyl --OCH.sub.3B1a double bond -- sec-butyl --OHB1b double bond -- iso-propyl --OHB2a single bond --OH sec-butyl --OHB2b single bond --OH iso-propyl --OH______________________________________
The avermectin compounds are generally isolated as mixtures of a and b components. Such compounds differ only in the nature of the R 2 substituent and the minor structural differences have been found to have very little effect on the isolation procedures, chemical reactivity and biological activity of such compounds.
In addition to these natural avermectins containing the 25-iso-propyl or 25-sec-butyl-substituent, closely related derivatives containing other branched or cyclic 25-alkyl or 25-alkenyl substituents, including those further substituted by heteroatoms such as oxygen, sulfur, nitrogen, and halogen, are known in the literature. These derivatives are obtained through various adjustments and additions to the fermentation procedures as described fully in the European Patent Application EPO 0 214 731.
Avermectins are products of microbial fermentations using the actinomycete Streptomyces avermitilis. These microbes use acetates and propionates as building blocks for most of the avermectin carbon chain, which is then further modified by microbial enzymes to give the completed avermectin molecules. It is known, however, that the carbon C-25 and the 2-propyl and 2-butyl substituents at this carbon are not derived from acetate or propionate units, but are derived from the amino acids L-valine and L-isoleucine, respectively. It was reasoned that these amino acids are deaminated to the corresponding 2-ketoacids, and that these then are decarboxylated to give 2-methylpropionic and 2-methylbutyric acids. These acids then have been found to be directly incorporated into the avermectin structures to give the 2-propyl and 2-butyl C-25 substituents, as is reported by Chen et al., Abstr. Pap. Am. Chem. Soc. (186 Meet., MBTD 28, 1983). It was also disclosed in European Patent Application number 0 214 731 that additions of large amounts of other acids such as cyclopentanoic, cyclobutyric, 2-methylpentanoic, 2-methylhexanoic, thiophene-3-carboxylic acids and others to the fermentation broth of S. avermitilis causes the microbes to accept these acids as substitutes and to make small amounts of avermectins containing these acids in form of new C-25 substituents. Examples of such new avermectin derivatives are:
25-(thien-3-yl)-25-de-(1-methylpropyl)avermectin A2a
25-(cyclohex-3-enyl)-25-de-(1-methylpropyl)avermectin A2a
25-cyclohexy-25-de-(1-methylpropyl)avermectin A2a
25-(1-methylthioethyl)-25-de-(1methylpropyl)avermectin A2a
25-(2-methylcyclopropyl)-25-de-(1-methylpropyl)avermectin A2a.
Similar experiments producing avermectins "c" and "d" containing as C-25 substituents a 2-pentyl and 2-hexyl group are described by T. S. Chen et al. in Arch. Biochem. Biophys. 1989, 269, 544-547.
Still additional avermectin derivatives are produced through artificial modification of the fermentation of Streptomyces avermitilis either by addition of metabolic inhibitors such as sinefungin (as described by Schulman et al., J. Antibiot. 1985, 38, 1494-1498) or by mutation of the parent strain (as described by Schulman et al., Antimicrobial Agents and Chemotherapy, 1987, 31, 744-747, and by EP-276-131-A to Pfizer INC.). Some of these avermectin derivatives are still further modified and are missing one or two of the 3'- and 3"-O-methyl groups (Schulman et al., J. Antibiot. 1985, 38, 1494-1498).
The fermentation products have been chemically modified in order to obtain further antiparasitic and insecticidal analogs with improved properties. Publications of such procedures in the scientific and patent literature have been reviewed by Fisher, M. H.; Mrozik, H.; in Macrolide Antibiotics; Omura, S., Ed.; Academic: New York, 1984; pp. 553-606, and by Davies, H. G.; Green, R. H. Nat. Prod. Rep., 1986, 3, 87-121.
For example, a group of semisynthetic avermectin derivatives were obtained by hydrogenating specifically the 22,23-double bond of avermectin B1 giving 22,23-dihydroavermectin B1 derivatives which have very potent anthelmintic and antiparasitic properties. Other examples of semisynthetic avermectin derivatives contain a 8,9-oxide group, a 4α-hydroxy or acyloxy group, a 23-keto group, which all are potent antiparasitic and insecticidal compounds.
It has also been described by Mrozik in U.S. Pat. No. 4,427,663 that amino substituents at the 4"- and 4'-positions have very high antiparasitic and insecticidal activities.
These compounds may be used as starting materials for the compounds of this invention without further modification, or when containing additional reactive groups, which are not to be modified under the reaction conditions applied, only after protection of such with a suitable protecting group.
SUMMARY OF THE INVENTION
The instant invention is concerned with novel avermectin derivatives, specifically those derivatives which are modified at the 3- and 4-positions. Specifically 3-hydroxy and 4-oxo, 4-epoxide, 4,4 a dihydroxy and the 4-oxo compounds are prepared. The compounds are prepared by the oxidation of the known 3-hydroxy 4-exomethylene compound. Thus, it is an object of this invention to describe such compounds. It is a further object of this invention to describe processes for the preparations of such compounds. It is a further object of this invention to describe a series of process steps which enables the preparations of avermectin compounds with a radio-active carbon label at the 4a-position. A still further object of this invention is to describe the use of such compounds as anthelmintic agents. A still further object is to describe compositions containing such compounds as the active ingredient thereof. Further objects will be apparent from a reading of the following description.
DESCRIPTION OF THE INVENTION
The compounds of the instant invention are best realized in the foregoing structural formula: ##STR3## where R 1 is hydroxy or loweralkanoyloxy; R 2 is hydroxy or loweralkanoyloxy and R 3 is hydroxymethyl or loweralkanoyloxy methyl; or
R 2 and R 3 together represent oxo or an epoxide;
R 4 is hydroxy, loweralkoxy, loweralkanoyl, oxo or oximino;
R 5 is hydrogen, hydroxy, ##STR4## where R 8 is hydroxy, oxo, amino or mono- or di-substituted amino where the substituents are loweralkyl or loweralkanoyl;
R 6 is hydrogen, hydroxy or oxo and the broken line at the 22,23-position indicates a 22,23-single bond or the broken line at 22,23 indicates a 22,23-double bond and R 6 is not present; and
R 7 is loweralkyl or loweralkenyl or cycloloweralkyl.
The term "loweralkyl" as used in the instant applications is intended to include those alkyl group at from 1 to 6 carbon atoms of either a straight or branched chain configuration. Examples of such alkyl groups are methyl, ethyl, propyl, isopropyl, butyl, tertiary butyl, pentyl, isopentyl, hexyl and the like.
The term "loweralkoxy" is intended to include those alkoxy groups of from 1 to 6 carbon atoms of either a straight or branched configuration. Examples of such alkoxy groups are methoxy, ethoxy, propoxy, isopropoxy, butoxy, secondary butoxy, pentoxy, hexoxy and the like.
The term "loweralkanoyl" is intended to include those alkanoyl groups of from 1 to 6 carbon atoms of either a straight or branched configuration. Examples of such alkanoyl groups are formyl, acetyl, propionyl, butyryl, isobutyryl, pentanoyl, hexanoyl, and the like.
Preferred compounds of the instant invention are realized in the foregoing structural formula wherein R 1 is hydroxy;
R 2 is hydroxy and R 3 is hydroxy methyl; or
R 2 and R 3 together represent oxo or an epoxide;
R 4 is hydroxy, loweralkoxy, oxo or oximino;
R 5 is hydrogen, hydroxy, or ##STR5## where R 8 is hydroxy, amino or mono- or di-substituted amino when the substituents are lower alkyl or lower alkanoyl;
R 6 is hydrogen or hydroxy and the broken line at 22,23- represents a 22,23-single bond; and
R 7 is lower alkyl.
Further preferred compounds of the instant invention are realized in the foregoing structure wherein R 1 , R 2 and R 3 are as defined above;
R 4 is hydroxy, methoxy or oximino;
R 5 is ##STR6## R 8 is hydroxy, amino, methylamino or acetylamino; R 6 is as defined above; and
R 7 is isopropyl or sec-butyl.
The compounds of the instant invention are prepared by the process outlined in the following reaction scheme wherein, for simplicity, only carbon atoms 2 through 7 are shown: ##STR7##
In the foregoing Reaction Scheme, compounds 1, 2A and 2B and the preparation thereof are disclosed in Fraser-Reid et. al. J. Org. Chem., 53, pg 923-925 (1988).
The immediate starting material for the compounds and process of this invention are prepared by the procedures described in Fraser-Reid et al supra where the 4a-methyl group is substituted with a phenylseleno group using N-(phenylseleno) phthalimide to prepare Compound 1 in the Reaction Scheme. This compound, after suitable protection, is treated with hydrogen peroxide in pyridine to prepare the stereoisomeric pair 2A and 2B.
The 3β-hydroxy compound, 2B, is only used with the next step of the reaction schemes because the 3α-stereochemistry of 2A prevents the proper reaction to compound 3. The reaction of compound 2B to compound 3 is accomplished with an oxidizing reagent, preferably osmium tetroxide. Other oxidizing reagents have been tried such as permanganate, but osmium tetroxide has been found to be superior. The reaction is carried out in a nonpolar solvent preferably a hydrocarbon such as benzene or toluene. Benzene is preferred. The reaction is carried out preferably at room temperature and is complete in from 5 minutes to 5 hours. Higher temperature, up to 50° C. will reduce the reaction time somewhat.
The trihydroxy compound 3 is treated with lead acetate in a hydrocarbon solvent such as benzene or toluene at a reaction temperature of from 20° to 60° C., preferably about 40°-50° C. to prepare the 4-oxo compound (4). The reaction is very fast and is generally complete as soon as the lead tetracetate is added to the starting material solution. The reaction may be followed chromatographically to determine that the reaction is complete.
Compound 4 is then treated with a methylenating ylide reagent. Several such reagents are available however, the methylated ylide from dimethylsulfoxide (See Example 6) has been found to be very simple to prepare and the best reagent for introducing radioactive carbon to the molecule. The ylide reagent is prepared as described in Corey et al JACS 86 pg. 1353 (1965). The reaction with the 4-oxo compound is carried out in an inert solvent such as methylene chloride, chloroform, THF, ether and the like, preferably methylene chloride, at room temperature. The reaction is very simple and is generally complete in from 10 minutes to 1 hour.
Compound 5 in then reconverted to compound 2B, except for the presence of a radiolabeled carbon atom at the 4-position by using an epoxide deoxygenating reagent such as 3-methylbenzothiazole-2-selone. The reaction is carried out in an inert solvent, preferably a hydrocarbon such as benzene at room temperature and is complete in for 5 to 20 hours.
The 4-methylene reagent, compound 2B, now with a radiolabel at the 4-methylene can be converted back to the avermectin structure without the 3-hydroxy by following the procedures of Fraser-Reid et al. Generally the procedure involves the preparation of the methanesulfonyl derivative of the 3-hydroxy, the bromination of the 4-methylene which simultaneously cleaves the methanesulfornyloxy group and forms the 4,5-double bond. The 4a-bromo can then be cleaved being the normal avermectin structure with the correct stereochemistry and radiolabeled at the 4a methyl group.
It is noted that in the foregoing Reaction Scheme, the process proceeds from Compound 2B to Compound 5 and then back to Compound 2B. This circular process has advantages because in Compound 2B the carbon atom at 4a, the exomethylene carbon atom, at the start of the process, is not the same 4a carbon atom at the end of the process. This process thus allows the 4a carbon to be changed to a radioactive carbon atom such as isotopic 13 C or radioactive 14 C. The original 4a-carbon atom would have been synthesized during the natural fermentation process that originally prepared the avermectin carbon atom and the specific inclusion of a radioactive carbon atom at a particular site would have been impossible. The specific inclusion of radioactive carbon atoms in the avermectin molecule is very important in carrying out studies to determine the fate of the molecule when it is administered to a living animal or when it is applied to plants, soils or aquatic environments. Thus, an aspect of this invention is the process of incorporating a radioactive carbon atom specifically into the 4a position of the avermectin molecule.
In addition, however, all of the compounds and derivatives thereof, that are prepared as intermediates in the cyclic process from compound 2B and back again to compound 2B are unique avermectin compound and active anthelmintic agents.
PREPARATION OF STARTING MATERIALS
The ultimate starting materials for the compounds of this invention are the avermectin fermentation products defined above which have the isopropyl or sec-butyl group at the 25-position. Thus it is apparent that additional reactions are required to prepare many of the immediate starting materials for the instant compounds. Specifically, reactions are carried out at the 4', 4", 5', 13, and 23 positions. In addition, during the various reactions described above, and below it may be necessary to protect various reactive groups to prevent the undesired reaction of such groups. In addition, protection of such reactive groups may facilitate the separation of the various products. Following the described reactions, the protecting groups may be removed and the unprotected product isolated. The protecting group employed is ideally one which may be readily synthesized, will not be affected by the reaction with the various reagents employed and may be readily removed without affecting any other functions of the molecule. It is noted that the instant protected compounds are novel and have considerable antiparasitic activity. They are included within the ambit of the instant invention. One preferred type of protecting group for the avermectin type of molecule is the tri-substituted silyl group, preferably the trialkyl silyl group. One especially preferred example, is the t-butyl dimethylsilyl group. The reaction preparing the protected compound is carried out by reacting a hydroxy compound with the appropriately substituted silylhalide, preferably the silylchloride in an aprotic polar solvent such as dimethylformamide. Imidazole is added as a catalyst. The reaction is complete in from 1 to 24 hours at from 0° to 25° C. For the 5-position hydroxy group the reaction is complete in from 1/2 to 3 hours at from 0° C. to room temperature. This reaction is selective to the 5 position under the conditions above described and very little, if any, silylation is observed at other hydroxy substituted positions.
The silyl groups are then removed after the other reactions have been carried out. The silyl group or groups are removed by stirring the silyl compound in methanol catalyzed by a catalytic amount of an acid, preferably a sulfonic acid such as p-toluene sulfonic acid. The reaction is complete in about 1 to 12 hours at from 0° to 50° C. Alternatively, the silyl group or groups can be removed with a hydrogen fluoride-pyridine complex in an organic solvent such as tetrahydrofuran. The reaction is complete in from about 3 to 24 hours and is preferably carried out at room temperature.
Additional reactions which may be carried out to prepare the compounds of this invention are the selective removal of one of the α-L-oleandrosyl moieties (described in U.S. Pat. No. 4,206,205 to Mrozik et al.).
The reaction conditions which are generally applicable to the preparation of both the mono-saccharide and aglycone involve dissolving the avermectin compound or the hydrogenated avermectin compound in an aqueous acidic non-nucleophilic organic solvent, miscible with water, preferably dioxane, tetrahydrofuran, dimethoxyethane, dimethylformamide, bis-2-methoxyethyl ether, and the like, in which the water concentration is from 0.1 to 20% by volume. Concentrated sulfuric acid is added to the aqueous organic solvent to the extent of 0.01 to 10% by volume. The reaction mixture is generally stirred at about 20°-40° C., preferably at room temperature, for from 6 to 24 hours. The lower concentration of acid, from about 0.01 to 0.1% will predominately produce the monosaccharide under the above reaction conditions. Higher acid concentrations, from about 1 to 10% will predominantly produce the aglycone under the above reaction conditions. Intermediate acid concentrations will generally produce mixtures of monosaccharide and aglycone. The products are isolated, and mixtures are separated by techniques such as column, thin layer preparative and high pressure liquid chromatography, and other known techniques.
The acids which may be employed in the above process include mineral acids and organic acids such as sulfuric, hydrohalic, phosphoric, trifluoroacetic, trifluoro methane sulfonic and the like. The hydrohalic acids are preferably hydrochloric or hydrobromic. The preferred acid in the above process is sulfuric acid.
A further procedure for the preparation of the monosaccharide or aglycone of the avermectin compounds or of the hydrogenated avermectin compounds utilizes a different solvent system for the mono-saccharide and the aglycone. The procedure for the preparation of the monosaccharide uses 1% acid by volume in isopropanol at from 20°-40° C., preferably room temperature, for from 6 to 24 hours. For the preparation of the aglycone, 1% acid, by volume, in methanol under the foregoing reaction conditions has been found to be appropriate.
Any strong inorganic or organic acid is appropriate for this process, and again sulfuric acid is the preferred acid.
It has also been observed that the mono-saccharide is prepared during the course of the reaction used to remove the trialkylsilyl protecting group. Since acid catalysis is used to remove the protecting group, this is expected. However, in such cases, both the desired product and the monosaccharide are prepared and they can be readily separated using the above-described techniques.
The 4"-, 4'-, 13- and/or 23-hydroxy groups are oxidized to the 4"-, 4'-, 13- and/or 23-keto groups respectively using oxidizing agents such as pyridinium dichromate; oxalylchloride-dimethylsulfoxide; acetic anhydride-dimethylsulfoxide; chromic acid-dimethylpyrazole; chromic acid; trifluoromethylacetic anhydride-dimethylsulfoxide; chromic acid-acetic acid; and the like. Oxalylchloride-dimethylsulfoxide (Swern oxidation) is the preferred oxidizing method. Suitably protectd compounds, as described above, are employed. The reaction is carried out at from dry-ice bath temperatures to room temperature, preferably from dry-ice bath temperatures to 0° C., and is complete in from 1-24 hours. The reaction may be carried out in any solvent in which the starting materials are reasonably soluble, and which will not react with the oxidizing agent. Such solvents as dimethylformamide, dimethylsulfoxide, methylene chloride, chloroform, carbon tetrachloride and the like are acceptable. For pyridinium dichromate reactions, dimethylformamide and dimethylsulfoxide are preferred. For chromic acid-dimethylpyrazole reactions, methylene chloride is preferred. The compounds are isolated from the reaction mixture using procedures known to those skilled in the art.
The4' or 4"-keto compound is aminated to prepare the unsubstituted amino compound as described in U.S. Pat. No. 4,427,663 to Mrozik. The reaction is carried out in an inert solvent such as methanol at from -10° to +25° C. using ammonium salts and sodium cyanoborohydride as the aminating and reducing reagents, respectively. The reaction is complete in from 15 minutes to 24 hours and the product 4"-deoxy-4"-amino compound is isolated using techniques known to those skilled in the art. Suitable ammonium salts are the acetate, propionate, benzoate and the like. The acetate is preferred.
As a variation to the foregoing amination reaction, methyl ammonium salts can be used in place of the ammonium salts to prepare the monomethyl substituted compound directly. The same reagents, salts and reaction conditions as described above can be used for such a reaction.
The substitution reaction wherein the substituent on the various hydroxy groups or on the 4"-amine is an acyl function is carried out using an acylating reagent in the presence of a base in an inert solvent. The acylation of avermectin compounds, is fully described in U.S. Pat. No. 4,201,861 to Mrozik et al. THe preferred acylating reagents are loweralkanoyl anhydrides, loweralkanoyl halides, substituted benzene sulfonyl chlorides, lower alkyl sulfonyl chlorides, and the like. The reaction is carried out in an inert solvent such as methylene chloride in the presence of a non-reactive base such as pyridine or triethylamine in order to neutralize the acid produced during the course of the reaction. The reaction temperature is from -10° to 25° C. and the reaction is complete in from 5 minutes to 8 hours. The product is isolated using known techniques.
The reaction for the preparation of the 4'-or 4"-deoxy-4'- or 4"-dialkylamino compounds is carried out using the alkylating reaction conditions of an excess of a carbonyl compound, preferably formaldehyde and a reducing agent such as sodium cyano borohydride, in methanol. The reaction is carried out in a solvent suitable to dissolve the organic starting material using excess aqueous formaldehyde along with the presence of a small amount of acid such as acetic acid to facilitate the reaction. The reaction is carried out at from -10° to +25° C. with the solution of the avermectin compound in methanol added dropwise over a period of from 30 to 60 minutes to the alkylating reagent mixture and the product is isolated using known techniques.
Further reactions of the avermectin compounds are possible to prepare the compounds of this invention.
Following the preparation of the aglycone (R 5 is hydroxy at the 13 position), U.S. Pat. Nos. Re. 32,006 and Re. 32,034 to Chabala et al. disclose the hydroxy group displacement with a halogen using a reagent such as benzene sulfonylhalide, and the halogen is removed by reduction using a reducing agent such as trialkyltin hydride.
The hydroxy group at 5 may be alkylated following the procedures described in U.S. Pat. No. 4,200,581 to Fisher et al.
Another of the starting materials used in the foregoing reaction scheme are those in which the 22,23 double bond of the "1" type compounds has been reduced to a single bond. As is readily apparent from an analysis of the structure of avermectin starting materials there are 5 unsaturations in the 1-series of compounds. Thus in the 1-series of compounds it is necessary to reduce the 22,23 double bond while not affecting the remaining four unsaturations or any other functional group present on the molecule in order to selectively prepare the 22,23 dihydro avermectins. It is necessary to select a specific catalyst for the hydrogenation, one that will selectively hydrogenate the least hindered from among a series of unsaturations. The preferred catalyst for such a selective hydrogenation procedure is one having the formula:
[(R.sub.9).sub.3 P).sub.3 RhY)]
wherein:
R 9 is loweralkyl, phenyl or loweralkyl substituted phenyl and Y is halogen. The reduction procedure is completely described in U.S. Pat. No. 4,199,569 to Chabala et. al.
The instant compounds are potent endo-and ecto-antiparasitic agents against parasites particularly helminths, ectoparasites, insects, and acarides, infecting man, animals and plants, thus having utility in human and animal health, agriculture and pest control in household and commercial areas.
The disease or group of diseases described generally as helminthiasis is due to infection of an animal host with parasitic worms know as helminths. Helminthiasis is a prevalent and serious economic problem is domesticated animals such as swine, sheep, horses, cattle, goats, dogs, cats, fish, buffalo, camels, llamas, reindeer, laboratory animals, furbearing, animals, zoo animals and exotic species and poultry. Among the helminths, the group of worms described as nematodes causes widespread and often times serious infection in various species of animals. The most common genera of nematodes infecting the animals referred to above are Haemonchus, Trichostrongylus, Ostertagia, Nematodirus, Copperia, Ascaris, Bunstomum, Oesophagostomum, Chabertia, Trichuris, Strongylus, Trichonema, Dictyocaulus, Capillaria, Habronema, Druschia, Heterakis, Toxocara, Ascaridia, Oxyuris, Ancylostoma, Unciniaria, Toxascaris and Parascaris. Certain of these, such as Nematodirsu, Cooperia, and Oesophagostomum attack primarily the intestinal tract while others, such as Haemonchus and Ostertagia, are more prevalent in the stomach while still others such as Dictyocaulus are found in the lungs. Still other parasites may be located in other tissues and organs of the body such as the heart and blood vessels, subcutaneous and lymphatic tissue and the like. The parasitic infections known as helminthiases lead to anemia, malnutrition, weakness, weight loss, severe damage to the walls of the intestinal tract and other tissues and organs and, if left untreated, may result in death of the infected host. The compounds of this invention have unexpectedly high activity against these parasites, and in addition are also active against Dirofilaria in dogs and cats, Nematospiroides, Syphacia, Aspiculuris in rodents, arthropod ectoparasites of animals and birds such as ticks, mites, lice, fleas, blowflies, in sheep Lucilia sp., biting insects and such migrating dipterous larvae as Hypoderma sp. cattle, Gastrophilus in horses, and Cuterebra sp. in rodents and nuisance flies including blood feeding flies and filth flies.
The instant compounds are also useful against parasites which infect humans. The most common genera of parasites of the gastro-intestinal tract of man are Ancylostoma, Necator, Ascaris, Strongyloides, Trichinella, Capillaria, Trichuris, and Enterobius. Other medically important genera of parasites which are found in the blood or other tissues and organs outside the gastrointestinal tract are the filiarial worms such as Wuchereria, Brugia, Onchocerca and Loa, Dracunuculus and extra intestinal stages of the intestinal worms Strongyloides and Trichinella. The compounds are also of value against arthropods parasitizing man, biting insects and other dipterous pests causing annoyance to man.
The compounds are also active against household pests such as the cockroach, Blatella sp., clothes moth, Tineola sp., carpet beetle, Attagenus sp., the housefly Musca domestica as well as fleas, house dust mites, termites and ants.
The compounds are also useful against insect pests of stored grains such as Tribolium sp., Tenebrio sp. and of agricultural plants such as aphids, (Acyrthiosiphon sp.); against migratory orthopterans such as locusts and immature stages of insects living on plant tissue. The compounds are useful as a nematocide for the control of soil nematodes and plant parasites such as Meloidogyne sp. which may be of importance in agriculture. The compounds are also highly useful in treating acerage infested with fire ant nests. The compounds are scattered above the infested area in low levels in bait formulations which are broght back to the nest. In addition to a direct-but-slow onset toxic effect on the fire ants, the compound has a long-term effect on the nest by sterilizing the queen which effectively destroys the nest.
The compounds of this invention may be administered in formulations wherein the active compound is intimately admixed with one or more inert ingredients and optionally indlucing one or more additiona active ingredients. The compounds may be used in any composition known to those skilled in the art for administration to humans and animals, for application to plants and for premise and area application to control household pests in either a residential or commercial setting. For application to humans and animals to control internal and external parasites, oral formulations, in solid or liquid or parenteral liquid, implant or depot injection forms may be used. For topical application dip, spray, powder, dust, pour-on, spot-on, jetting fluid, shampoos, collar, tag or harness, may be used. For agricultural premise or area application, liquid spray, powders, dust, or bait forms may be used. In addition "feed-through" forms may be used to control nuisance flies that feed or breed in animal waste. The compounds are formulated, such as by encapsulation, to lease a residue of active agent in the animal waste which controls filth flies or owther arthropod pests.
These compounds may be administered orally in a unit dosage form such as a capsule, bolus or tablet, or as a liquid drench where used as an anthelmintic in mammals. The drench is normally a solution, suspension or dispersion of the active ingredient usually in water together with a suspending agent such as bentonite and a wetting agent or like excipient. Generally, the drenches also contain an antifoaming agent. Drench formulations generally contain from about 0.001 to 0.5% by weight of the active compound. Preferred drench formulations may contain from 0.01 to 0.1% by weight. The capsules and boluses comprise the active ingredient admixed with a carrier vehicle such as starch, talc, magnesium stearate, or di-calcium phosphate.
Where it is desired to administer the instant compounds in a dry, solid unit dosage form, capsules, boluses or tablets containing the desired amount of active compound usually are employed. These dosage forms are prepared by intimately and uniformly mixing the active ingredient with suitable finely divided diluents, fillers, disintegrating agents, and/or binders such as starch, lactose, talc, magnesium stearate, vegetable gums and the like. Such unit dosage formulations may be varied widely with respect to their total weight and content of the antiparasitic agent depending upon factors such as the type of host animal to be treated, the severity and type of infection and the weight of the host.
When the active compound is to be administered via an animal feedstuff, it is intimately dispersed in the feed or used as a top dressing or in the form of pellets or liquid which may then be added to the finished feed or optionally fed separately. Alternatively, feed based individual dosage forms may be used such as a chewable treat. Alternatively, the antiparasitic compounds of this invention may be administered to animals parenterally, for example, by intraruminal, intramuscular, intravascular, intratracheal, or subcutaneous injection in which the active ingredient is dissolved or dispersed in a liquid carrier vehicle. For parenteral administration, the active material is suitably admixed with an acceptable vehicle, preferably of the vegetable oil variety such as peanut oil, cotton seed oil and the like. Other parenteral vehicles such as organic preparation using solketal, glycerol formal, propylene glycol, and aqueous parenteral formulations are also used. The active compound or compounds are dissolved or suspended in the parenteral formulation for administration; such formulations generally contain from 0.0005 to 5% by weight of the active compound.
Although the antiparasitic agents of this invention find their primary use in the treatment and/or prevention of helminthiasis, they are also useful in the prevention and treatment of diseases caused by other parasites, for example, arthropod parasites such as ticks, lice, fleas, mites and other biting arthropods in domesticated animals and poultry. They are also effective in treatment of parasitic diseases that occur in other animals including humans. The optimum amount to be employed for best results will, of course, depend upon the particular compound employed, the species of animal to be treated and the type and severity of parasitic infection or infestation. Generally good results are obtained with our novel compounds by the oral administration of from about 0.001 to 10 mg per kg of animal body weight, such total dose being given at one time or in divided doses over a relatively short period of time such as 1-5 days. With the preferred compounds of the invention, excellent control of such parasites is obtained in animals by administering from about 0.025 to 0.5 mg per kg of body weight in a single dose. Repeat treatments are given as required to combat re-infections and are dependent upon the species of parasite and the husbandry techniques being employed. The techniques for administering these materials to animals are known to those skilled in the veterinary field.
When the compounds described herein are administered as a component of the feed of the animals, or dissolved or suspended in the drinking water, compositions are provided in which the active compound or compounds are intimately dispersed in an inert carrier or diluent. By inert carrier is meant one that will not react with the antiparasitic agent and one that may be administered safely to animals. Preferably, a carrier for feed administration is one that is, or may be, an ingredient of the animal ration.
Suitable compositions include feed premixes or supplements in which the active ingredient is present in relatively large amounts and which are suitable for direct feeding to the animal or for addition to the feed either directly or after an intermediate dilution or blending step. Typical carriers or diluents suitable for such compositions include, for example, distillers' dried grains, corn meal, citrus meal, fermentation residues, ground oyster shells, wheat shorts, molasses solubles, corn cob meal, edible bean mill feed, soya grits, crushed limestone and the like. The active compounds are intimately dispersed throughout the carrier by methods such as grinding, stirring, milling or tumbling. Compositions containing from about 0.005 to 2.0% weight of the active compound are particularly suitable as feed premixes. Feed supplements, which are fed directly to the animal, contain from about 0.0002 to 0.3% by weight of the active compounds.
Such supplements are added to the animal feed in an amount to give the finished feed the concentration of active compound desired for the treatment and control of parasitic diseases. Although the desired concentration of active compound will vary depending upon the factors previously mentioned as well as upon the particular compound employed, the compounds of this invention are usually fed at concentrations of between 0.00001 to 0.002% in the feed in order to achieve the desired anti-parasitic result.
In using the compounds of this invention, the individual compounds may be prepared and used in that form. Alternatively, mixtures of the individual compounds may be used, or other active compounds not related to the compounds of this invention.
The compounds of this invention are also useful in combatting agricultural pests that inflict damage upon crops while they are growing or while in storage. The compounds are applied using known techniques as sprays, dusts, emulsions and the like, to the growing or stored crops to effect protection from such agricultural pests.
The following examples are provided in order that this invention might be more fully understood; they are not to be construed as limitative of the invention.
EXAMPLE 1
4a-Phenylseleno avermectin B1
A solution of 11.6 of 4a-hydroxy avermectin B1a/B1b (See U.S. Pat. No. 4,457,920 to Mrozik) in 70 mL of methylene chloride under nitrogen is cooled to -20° C. and combined with 9.0 mL of tri-n-butylphosphine and 8.0 g of N-(phenylseleno)phthalimide. The reaction mixture is stirred for 1 hour, the solvent is evaporated in vacuo, the residue is combined with 100 mL of ether-hexane 1:1 and the precipitate of phthalimide is removed by filtration. The ether-hexane is evaporated in vacuo and the product is chromatographed on a silica gel column using 2% methanol in methylene chloride as eluant. Evaporation of the solvent in vacuo affords 13.1 g of the phenylselenide which is 92% pure by HPLC analysis. The product is identified by nuclear magnetic resonance and mass spectrometry as 4a-phenylseleno avermectin B1a/B1b.
EXAMPLE 2
4a-Phenylseleno-4",5-bis-O-tert-butyl dimethylsily 7-O-trimethylsilyl avermectin B1
A solution of 13.1 g of the product of Example 1 and 5.2 g of imidazole in 100 mL of dry dimethylformamide is combined with 7.7 g of tert-butyldimethylsilyl chloride and stirred at room temperature for 24 hours. The resulting solution of 4 is then combined with 10 mL of bis(trimethylsilyl)trifluoroacetamine, stirred for 4 hours, combined with 200 mL of ethyl acetate, and washed 4 times with 100 mL of water. The ethyl acetate layer is dried over sodium sulfate, evaporated in vacuo, and the residue is combined with 100 mL of ethyl acetate-hexane 1:7 and clarified by filtration. The product obtained upon solvent evaporation is chromatographed on a silica gel column using a gradient of 5% to 15% ethyl acetate in hexane to afford 2.2 g of the title compound identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 3
3-Hydroxy-4-methylene 4",5-bis-O-tert-butyldimethylsilyl-7-O-trimethylsilyl avermectin B1a
A solution of 2.2 g of the product of Example 2 in 30 mL of pyridine is cooled in an ice bath and 3.0 mL of 30% hydrogen peroxide is added with stirring continued for 1 hour. 100 mL of ether is added, and the solution is washed several times with water and repeatedly with 0.05N hydrochloric acid until free of pyridine, and finally with water to neutrality. The ether is dried over magnesium sulfate, evaporated, and the product is chromatographed on a silica gel column using a gradient of 5% to 15% ethyl acetate in hexane as eluant. The fractions are monitored by silica gel thin layer chromatography using hexane-tetrahydrofuran 3:1 as the developing solvent. The product fractions are combined and evaporated to afford 1.2 g of the title compound as a mixture of approximately 3 parts 3B-hydroxy and 1 part 3α-hydroxy compound identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 4
3β,4α,4a trihydroxy 4",5 -bis-O-tert-butyldimethylsilyl 7-O-trimethylsilyl avermectin B1
100 mg of the 3β-hydroxy compound of Example 3 is dissolved in 2 mL of pyridine and 0.1 mL of a 1.0M solution of sodium tetroxide in benzene is added. After stirring for 1 hour at room temperature, 1.5 mL of a 0.4M solution of sodium bisulfate in pyridine-water 40:60 is added and stirring is contained for 4 hours. The mixture is combined with 20 mL of ether, washed several times with water, dried over magnesium sulfate, and the ether evaporated in vacuo. The product is chromatographed on 2 silica gel preparative chromatography plates 0.5 mm thick using hexane-THF 3:1 as the developing solvent. The product bands are eluted with ethanol-ethyl acetate 1:5 to afford 51 mg of the title compound which is identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 5
3β-Hydroxy-4-oxo-4",5-bis-O-tertbutyldimethylsilyl-7-O-tri-methylsilyl avermectin B1
400 mg of the product of Example 4 in 5 mL of benzene is stirred in a bath at 50° C., and a 0.05M solution of lead tetracetate in benzene is added dropwise while monitoring the reactions by HPLC for unreacted 1. 30 mL of ether is added, the ether solution is washed several times with water, dried over sodium sulfate, and the product is purified by preparative thin layer chromatography in hexane-tetrahydrofuran 3:1. Elution with 5% ethanol in ethylacetate afforded 220 mg of the title compound, identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 6
Preparation of labeled Methylenating Reagent ##STR8##
The carbon isotope (*) is introduced into reagent 6a by the procedure of E. J. Corey, et al JACS 86 1353 (1965).
The isotopic methylenating reagent 6b is prepared by combined 264 mg of 6a, 132 mg of 18-crown-6, 120 mg of potassium tert-butoxide and 5 mL of tetrahydrofuran and stirring the mixture at room temperature for 3 hours. On standing, the salts settle out, and assay of the supernatant indicated a 0.16M solution of 6b.
EXAMPLE 7
3β-Hydroxy 4,4a epoxide 4",5-bis-O-tertbutyldimethylsilyl-7-O-trimethylsilyl avermectin B1
36 mg of the product of Example 5 in 4 mL of methylene chloride is combined with 0.2 mL of a 0.16M solution of the reagent 6b prepared in Example 6 in tetrahydrofuran and stirred for 30 minutes. Analysis by HPLC indicated an equal mixture of the epimeric and 4,4a epoxides. Ether was added and the solution was washed with 0.05N acetic acid, several times with water, dried over sodium sulfate and concentrated to a small volume. The product was flash chromatographed on a column of 1 g of silica gel using ether as eluant. Evaporation of the solvent afforded 27 mg of a mixture of the title compound, identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 8
3β-Hydroxy-4-methylene-4",5-bis-O-tertbutyldimethylsilyl-7-O-trimethylsilyl avermectin B1
A solution of 27 mg of epoxides the product of Example 8, 25 mg of 3-methylbenzothiazole-2-selone and 5 μL of trifluoroacetic acid is kept at room temperature for 13 hours, whereupon analysis by HPLC indicate complete conversion to the 4-exomethylene compound. Ether is added, the solution is washed several times with water, dried over sodium sulfate, and evaporated to a small volume. The product is isolated by HPLC on a Vydac C18 semi-preparative column using methanol-acetonitrile-water 30:65:5 as eluant and UV monitoring at 245 nm. The combined product fractions are evaporated in vacuo below 40° C. to afford the title compound, identified by nuclear magnetic resonance and mass spectrometry. The product is chromatographically identical to the product of Example 3 by HPLC and by silica gel thin layer chromatography.
EXAMPLE 9
3-Methane sulfonyloxy-4-methylene-4",5-bis-O-tert-butyl di-methylsilyl-7-O-trimethylsily avermectin B1
A solution of 36 mg of the product of Example 8 in 4 mL of methylene chloride at 0° C. is combined with 1 mg of dimethylaminopyridine, 0.1 mL of triethylamine and 7.0 μL of methanesulfonylchloride. The mixture is stirred for 5 minutes, 1.0 mL of saturated sodium bicarbonate solution is added, the organic layer is washed several times with water, dried over sodium sulfate and concentrated to a small volume. The product is chromatographed on silica gel to afford 26 mg of the title compound, identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 10
4a-Bromo-4",5-bis-O-tert butyl dimethylsilyl-7-O-trimethyl-sily avermectin B1
38 mg of the product of Example 9 in 5 mL of tetrahydrofuran under nitrogen is combined with 30 mg of lithium bromide and the mixture is refluxed for 1 hour, cooled, and diluted with ether. The ether is washed several times with water, dried over sodium sulfate and concentrated to a small volume. The product is chromatographed on silica gel to afford 28 mg of the title compound, identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 11
4-Methyl-4",5-bis-O-tert butyl dimethylsilyl-7-O-trimethyl-silyl avermectin B1
30 μL of a 1.0M solution of sodium borohydride in dimethylformamide is added to a stirred solution of 38 mg of the product of Example 10 in 1.0 mL of dimethylformamide, and the reaction is monitored by silica gel thin layer chromatography. The addition is repeated until the starting material is absent, and ether is added to the mixture. The ether is washed several times with water, dried over sodium sulfate and the product is chromatographed on silica gel to afford 28 mg of the title compound, identified by nuclear magnetic resonance and mass spectrometry.
EXAMPLE 12
Avermectin B1
In a polypropylene vial, 35 mg of the product of Example 11 is combined with 3 mL of anhydrous hydrogen fluoride-pyridine-tetrahydrofuran prepared by mixing 0.3 mL of 70% hydrogen fluoride-pyridine, 0.9 mL of pyridine and 1.8 mL of tetrahydrofuran. After stirring at 20° for 2 days the mixtures is diluted with ether and washed several times with water. The product is chromatographed on silica gel to afford 15 mg of the title compound identified by nuclear magnetic resonance and mass spectrometry. | There are disclosed avermectin derivatives which are avermectin modified at the 3- and 4-positions. The 3-hydroxy and 4-keto, epoxide and hydroxy (hydroxymethyl) derivatives and the 4-oxo compound are prepared from the natural avermectin by moving the 3,4-double bond exocyclic at 4 and forming a 3-hydroxy group. Osmolation gave an α,β-diol across the double bond and cleavage of the diol provided the 4-oxo compound. The 4-oxo compound is epoxidized with an ylide reagent. The compounds are useful as anthelmintic agents and compositions for that use using the compounds as the active ingredient thereof are also described. | 0 |
FIELD OF THE INVENTION
The present invention relates to thermoplastic polyesters having improved impact properties and to impact-modifier compositions.
BACKGROUND OF THE INVENTION
Thermoplastic polyesters, such as PBT (polybutylene terephthalate) and PET (polyethylene terephthalate) possess excellent dimensional-stability, heat-resistance and chemical-resistance properties which are used in the electrical, electronic and motor-vehicle fields. However, at high temperature, during conversion operations, a reduction in the molecular weight of the polymer may occur, leading to a reduction in the impact strength properties. In addition, polyesters have poor fracture-resistance properties in the case of notched components.
The present invention provides thermoplastic polymers in which an impact-modifier composition is added in order to obtain improved impact properties, including low-temperature toughness. The present invention also relates to this impact-modifier composition that is added to the polyesters to improve the impact properties thereof. These modifier compositions make it possible to achieve impact properties superior to those obtained with each of the compounds separately.
Patent U.S. Pat. No. 4,753,890 (=EP 174,343) describes polyesters, such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT) modified by ethylene-alkyl (meth)acrylate-glycidyl (meth)acrylate copolymers.
Patent EP 737,715 describes PBTs modified by a blend of an ethylene-methyl methacrylate-glycidyl methacrylate copolymer and of a copolymer of the core-shell type. These core-shell copolymers comprise fine particles having an elastomer core and a thermoplastic shell.
Patent EP 531,008 describes PBT/polycarbonate blends containing copolymer core-shells and copolymers which are either ethylene-glycidyl methacrylate copolymers or ethylene-vinyl acetate-glycidyl methacrylate copolymers.
Patent U.S. Pat. No. 5,369,154 describes PET/polycarbonate blends containing four different modifiers: a copolymer comprising an epoxide, a copolymer core-shell, an SBR- or SBS- or EPR-type elastomer and an SAN- or ABS-type copolymer.
Patent EP 115,015 describes PET or PBT containing linear low-density polyethylene (LLDPE), glass fibres and optionally a core-shell copolymer.
Patent EP 133,993 describes PET containing a core-shell copolymer and a copolymer of ethylene with either an alkyl acrylate or (meth)acrylic acid.
Japanese Patent Application JP 01,247,454 A, published on 3 Oct. 1989 describes PBT containing an ethylene-alkyl (meth)acrylate copolymer and an ethylene-glycidyl methacrylate copolymer.
Patents EP 838,501 and EP 511,475 describe compositions similar to those of the above Japanese application.
Patent EP 803,537 describes PET and polycarbonate containing a copolymer comprising glycidyl methacrylate. Firstly, the polycarbonate and the copolymer comprising glycidyl methacrylate are blended together and then this blend is incorporated into the PET.
Patent EP 187,650 describes PET containing a core-shell copolymer and a copolymer of ethylene with either maleic anhydride or a (meth)acrylic acid.
It has been seen from the prior art that saturated polyesters can have their impact properties improved by the addition of a core-shell copolymer. These polymers have a particularly well defined structure in which the core consists of a polymer having an elastomeric character and in which the shell has a thermoplastic character. It has also been seen that the improvement in impact strength may be obtained by also incorporating a dispersed phase of an impact modifier optionally containing reactive functional groups capable of reacting with the functional groups of the polyesters. This reactivity makes it possible to ensure a fine and homogeneous dispersion of the modifier as well as good adhesion. The core-shell copolymer may itself also be functionalized in order to allow better adhesion to the matrix. However, this reactivity is sometimes high and may lead to a reduction in the melt flow index. This reduction in the melt flow index is prejudicial to the injection moulding of large parts or of fine parts.
It has now been found that it is possible to improve the impact properties of thermoplastic polyesters by adding to them three kinds of modifier, namely: (a) a core-shell copolymer, (b) an ethylene-unsaturated epoxide copolymer or an ethylene-unsaturated carboxylic acid anhydride copolymer or blends thereof and (c) an ethylene-alkyl (meth)acrylate copolymer or an optionally neutralized ethylene-(meth)acrylic acid copolymer or blends thereof. This modification does not result in a drop in the melt flow index compared with the prior art and even improves it. These modifiers improve the impact strength properties either at room temperature or at low temperatures, depending on the ratio which is chosen between the three components (a), (b) and (c), compared with compositions encountered in patents EP 511,475 and EP 174,343. They also allow the material to have better melt flow compared with compositions as described in EP 737,715.
The present invention relates to thermoplastic polyester compositions comprising, by weight, the total being 100%:
60 to 99% of a thermoplastic polyester; 1 to 40% of an impact modifier comprising:
(a) a core-shell copolymer (A); (b) an ethylene copolymer (B) chosen from ethylene-unsaturated carboxylic acid anhydride copolymers (B1), ethylene-unsaturated epoxide copolymers (B2) and blends thereof; (c) a copolymer (C) chosen from ethylene-alkyl (meth)acrylate copolymers (C1), optionally neutralized ethylene-(meth)acrylic acid copolymers (C2) and blends thereof.
The present invention also relates to an impact-modifier composition which can be added to thermoplastic polyesters to improve their impact properties and which comprise:
(a) a core-shell copolymer (A); (b) an ethylene copolymer (B) chosen from ethylene-unsaturated carboxylic acid anhydride copolymers (B1), ethylene-unsaturated epoxide copolymers (B2) and blends thereof; (c) a copolymer (C) chosen from ethylene-alkyl (meth)acrylate copolymers (C1), optionally neutralized ethylene-(meth)acrylic acid copolymers (C2) and blends thereof.
DESCRIPTION OF THE INVENTION
The term “MFI” (standing for Melt Flow Index) denotes the melt flow index in g/10 minutes at a given temperature and under a given load.
The term “thermoplastic polyester” denotes polymers which are saturated products coming from the condensation of glycols and of dicarboxylic acids, or of their derivatives. Preferably, they comprise the products of the condensation of aromatic dicarboxylic acids having from 8 to 14 carbon atoms and of at least one glycol chosen from the group consisting of neopentyl glycol, cyclohexanedimethanol and aliphatic glycols of formula HO(CH 2 ) n OH in which n is an integer ranging from 2 to 10. Up to 50 mol % of the aromatic dicarboxylic acid may be replaced with at least one other aromatic dicarboxylic acid having from 8 to 14 carbon atoms, and/or up to 20 mol % may be replaced with an aliphatic dicarboxylic acid having from 2 to 12 carbon atoms.
The preferred polyesters are polyethylene terephthalate (PET), poly(1,4-butylene) terephthalate (PBT), 1,4-cyclohexylene dimethylene terephthalate/isophthalate) and other esters derived from aromatic dicarboxylic acids such as isophthalic acid, dibenzoic acid, naphthalene dicarboxylic acid, 4,4′-diphenylenedicarboxylic acid, bis(p-carboxyphenyl)methane acid, ethylene bis(p-benzoic) acid, 1,4-tetramethylene bis(p-oxybenzoic) acid, ethylene bis(para-oxybenzoic) acid, 1,3-trimethylene bis(p-oxybenzoic) acid, and glycols such as ethylene glycol, 1,3-trimethylene glycol, 1,4-tetramethylene glycol, 1,6-hexamethylene glycol, 1,3-propylene glycol, 1,8-octamethylene glycol and 1,10-decamethylene glycol.
The MFI of these polyesters, measured at 250° C. and with 2.16 kg or 5 kg (for PBT) or at 275° C. and with 2.16 kg (for PET), may vary from 2 to 100 and advantageously from 10 to 80.
It would not be outside the scope of the invention if the polyesters consisted of several diacids and/or several diols. It is also possible to use a blend of various polyesters.
It would not be outside the scope of the invention if the polyesters contained copolyetheresters. These copolyetheresters are copolymers containing polyester blocks and polyether blocks having polyether units derived from polyetherdiols such as polyethylene glycol (PEG), polypropylene glycol (PPG) or polytetramethylene glycol (PTMG), dicarboxylic acid units such as terephthalic acid units, and short, chain-extender, diol units such as glycol (1,2-ethanediol) or 1,4-butanediol. The linking of the polyethers with the diacids forms the flexible segments whereas the linking of the glycol or butanediol with the diacids forms the rigid segments of the copolyetherester. These copolyetheresters are thermoplastic elastomers. The proportion of these copolyetheresters may represent from 0 to 500 parts per 100 parts of thermoplastic polyester.
It would not be outside the scope of the invention if the polyesters contained polycarbonate. In general, the term “polycarbonate” denotes polymers comprising the following units:
in which R 1 is an aliphatic, alicyclic or aromatic divalent group which may contain up to 8 carbon atoms. By way of example of R 1 , mention may be made of ethylene, propylene, trimethylene, tetramethylene, hexamethylene, dodecamethylene, poly(1,4-[2-butenylene]), poly( 1 , 10 -[(2-ethyldecylene]), 1,3-cyclopentylene, 1,3-cyclohexylene, 1,4-cyclohexylene, m-phenylene, p-phenylene, 4,4′-diphenylene, 2,2-bis(4-phenylene)propane and benzene-1,4-dimethylene. Advantageously, at least 60% of the R 1 groups in the polycarbonate and preferably all the groups R 1 are aromatic groups of formula:
—R—Y—R 3 —
in which R 2 et R 3 are divalent monocyclic aromatic radicals and Y is a linking radical containing one or two atoms which separate R 2 and R 3 . The free valences are generally in the meta or para position with respect to Y. R 2 and R 3 may be substituted or unsubstituted phenylenes; as substituents, mention may be made of alkyl, alkenyl, halogen, nitro and alkoxy. Preferably, the phenylenes are unsubstituted; they may be together or separately meta or para and are preferably para. The linking radical Y is preferably such that one atom separates R 2 from R 3 and is preferably a hydrocarbon radical such as methylene, cyclohexylmethylene, 2-[2.2.1]bicycloheptylmethylene, ethylene, 2,2-propylene, 1,1-(2,2-dimethylpropylene), 1,1-cyclohexylene, 1,1-cyclopentadecylene, cyclo-dodecylene, carbonyl, the oxy radical, the thio radical and sulfone. Preferably, R 1 is 2,2-bis(4-phenylene)propane which comes from bisphenol A, that is to say Y is isopropylidene and R 2 and R 3 are each p-phenylene. Advantageously, the intrinsic viscosity of the polycarbonate, measured in methylene chloride at 25° C., is between 0.3 and 1 dl/g.
The proportion of polycarbonate may represent from 0 to 300 parts per 100 parts of thermoplastic polyester.
With regard to the core-shell copolymer (A), abbreviated as CS in what follows, this is in the form of fine particles having an elastomer core and at least one thermoplastic shell. The particle size is generally between 50 and 1000 nm and advantageously between 100 and 500 nm.
By way of example of the core, mention may be made of isoprene homopolymers or butadiene homopolymers, copolymers of isoprene with at most 30 mol % of a vinyl monomer and copolymers of butadiene with at most 30 mol % of a vinyl monomer. The vinyl monomer may be styrene, an alkylstyrene, acrylonitrile or an alkyl (meth)acrylate. Another core family consists of the homopolymers of an alkyl (meth)acrylate and the copolymers of an alkyl (meth)acrylate with at most 30 mol % of a vinyl monomer. The alkyl (meth)acrylate is advantageously butyl acrylate. The vinyl monomer may be styrene, an alkylstyrene, acrylonitrile, butadiene or isoprene. The core of the copolymer (A) may be completely or partly crosslinked. All that is required is to add at least difunctional monomers during the preparation of the core; these monomers may be chosen from poly(meth)acrylic esters of polyols, such as butylene di(meth)acrylate and trimethylolpropane trimethacrylate. Other difunctional monomers are, for example, divinylbenzene, trivinylbenzene, vinyl acrylate and vinyl methacrylate. The core can also be crosslinked by introducing into it, by grafting or as a comonomer during the polymerization, unsaturated functional monomers such as anhydrides of unsaturated carboxylic acids, unsaturated carboxylic acids and unsaturated epoxides. Mention may be made, for example, of maleic anhydride, (meth)acrylic acid and glycidyl methacrylate.
The shell(s) are styrene homopolymers, alkylstyrene homopolymers or methyl methacrylate homopolymers, or copolymers comprising at least 70 mol % of one of the above monomers and at least one comonomer chosen from the other above monomers, vinyl acetate and acrylonitrile. The shell may be functionalized by introducing into it, by grafting or as a comonomer during the polymerization, unsaturated functional monomers such as anhydrides of unsaturated carboxylic acids, unsaturated carboxylic acids and unsaturated epoxides. Mention may be made, for example, of maleic anhydride, (meth)acrylic acid and glycidyl methacrylate.
By way of example, mention may be made of core-shell copolymers (A) having a polystyrene shell and core-shell copolymers (A) having a PMMA shell. There are also core-shell copolymers (A) having two shells, one made of polystyrene and the other, on the outside, made of PMMA. Examples of copolymers (A) and their method of preparation are described in the following patents: U.S. Pat. No. 4,180,494, U.S. Pat. No. 3,808,180, U.S. Pat. No. 4,096,202, U.S. Pat. No. 4,260,693, U.S. Pat. No. 3,287,443, U.S. Pat. No. 3,657,391, U.S. Pat. No. 4,299,928 and U.S. Pat. No. 3,985,704.
By way of example, mention may be made of core-shell copolymers (A) having a core based on an alkyl acrylate or on a polyorganosiloxane rubber or a mixture thereof and a shell based on a polyalkyl methacrylate or a styrene-acrylonitrile copolymer, characterized in that the said impact additive comprises:
a) 70 to 90% by weight of an elastomeric crosslinked core which is composed:
1) of 20 to 100% by weight, and preferably 20 to 90%, of a core consisting of an n-alkyl acrylate copolymer (I), the alkyl group of which has a number of carbons ranging from 5 to 12 or a mixture of an alkyl acrylate, the linear or branched alkyl group of which has a number of carbons ranging from 2 to 12, or of a polyorganosiloxane rubber, of a polyfunctional crosslinking agent possessing in its molecule unsaturated groups, at least one of which is of the CH 2 ═C<vinyl type, and, optionally, of a polyfunctional grafting agent possessing in its molecule unsaturated groups, at least one of which is of the CH 2 ═CH—CH 2 — allyl type, the said core containing a molar quantity of crosslinking agent and, optionally, of a grafting agent ranging from 0.05 to 5%, 2) of 80 to 0% by weight, and preferably 80 to 10% of a sheath surrounding the core and consisting of an n-alkyl acrylate copolymer (II), the alkyl group of which has a number of carbons ranging from 4 to 12 or of a mixture of alkyl acrylates as defined above in 1) and of a grafting agent possessing in its molecule unsaturated groups, at least one of which is of the CH 2 ═CH—CH 2 — allyl type, the said sheath containing a molar amount of grafting agent ranging from 0.05 to 2.5%;
b) 30 to 10% by weight of a shell grafted onto the said core consisting of a polymer of an alkyl methacrylate, the alkyl group of which has a number of carbons ranging from 1 to 4 or else of a random copolymer of an alkyl methacrylate, the alkyl group of which has a number of carbons ranging from 1 to 4 and of an alkyl acrylate, the alkyl group of which has a number of carbons ranging from 1 to 8, containing a molar amount of alkyl acrylate ranging from 5 to 40% or else consisting of a styrene-acrylonitrile copolymer.
Optionally, 0.1 to 50% by weight of the vinyl monomers possess functional groups.
This type of core-shell copolymer is described in the Applicant's Patent Application EP-A-776 915 and Patent U.S. Pat. No. 5,773,520.
By way of example, mention may be made of core-shell copolymers (A) consisting (i) of 75 to 80 parts of a core comprising at least 93 mol % of butadiene, 5 mol % of styrene and 0.5 to 1 mol % of divinylbenzene and (ii) of 25 to 20 parts of two shells essentially of the same weight, the inner one made of polystyrene and the outer one made of PMMA.
Advantageously, the core represents 70 to 90% by weight of (A) and the shell represents 30 to 10%.
With regard to ethylene-unsaturated carboxylic acid anhydride copolymers (B1), these may be polyethylenes grafted by an unsaturated carboxylic acid anhydride or ethylene-unsaturated carboxylic acid anhydride copolymers which are obtained, for example, by radical polymerization.
The unsaturated carboxylic acid anhydride may be chosen, for example, from maleic, itaconic, citraconic, allylsuccinic, cyclohex-4-ene-1,2-dicarboxylic, 4-methylenecyclohex-4-ene-1,2-dicarboxylic, bicyclo-[2.2.11]hept-5-ene-2,3-dicarboxylic and x-methylbicyclo-[2.2.11]hept-5-ene-2,2-dicarboxylic anhydrides. Advantageously, maleic anhydride is used. It would not be outside the scope of the invention to replace all or part of the anhydride with an unsaturated carboxylic acid such as, for example, (meth)acrylic acid.
With regard to the polyethylenes onto which the unsaturated carboxylic acid anhydride is grafted, the term “polyethylene” should be understood to mean homopolymers or copolymers.
By way of comonomers, mention may be made of:
alpha-olefins, advantageously those having from 3 to 30 carbon atoms; by way of examples of alpha-olefins, mention may be made of propylene, 1-butene, 1-pentene, 3-methyl-1-butene, 1-hexene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicocene, 1-dococene, 1-tetracocene, 1-hexacocene, 1-octacocene and 1-triacontene; these alpha-olefins may be used separately or as a mixture of two or more of them;
esters of unsaturated carboxylic acids, such as, for example, alkyl (meth)acrylates, the alkyls possibly having up to 24 carbon atoms; examples of alkyl acrylates or methacrylates are especially methyl methacrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate and 2-ethylhexyl acrylate;
vinyl esters of saturated carboxylic acids, such as, for example, vinyl acetate or vinyl propionate;
dienes such as, for example, 1,4-hexadiene.
the polyethylene may include several of the above comonomers.
Advantageously, the polyethylene, which may be a blend of several polymers, comprises at least 50 mol % and preferably 75 mol % of ethylene and its density may be between 0.86 and 0.98 g/cm 3 . The MFI (at 190° C./2.16 kg) is advantageously between 0.1 and 1000.
By way of example of polyethylenes, mention may be made of:
low-density polyethylene (LDPE)
high-density polyethylene (HDPE)
linear low-density polyethylene (LLDPE)
very low-density polyethylene (VLDPE)
polyethylene obtained by metallocene catalysis, that is to say polymers obtained by the copolymerization of ethylene and of an alpha-olefin such as propylene, butene, hexene or octene in the presence of a single-site catalyst generally consisting of a zirconium or titanium atom and of two alkyl cyclic molecules linked to the metal. More specifically, the metallocene catalysts are usually composed of two cyclopentadiene rings linked to the metal. These catalysts are frequently used with aluminoxanes as cocatalysts or activators, preferably methylaluminoxane (MAO). Hafnium may also be used as the metal to which the cyclopentadiene is fixed. Other metallocenes may include transition metals of Groups IV A, V A and VI A. Metals from the series of lanthanides may also be used.
EPR (ethylene-propylene-rubber) elastomers;
EPDM (ethylene-propylene-diene) elastomers;
blends of polyethylene with an EPR or an EPDM;
ethylene-alkyl (meth)acrylate copolymers possibly containing up to 60%, and preferably 2 to 40%, by weight of (meth)acrylate.
The grafting is an operation known per se.
With regard to the ethylene-unsaturated carboxylic acid anhydride copolymers, that is to say those in which the unsaturated carboxylic acid anhydride is not grafted, these are copolymers of ethylene, the unsaturated carboxylic acid anhydride and, optionally another monomer which may be chosen from the comonomers mentioned above in the case of the ethylene copolymers intended to be grafted.
Advantageously, ethylene-maleic anhydride copolymers and ethylene-alkyl (meth)acrylate-maleic anhydride copolymers are used. These copolymers comprise from 0.2 to 10% by weight of maleic anhydride and from 0 to 40%, preferably 5 to 40%, by weight of alkyl (meth)acrylate. Their MFIs (190° C./2.16 kg) are between 0.5 and 200. The alkyl (meth)acrylates have already been described above. It is possible to use a blend of several copolymers (B1). It is also possible to use an ethylene-maleic anhydride copolymer/ethylene-alkyl (meth)acrylate-maleic anhydride copolymer blend.
The copolymer (B1) is commercially available—produced by radical polymerization at a pressure which may range between 200 and 2500 bar and is sold in the form of granules.
With regard to (B2), the ethylene-unsaturated epoxide copolymers may be obtained by the copolymerization of ethylene with an unsaturated epoxide or by grafting the unsaturated epoxide to the polyethylene. The grafting may be carried out in the solvent phase or onto the polyethylene in the melt in the presence of a peroxide. These grafting techniques are known per se. With regard to the copolymerization of ethylene with an unsaturated epoxide, it is possible to use so-called radical polymerization processes usually operating at pressures between 200 et 2500 bar. By way of example of unsaturated epoxides, mention may be made of:
aliphatic glycidyl esters and ethers, such as allyl glycidyl ether, vinyl glycidyl ether, glycidyl maleate, glycidyl itaconate, glycidyl acrylate and glycidyl methacrylate; and alicyclic glycidyl esters and ethers, such as 2-cyclohex-1-ene glycidyl ether, diglycidyl cyclohexene-4-5-carboxylate, glycidyl cyclohexene-4-carboxylate, glycidyl 2-methyl-5-norbornene-2-carboxylate and diglycidyl endo-cis-bicyclo[2.2.1]hept-5-ene-2,3-dicarboxylate.
With regard to grafting, the copolymer is obtained by grafting a polyethylene homopolymer or copolymer as described in the case of (B1) above, except that an epoxide is grafted instead of an anhydride.
With regard to copolymerization, the principle is similar to that described in the case of (B1) above except that an epoxide is used. There may also be other comonomers, as in the case of (B1).
The product (B2) is advantageously an ethylene-alkyl (meth)acrylate-unsaturated epoxide copolymer or an ethylene-unsaturated epoxide copolymer. Advantageously, it may contain up to 40%, preferably 5 to 40%, by weight of alkyl (meth)acrylate and up to 10%, preferably 0.1 to 8%, by weight of unsaturated epoxide.
Advantageously, the epoxide is glycidyl (meth)acrylate.
Advantageously, the alkyl (meth)acrylate is chosen from methyl (meth)acrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate and 2-ethylhexyl acrylate. The amount of alkyl (meth)acrylate is advantageously from 20 to 35%. The MFI (at 190° C./2.16 kg) is advantageously between 0.5 and 200.
It is possible to use a blend of several copolymers (B2). It is also possible to use an ethylene-alkyl (meth)acrylate-unsaturated epoxide copolymer/ethylene-unsaturated epoxide copolymer blend.
This copolymer (B2) may be obtained by the radical polymerization of the monomers.
It is also possible to use a blend of copolymers (B1) and (B2).
With regard to the ethylene-alkyl (meth)acrylate copolymer (C1), the alkyls may have up to 24 carbon atoms. Examples of alkyl acrylates or methacrylates are especially methyl methacrylate, ethyl acrylate, n-butyl acrylate, isobutyl acrylate and 2-ethylhexyl acrylate. The MFI (at 190° C./2.16 kg) of these copolymers is advantageously between 0.1 and 50. The alkyl (meth)acrylate content may be up to 40% by weight of (C1). Advantageously, the (meth)acrylate content is between 5 and 35% by weight of (C1). These copolymers may be manufactured by radical polymerization in a tube or autoclave at pressures of between 300 and 2500 bar.
With regard to the ethylene-(meth)acrylic acid copolymers (C2), the (meth)acrylic acid content may be up to 10 mol %, and advantageously between 1 and 5 mol %, of (C2). It would not be outside the scope of the invention if (C2) were to contain an alkyl (meth)acrylate in a proportion possibly up to 40% by weight of (C2). The acid functions may be completely or partly neutralized by a cation, such as lithium, sodium, potassium, magnesium, calcium, strontium, zinc and cadmium. The MFI (at 190° C./2.16 kg) of these copolymers is advantageously between 0.1 and 50. These copolymers may be manufactured by radical polymerization in a tube or autoclave at pressures of between 300 and 2500 bar.
It is also possible to use a blend of copolymers (C1) and (C2).
Advantageously, the impact constituents are in the following proportions by weight for a total of 100%:
(A) 15 to 80% (B) 5 to 60% (C) 5 to 80%
Particularly useful proportions are the following: A 20 to 35 25 to 35 40 to 75 B 40 to 60 5 to 10 10 to 35 C 10 to 40 60 to 70 10 to 35 A + B + C 100 100 100
Advantageously, the thermoplastic polyester compositions of the invention comprise, per 100 parts by weight, 65 to 95 parts and 35 to 5 parts of polyester and of impact modifier, respectively.
The invention also relates to an impact-modifier composition having these proportions.
The thermoplastic polyesters of the invention may also include, in addition to the impact modifier, slip agents, heat stabilizers, antiblocking agents, antioxidants, UV stabilizers and fillers. The fillers may be glass fibres, fire retardants, talc or chalk. These fillers may be contained in the impact modifiers.
The thermoplastic polyester/impact-modifier blends are prepared by the usual techniques for thermoplastic polymers in single-screw or twin-screw extruders, mixers or apparatuses of the BUSS® Ko-kneader type. The polyester and the constituents of the impact modifier, namely the copolymers (A), (B) and (C), may be introduced separately into the blending device. The constituents of the impact modifier may also be added in the form of a blend prepared in advance, possibly in the form of a masterbatch in the polyester. The additives may be added into these apparatuses, such as the slip agents, the antiblocking agents, the antioxidants, the UV stabilizers and the fillers, whether as they are or in the form of a masterbatch in the polyester or else in the form of a masterbatch with one or more of the copolymers (A) to (C). The impact-modifier composition comprising (A) to (C) which may be added to the polyesters is also prepared by the previous usual technique of blending thermoplastic polymers.
EXAMPLES
All the examples were produced with compositions comprising, by weight, between 70 to 80% of polyester and between 30 to 20% of impact modifier. The impact modifier either consists of A, B and C, in the case of the examples according to the invention, or of A and B, or of B and C, or of A, or of B, or of C. The notched Charpy impact strength complies with the ISO 179:93 standard (with kJ/m 2 as unit of measure) and the notched Izod impact strength is measured according to the ASTM D256 standard (with pound-foot/inch as unit of measure)—the higher the measured impact-strength value the better the impact strength.
The examples below were produced with PBT or with PET as polyester.
The following examples were produced with compositions comprising 80% by weight of PBT and 20% by weight of impact modifier.
These examples were produced with the following products:
AX 8900: ethylene-methyl acrylate-glycidyl methacrylate (GMA) copolymer comprising, by weight, 25% acrylate and 8% GMA, having an MFI of 6 (190° C./2.16 kg). It is sold under the Atofina brand name LOTADER®; AX 8930: ethylene-methyl acrylate-glycidyl methacrylate (GMA) copolymer comprising, by weight, 25% acrylate and 3% GMA, having an MFI of 6 (190° C./2.16 kg). It is sold under the Atofina brand name LOTADER®; Lotryl: ethylene-2-ethylhexyl acrylate copolymer comprising 35% acrylate by weight and having an MFI of 2 (190° C./2.16 kg); E920: MBS-type core-shell copolymer with a core essentially based on butadiene-styrene and a shell of PMMA, sold by Atofina under the brand name METABLEND®; EXL 2314: epoxy-functionalized acrylic core-shell copolymer sold by Röhm and Haas under the brand name PARALOID®; PBT: polybutylene terephthalate having an MFI of 20 (250° C./2.16 kg) sold by BASF under the brand name ULTRADUR® B4500.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the notched Charpy impact strength of PBT containing AX 8900 (comparative example), PBT containing EXL 2314 (comparative example) and PBT containing simultaneously (according to the invention) AX 8900, Lotryl and a core-shell copolymer. The proportions by weight of the constituents of the impact modifier are in the following format: (2.8/11.2/6, AX8900/lotryl/core-shell) (example).
The impact strength values are indicated at four different temperatures for each composition. The values in FIG. 1 are also given in TABLE 1 below.
TABLE 1
Notched Charpy impact strength (kJ/m 2 )
T =
T =
T =
T =
Impact modifier
23° C.
0° C.
−20° C.
−40° C.
AX 8900
76.4
17
9
6.5
2.8/11.2/6
73
20.5
14.5
9.1
AX 8900/Lotryl/EXL 2314
2.8/11.2/6
57.2
18
14
11.3
AX 8900/Lotryl/E920
1.4/12.6/6
63.7
10.4
AX 8900/Lotryl/EXL 2314
1.2/4.8/14
81.7
10.1
AX 8900/Lotryl/EXL 2314
EXL 2314
61.5
15.4
9.8
7
FIG. 2 shows the MFI of the above compositions containing the various impact modifiers and, in addition, the MFI of the PBT without any modifier: “pure PBT”. The values are also given in TABLE 2 below.
TABLE 2
MFI
(250° C./2.16 kg)
COMPOSITION
0.63
PBT + AX 8900
4.1
PBT + 2.8/11.2/6 AX 8900/Lotryl/EXL 2314
6.5
PBT + 2.8/11.2/6 AX 8900/Lotryl/E920
5.7
PBT + 1.4/12.6/6 AX 8900/Lotryl/EXL 2314
4.4
PBT + 1.2/4.8/14 AX 8900/Lotryl/EXL 2314
7.4
PBT + EXL 2314
20
Pure PBT
It may be clearly seen that the modifier of the invention gives better impact, particularly cold impact, results than AX 8900 or EXL 2314. However, the MFI is lower than with EXL 2314 used alone and much higher than with AX 8900 used alone, but easily sufficient for injection moulding.
FIG. 3 shows the notched Charpy impact strength at +23° C. for PBT containing, as impact modifier, either AX 8900, or Lotryl, or a mixture of these impact modifiers. These compositions are not according to the invention. FIG. 4 shows the impact strengths of the same compositions for other temperatures. The values are also given in TABLES 3 and 4.
TABLE 3
AX 8900/Lotryl
Notched Charpy
proportions
impact strength
AX 8900
Lotryl
(temperature 23° C.)
100
0
76.4
70
30
65.7
30
70
60.35
20
80
53.9
10
90
15
0
100
5
TABLE 4
PBT + 20%
Notched Charpy impact strength
(AX 8900 + Lotryl)
T = 0° C.
T = −20° C.
T = −40° C.
100/0 AX 8900/Lotryl
17
9.1
6.2
70/30 AX 8900/Lotryl
18.9
13.4
8.2
30/70 AX 8900/Lotryl
15.9
13.4
8.75
20/80 AX 8900/Lotryl
14.6
12
8.2
10/90 AX 8900/Lotryl
7.5
0/100 AX 8900/Lotryl
3.6
FIG. 5 shows the MFI of the above compositions containing the various impact modifiers and also the MFI of the PBT without a modifier: “pure PBT”. The values are also given in TABLE 5 below.
TABLE 5
PBT + 20%
MFI
(AX 8900 + Lotryl)
(250° C./2.16 kg)
100/0 AX 8900/Lotryl
0.63
70/30 AX 8900/Lotryl
1.5
30/70 AX 8900/Lotryl
2.7
20/80 AX 8900/Lotryl
3.6
10/90 AX 8900/Lotryl
5.5
0/100 AX 8900/Lotryl
12
Pure PBT
20
Comparing FIG. 1 with FIG. 4 , it may be seen that, with the modifier of the invention, a better impact strength is obtained, particularly at 0° C. and below 0° C., while still having a higher MFI.
FIG. 6 shows the notched Charpy impact strength at −40° C. for PBT containing, as impact modifier, either AX (AX8900 or AX8930), or a core-shell (EXL2314 or E920) or a mixture of these impact modifiers—these compositions are not according to the invention.
FIG. 7 shows the impact strength of these same compositions at +23° C. In these FIGS. 6 and 7 , the epoxide-based copolymer has been denoted by AX and the core-shell by CS. The values are also given in TABLE 6 and TABLE 7.
TABLE 6
PBT + 20% (AX + CS)
AX = AX 8900 or
Notched Charpy impact strength at −40° C.
AX 8930
AX 8900/
AX 8900/
AX 8930/
AX 8930/
CS = EXL 2314 or E920
EXL 2314
E920
EXL 2314
E920
100/0 AX/CS
6.2
6.2
5
5
70/30 AX/CS
9.8
10
8.8
9.9
30/70 AX/CS
7.8
14.75
7.1
9.8
20/80 AX/CS
9.2
10.25
10/90 AX/CS
13.8
0/100 AX/CS
6.75
8.2
6.75
8.2
TABLE 7
PBT + 20% (AX + CS)
AX = AX 8900 or
Notched Charpy impact strength at +23° C.
AX 8930
AX 8900/
AX 8900/
AX 8930/
AX 8930/
CS = EXL 2314 or E920
EXL 2314
E920
EXL 2314
E920
100/0 AX/CS
76.4
76.4
55.2
55.2
70/30 AX/CS
99
62.2
67.5
61
30/70 AX/CS
91.8
88.9
82.6
88.4
20/80 AX/CS
87.6
79.5
10/90 AX/CS
80
0/100 AX/CS
62
18
62
18
FIG. 8 shows the MFI of the above compositions containing the various impact modifiers and also the MFI of the PBT without a modifier: “pure PBT”. The values are also given in TABLE 8 below.
TABLE 8
PBT + 20% (AX + CS)
AX = AX 8900 or AX 8930
MFI (250° C./2.16 kg)
CS = EXL 2314 or E920
no change with the type of AX and CS
100/0 AX/CS
0.63
70/30 AX/CS
0.9
30/70 AX/CS
1.63
20/80 AX/CS
3.5
10/90 AX/CS
3
0/100 AX/CS
7.4
Pure PBT
20
Comparing FIG. 1 with FIG. 6 , it may be seen that the modifier of the invention results in superior cold impact strength values. By examining FIGS. 2 , 5 and 8 , it may be seen that the MFI of those compositions of the invention in which A, B and C are combined is unexpectedly higher in comparison with that obtained by combining the copolymers in pairs: A with B or B with C.
The examples below were produced with PBT/impact modifier compositions such as those defined in % by weight in TABLE 9. This table also give other values, such as the MFI of the compositions appearing therein, together with their impact strength by measuring the notched Izod impact behaviour according to the standard defined above at various temperatures T (T 20° C., −20° C., −30° C. and −40° C.).
The compositions exemplified below were produced with the following products:
PBT: polybutylene terephthalate having an MFI of 8.4 (250° C./5 kg) sold under the brand name CELANEX®1600A by Ticona; Lotryl: ethylene-butyl acrylate copolymer comprising 30% by weight of acrylate and having an MFI of 2(190° C./2.16 kg); AX8900: composition defined above; AM939: core-shell with an n-octyl acrylate core and a methyl methacrylate shell in proportions of 70 to 90% by weight for the n-octyl acrylate and 10 to 30% for the methyl methacrylate.
In view of the values listed in TABLE 9, it may be clearly seen that the compositions which include the impact modifier according to the invention gives better impact strength results within an exemplified temperature range going from room temperature to −40° C., unlike the compositions comprising only AX8900 (comparative 1) or AM939 (comparative 2) as impact modifier.
Impact strength tests were also carried out with compositions not according to the invention comprising two impact modifiers. These are the compositions called comparatives 3, 5 and 6 in TABLE 9. When the impact strength results obtained with such compositions are compared with the results obtained with the compositions comprising the trio AM939/Lotryl/AX8900, it is found that the use of the impact modifier according to the invention gives very good impact strength values over the temperature range exemplified, which is not the case with the comparatives 5 and 6, and also gives very good melt flow index results, which is not the case with comparative 3.
A synergy effect is therefore found between the protagonists of the AM939/Lotryl/AX8900 trio of the impact modifier according to the invention making it possible to achieve an appreciable compromise between impact strength and melt flow of the thermoplastic polyester compositions according to the invention.
The examples below were produced with PET/impact modifier compositions such as those defined in % by weight in TABLE 10. This table also give other values such as the MFI of the compositions appearing therein and their impact strength by measuring the notched Charpy impact behaviour according to the standard defined above at various temperatures T (T=20° C., 0° C. and −30° C.).
The examples below were made with the following products:
PET: polyethylene terephthalate having an MFI of 40–50 (275° C./2.16 kg) sold under the brand name ESTAPAK®9921 by Eastman; AX8900: composition defined above; E920: composition defined above; AM939: composition defined above; Lotryl: ethylene-butyl acrylate copolymer comprising 30% by weight of acrylate and having an MFI of 2 (190° C./2.16 kg).
In view of the MFI and impact strength results reported in TABLE 10, it may be seen that the compositions comprising only AX8900 (comparatives 1) and only the duo Lotryl/AX8900 (comparative 4) as impact modifier offer good impact strength to the detriment of melt flow index, which is mediocre. Furthermore, it is found by studying the results of the compositions comprising only a core-shell (AM939 in the case of comparative 2 or E920 in the case of comparative 3) as impact modifier that these compositions offer a poor impact strength but a better melt viscosity.
Analysis of our results obtained with compositions comprising the impact modifier according to the invention clearly shows an improvement in the viscosity over comparatives 1 and 4 together with an improvement in the impact strength over comparatives 2 and 3.
Our results indubitably demonstrate that our impact modifier is superior to the comparative impact modifiers and sheds light on the synergistic effect of the CS/Lotryl/AX8900 compounds, forming an impact modifier according to the invention, on the melt flow index and the impact strength of our thermoplastic polyester compositions.
Although the invention has been described in conjunction with specific embodiments, it is evident that many alternatives and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all of the alternatives and variations that fall within the spirit and scope of the appended claims. The foregoing references are hereby incorporated by reference.
TABLE 9
AM939/
Impact strength (foot.pound/inch)
PBT
AM939
Lotryl
AX8900
Lotryl/AX8900
MFI (g/10 min)
T = 20° C.
T = −20° C.
T = −30° C.
T = −40° C.
100%
0%
0%
0%
0/0/0
PBT Base
37.9
1–2
—
—
—
80%
0%
0%
20%
0/0/100
Comparative 1
6.7
17.6
2.9
—
—
75%
25%
0%
0%
100/0/0
Comparative 2
14.6
3.1
—
—
—
75%
12.5%
0%
12.5%
50/0/50
Comparative 3
0.6
25
23
23
18
75%
0%
25%
0%
0/100/0
Comparative 4
38.4
1.3
—
—
—
75%
0%
12.5%
12.5%
0/50/50
Comparative 5
11.7
15.1
2.6
—
—
75%
12.5%
12.5%
0%
50/50/0
Comparative 6
18.7
4.4
—
—
—
75%
7.5%
12.5%
5%
30/50/20
7.2
75%
7.5%
7.5%
10%
30/30/40
4.4
75%
7.5%
5%
12.5%
30/20/50
4.6
75%
12.5%
7.5%
5%
50/30/20
5.5
20
18
14.5
3
75%
12.5%
6.25%
6.25%
50/25/25
4.1
21.5
17.5
4
75%
12.5%
5%
7.5%
50/20/30
3.4
18.5
19
4
75%
15%
5%
5%
60/20/20
4.7
75%
15%
3%
7%
60/12/28
3.2
22.5
18.5
3.5
75%
17.5%
4.5%
3%
70/18/12
9.1
80%
10.0%
4.0%
6.0%
50/20/30
5.7
22.5
17.5
6
80%
10.0%
5.0%
5.0%
50/25/25
4.9
22
17
3
80%
10.0%
6.0%
4.0%
50/30/20
6.2
21
14.5
3
70%
15.0%
6.0%
9.0%
50/20/30
2.8
21
23
9
70%
15.0%
7.5%
7.5%
50/25/25
3.3
20.5
21
7
70%
15.0%
9.0%
6.0%
50/30/20
3.7
19.5
18
6.5
TABLE 10
Impact strength (kJ/m 2 )
PET
AM939
E920
Lotryl
AX8900
AM939/Lotryl/AX8900
MFI (g/10 min)
T = 20° C.
T = 0° C.
T = −30° C.
100%
PET Base
40–50
3.2
3.2
3.2
80%
20%
Comparative 1
1.8
22
15
7
80%
20%
Comparative 2
7
8
7.3
4.7
80%
20%
Comparative 3
9
5.4
4.7
3
80%
17%
3%
Comparative 4
1.6
19.9
15.1
9.5
80%
6%
11%
3%
28.6/57.1/14.3
5 to 6
12.6
10.7
7.2
80%
9%
9%
3%
42.9/42.9/14.3
7 to 8
12
10.8
6.7
80%
9%
9%
3%
42.9/42.9/14.3
2
12.7
11.3
7.6
80%
11%
6%
3%
57.1/28.6/14.3
2 to 3
10.1
8.1
5.3
80%
11%
6%
3%
57.1/28.6/14.3
6
10.5
9.3
5.8 | The invention concerns thermoplastic polyesters (such as PET or PBT) comprising, by weight, the total being 100%: 60 to 99% of thermoplastic polyester; 1 to 40% of impact modifier comprising: (a) a core-shell copolymer (A), (b) an ethylene copolymer (B) selected among ethylene copolymers (B1) and an unsaturated carboxylic acid anhydride, ethylene copolymers (B2) and an unsaturated epoxy compound and mixtures thereof, (c) a copolymer (C) selected among ethylene copolymers (C1) and an alkyl (meth)acrylate, ethylene copolymers (C2) and (meth)acrylic acid optionally neutralised and mixtures thereof. The invention also concerns an impact modifying composition which can be added in thermoplastic polyesters to improve their shock-proof properties and comprising constituents (A), (B) and (C). | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates to a method and a device for the measurement of ions by coupling different measurement methods/techniques.
[0003] 2. Prior Art
[0004] The measurement of ions is important particularly in connection with mass-spectrometric analysis methods. In the scope of materials analysis, for instance, ions are generated from a material sample, separated according to mass or other criteria and detected in a detector or a similar instrument.
[0005] Collectors, for example Faraday cups, are widely known detectors which can be used to measure the ion current as a voltage across a high resistance or in a high impedance amplifier. Secondary electron multipliers (SEMs) are also known. They operate with a conversion dynode at the input, on whose surface the incoming ions are neutralized and electrons are thereupon released. The electrons are then multiplied from stage to stage inside the SEM, so that even very small numbers of ions can be registered. It is also already known to operate an SEM in two different operating modes, namely analog mode and count mode. In order to record the electrons in analog mode, a signal is taken from one of the central stages. The count mode records the electrons arriving at the last stage of the SEM. The analog mode and count mode run in parallel with each other, for instance in the Finnigan Element 2 mass spectrometer from Thermo Electron. High ion currents can be measured using the analog mode, while the count mode evaluates the relatively smaller ion currents.
[0006] In particular applications, it is expedient to have a wide dynamic measurement range of more than nine orders of magnitude (more than 10 9 ). In order to quantify minor impurities or doping in mass-spectrometric materials analysis, for example, such as laser ablation ICP mass spectrometry or glow discharge mass spectrometry (GD-MS), it is advantageous to be able to measure both the primary component (matrix) and the impurities or doping. It is also often advantageous to record a process gas used in the mass spectrometer (carrier), for example argon or other noble gases. For many applications, especially GD-MS, it is advantageous to lower the detection limit for impurities or doping. Minute traces of the components which are present should be detectable, if possible in the sub-ppb range, at the same time as the primary component (matrix). It is moreover desirable to take measurements efficiently and rapidly since, in GD-MS applications for example, analyte material is continually being eroded from the sample surface. The material composition may vary as a function of the depth of the sample.
BRIEF SUMMARY OF THE INVENTION
[0007] It is an object of the invention to carry out measurements in the shortest possible time over a wide dynamic range. A time of 1 ms per measurement channel should preferably be achieved. It is furthermore desirable to have a dynamic range of 12 orders of magnitude or more (10 12 =sub-ppb), for example 1 cps to >10 12 cps.
[0008] The features of the method according to the invention is a method for the measurement of ions by coupling different measurement methods/techniques, a first detector being a collector and a second detector being an SEM, and the ions to be measured or resulting secondary particles being selectively delivered to the collector or the SEM. Accordingly, a first detector is a collector and a second detector is an SEM, the ions to be measured or resulting secondary particles being selectively delivered to the collector or the SEM. By coupling the two detector types, it is possible to cover a wide dynamic measurement range even for high ion currents.
[0009] The SEM is preferably operated selectively in analog mode and in count mode. This gives an even wider dynamic measurement range. The measurement ranges may also overlap one other. This may be advantageous for standardizing the measurements with respect to one another.
[0010] In particular, at least one Faraday cup is provided as the collector. This technique is known, and need not be explained further. According to another concept of the invention, the collector is operated with an integrating electronic circuit (integrator). This allows fast measurements in the range of 1 ms or less. Without an integrator, longer measurement times are often required since the transient and decay phenomena of the electrical quantities being measured then necessitate longer minimum measurement times.
[0011] According to another concept of the invention, the ions first generate secondary particles for measurement using the SEM, and then these secondary particles travel to the SEM. The secondary particles are generally electrons. They are generated outside the SEM, for instance at a separate conversion dynode. The advantages of this measure are the extended life of the SEM and a reduction in the mass dependencies of the measurement results.
[0012] The measurement ranges of the collector and of the SEM preferably overlap one other, in particular by at least two orders of magnitude (10 2 ). The same may apply to the measurement ranges inside the SEM, that is to say for the count mode on the one hand and the analog mode on the other hand. Overlap of the measurement ranges allows more straightforward calibration of the various measurement ranges with respect to one another. The different measurement ranges are preferably calibrated with respect to one another during the measurement.
[0013] The calibration is advantageously carried out by measuring the same ion mass for all measurement ranges, or at least for pairs of adjacent measurement ranges, and by matching the results. When using argon as the carrier gas, for example, an argon isotope with a suitable intensity such as the argon isotope with the mass number 36 may be used for calibrating all three measurement ranges. The mass spectrometer preceding the detector performs a scan over the relevant mass range. The results obtained can be presented in a diagram as a signal peak for said isotope. There is then an overlap of measurement ranges in a lower part of the leading peak edge and at the top of the peak. The measurement ranges may be calibrated with respect to one another while the measurement is running, so that the measurement results are immediately standardized with respect to one another.
[0014] The ions to be measured are preferably separated beforehand in a mass spectrometer. A double focusing mass spectrometer with a magnetic sector and an electrostatic sector, or a quadrupole mass spectrometer are preferred. Preferred techniques are ICP mass spectrometry, ICP mass spectrometry coupled with laser ablation or glow discharge mass spectrometry (GD-MS).
[0015] Preferred applications are mass-spectrometric materials analysis, for instance the measurement of impurities or doping in a primary component (matrix).
[0016] Another example of an application is GD-MS, with a depth profile of a material sample being compiled. The faster the detector operates and the faster the measurements can be carried out, the greater is the depth resolution.
[0017] Automatic switching between the individual detectors and the associated measurement ranges is advantageously provided. Only in this way is it feasible to compile a depth profile of a material sample consisting of different layers (with a widely varying element composition).
[0018] The device according to the invention for the measurement of ions has a collector as the first detector and an SEM as the second detector. A steering unit, for instance a deflector, is furthermore provided for selectively steering the ions or resulting secondary particles into the collector or the SEM.
[0019] According to another concept of the invention, the SEM may be preceded by a conversion dynode so that only electrons enter the SEM. These are formed at the conversion dynode after the ions impact on it. The conversion dynode is therefore not part of the SEM. This extends the life of the SEM. The mass dependency of any calibration is furthermore reduced.
[0020] The steering unit is advantageously arranged and aligned so that the ions travel to the collector in a setting in which there is no deflection or only minor deflection, and the ions or resulting secondary particles travel to the SEM in a setting in which deflection takes place.
[0021] The steering unit advantageously contains a conversion dynode so that the particles traveling from the deflector to the SEM are (secondary) electrons.
[0022] According to another concept of the invention, the steering unit contains a deflector electrode which is arranged between the conversion dynode and the SEM, the deflector electrode having at least one passage for the electrons. The deflector electrode is preferably designed in the shape of a ring or at least with a central opening, or as a grid for the electrons coming from the conversion dynode to pass through.
[0023] According to another concept of the invention, the SEM has at least two terminals (signal outputs), namely a terminal for an analog mode and a terminal for a count mode.
[0024] The device according to the invention may have a switching unit for switching between a signal output of the collector and the terminals of the SEM. Constant switching between the different detectors and/or between the terminals of the SEM is provided in order to cover a wider dynamic measurement range within a measurement. The switching unit may be part of an evaluation unit. It is preferable not to switch between the terminals of the SEM, but to record either the collector or both terminals of the SEM at the same time. Beyond a threshold, the count mode is automatically switched off and only the analog mode continues to be used, in order to protect the rear dynodes of the SEM against overload and to minimize nonlinearities and major dead time effects.
[0025] According to another concept of the invention, the collector is provided with an integrator for integrating the signal obtained from the collector. Usually, the ion current received by a collector is dissipated across a high resistance and the resulting voltage is measured. The voltage is then a measure of the ion current in question. The measurement time required for this is relatively long because of the transient and decay processes. The measurement time can be reduced by using the integrator at the collector, for instance a Faraday cup. Measurement intervals of only 1 ms are possible in this way, regardless of the signal level and even the signal level of the last measurement value. The integrator is a simple electronic circuit for adding up (integrating) the incident ion current, and need not be explained further.
[0026] According to another concept of the invention, a calibrating unit is provided for calibrating the results of the measurement using the collector with respect to the measurement by the SEM in analog mode, and for calibrating the results of the measurement by the SEM in analog mode and the SEM in count mode (or vice versa). It is expedient to produce the calibrating unit as software, namely as a component of software for evaluating the individual signals and/or as part of an evaluation unit.
[0027] Other features of the invention will become apparent from the patent claims and the description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Preferred embodiments of the invention will be presented in more detail below with reference to drawings, in which:
[0029] FIG. 1 shows a schematic arrangement of individual elements of a device according to the invention,
[0030] FIG. 2 shows a specific example of the arrangement according to FIG. 1 ,
[0031] FIG. 3 shows a representation of the overlap of the measurement ranges within the device according to the invention,
[0032] FIG. 4 shows a representation of the calibration of the different measurement ranges over the course of the peak of the argon isotope with the mass number 36.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] According to FIG. 1 , ions from an ion source 10 are (optionally) separated in an analyzer 11 according to their mass-to-charge ratio or other criteria. The ion current coming from the analyzer 11 is processed by optional filter elements 12 , 13 . For example, 12 denotes ion optics and 13 denotes an energy filter.
[0034] The ion current then enters a steering unit 14 with an optional integrated or separate conversion dynode 15 . In the present example, this is an integrated conversion dynode. In the steering unit 14 , the ion beam is steered with the aid of at least one deflector electrode 16 into a collector 17 , here designed as a Faraday cup, into a secondary electron multiplier (SEM) 18 or via the conversion dynode 15 into the SEM 18 , depending on which operating mode is intended.
[0035] The SEM 18 has terminals (connections or signal outputs) 19 , 20 for an analog mode and a count mode. The two measuring modes of the SEM 18 can be performed alternately or (preferably) at the same time.
[0036] The signals or information obtained by means of the two detectors (collector 17 , SEM 18 ) are subjected to evaluation in an evaluation unit 21 . All the necessary calculations are carried out in the evaluation unit 21 . Logic-function interconnection of the evaluation unit 21 with a control unit (not shown) is also provided for the device as a whole.
[0037] FIG. 2 shows the multiplicity of aforementioned components in a specific arrangement. The ion source 10 is not indicated. Only part of the analyzer 11 is depicted, namely an electrostatic analyzer 12 —here as part of a double focusing mass spectrometer. The ion source is preferably and ICP or GD (inductive coupled plasma/glow discharge) ion source.
[0038] The steering unit 14 is arranged so that an ion beam travels to the collector 17 if it is not deflected, or if it is deflected only to a minor extent. The conversion dynode 15 and the deflector electrode 16 are arranged mutually parallel, and preferably also essentially parallel to the ion beam emerging from the filter element 13 . In this case, the deflector electrode 16 is provided between the conversion dynode 15 and the SEM 18 . The deflector electrode 16 has at least one opening for the electrons formed from the ions at the conversion dynode 15 to pass through.
[0039] Measurements over a dynamic measurement range of more than 9 orders of magnitude (10 9 ) are possible with the device according to the invention and the method according to the invention. In particular, twelve orders of magnitude (10 12 ) can be measured. This is possible here owing to the relative arrangement of three measurement ranges, namely the measurement range of the collector 17 (Faraday cup) with an integrator, the measurement range of the SEM in analog mode and the measurement range of the SEM in count mode.
[0040] Said measurement ranges overlap one another, preferably by two orders of magnitude (10 2 ) in each case. The overlap of the measurement ranges is shown in FIG. 3 . The signal in question is represented as a function of an ion concentration. The measurement is carried out using the collector (dashed line) for the largest number of ions per unit time, using the analog mode (dotted line) for medium ion concentration and using the count mode (continuous line) of the SEM for the weakest ion concentration. Said three measurement ranges overlap one another so that the outer two ranges are almost contiguous.
[0041] An essential advantage of the mutually overlapping measurement ranges is the opportunity for automatic calibration while the measurement is running. The signals in the overlap range of two measurement ranges can be compared with each other and standardized with respect to each other, so that correction factors or summands can also be used outside the measurement-range overlaps.
[0042] FIG. 4 illustrates the calibration of the measurement ranges with reference to a specific example. In many applications, argon is used as a gas for generating the ions or as a carrier gas for the ion current. Argon can therefore be detected in the spectrum. FIG. 4 shows a selective scan by the mass spectrometer over a complete peak of the argon isotope with the mass number 36. The ion concentration is so great at the highest point of the peak (peak top) that measurements are possible in the collector measurement range and in the analog mode measurement range (SEM). These two measurement ranges are therefore calibrated with respect to each other during a scan over the peak top.
[0043] On the other hand, the measurement range for the analog mode and the measurement range for the count mode overlap each other in a lower range of the same peak, namely at the start of a leading edge or at the end of a trailing edge. Calibration of the two said measurement ranges with respect to each other is accordingly carried out there.
[0044] The particular advantage of this is that a calibration can be carried out comprehensively (for all the measurement ranges) during a single scan with the same ion mass.
LIST OF REFERENCES
[0000]
10 Ion source
11 Analyzer
12 Filter element/Ion optics
13 Filter element/Energy filter
14 Steering unit
15 Conversion dynode
16 Deflector electrode
17 Collector
18 SEM
19 Terminal (analog mode)
20 Terminal (count mode)
21 Evaluation electronics
22 Electrostatic analyzer— | The invention relates to a method and a device for the measurement of ions by coupling different measurement methods/techniques, a first detector being a collector ( 17 ) and a second detector being an SEM ( 18 ), and the ions to be measured or resulting secondary particles being selectively delivered to the collector or the SEM. The SEM ( 18 ) is operated selectively in analog mode or count mode. The collector ( 17 ) is provided with an integrator. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a device for stabilizing a ladder used to provide access to the roof of a structure. More specifically, the invention relates to a device that engages the eaves of a roof and secures the ladder in position.
[0003] 2. Background
[0004] Ascending a ladder to the roof of a structure is inherently dangerous. Typically, the ladder is leaned against the edge of a roof, which may not provide adequate stability. If not secured in some fashion, the ladder may fall to one side or may fall backward away from the roof. A number of inventions have been proposed to address this problem. Quite a few patents have been issued for devices intended to stabilize a ladder. These include, for example:
Patent Number Inventor(s) Issue Date 783,259 Friend Feb. 21, 1905 1,467,597 Wendel Sep. 11, 1923 2,815,160 Gilmour et al. Dec. 3, 1957 4,823,912 Gould et al. Apr. 25, 1989 4,949,810 Dwinnell Aug. 21, 1990 5,012,895 Santos May 7, 1991 5,067,588 Bendickson Nov. 26, 1991 5,117,941 Gruber Jun. 2, 1992 5,165,501 Donahey Nov. 24, 1992 5,180,032 Hidalgo Jan. 19, 1993 5,383,533 Nikula et al. Jan. 24, 1995 5,509,500 Delagera Apr. 23, 1996 5,743,356 Mitchell Apr. 28, 1998 5,775,465 Vossler Jul. 7, 1998 5,971,100 DeLeon et al. Oct. 26, 1999 6,009,974 Jones Jan. 4, 2000 6,012,546 Bee et al. Jan. 11, 2000 6,019,191 Flores Feb. 1, 2000 6,045,102 Terenzoni Apr. 4, 2000 6,394,229 Hastreiter May 28, 2002 6,412,600 Wolfman Jul. 2, 2002 6,427,803 Moore Aug. 6, 2002 6,513,625 Gaskins Feb. 4, 2003 6,578,665 DeBaca et al. Jun. 17, 2003
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a device for stabilizing a ladder. In one embodiment the device comprises a clamp adapted to engage a side rail of the ladder, an arm extending from the clamp and a screw member disposed at the end of the arm. The ladder is leaned against the roof in the conventional manner and the device is positioned on the side rail of the ladder with the arm extending under the eaves. The screw member is then tightened against the underside of the roof (or against the soffit if there is one) to secure the ladder in position.
[0006] In another embodiment, a ladder stabilizer is configured as a strap that may be wrapped around the side rails of a ladder and nailed to a roof. The strap has fittings at each end that facilitate coupling two or more straps together end to end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view showing a ladder stabilizer in accordance with the present invention.
[0008] FIG. 2 is a diagrammatic view showing the device in use to stabilize a ladder against a roof.
[0009] FIG. 3 illustrates a strap device for stabilizing a ladder.
[0010] FIG. 4 is a perspective view of an end fitting for the strap shown in FIG. 3 .
[0011] FIG. 5 is a plan view of the end fitting shown in FIG. 4 .
[0012] FIG. 6 is a partial cross-sectional view through line 6 - 6 of FIG. 5 .
[0013] FIG. 7 illustrates another strap device for stabilizing a ladder.
[0014] FIG. 8 is a detailed view of the strap assembly shown in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0016] FIG. 1 shows a ladder stabilizer 10 in accordance with the present invention. The stabilizer comprises a clamp portion 20 , an arm 30 extending from the clamp portion and a screw 40 . Clamp portion 20 includes a pair of grips 21 that are slotted to engage rail 102 of ladder 100 .
[0017] The length of arm 30 is preferably adjustable. To facilitate this, arm 30 comprises an outer section 31 and an inner telescoping section 32 . A pin 34 engages one of a plurality of holes 35 to secure the telescoping sections together at a desired length. An upward reaching section 33 extends from the end of inner section 32 . Screw 40 is threaded through section 33 . Screw 40 has a handle portion 41 at its lower end and a foot potion 42 at its upper end.
[0018] Various materials are suitable for the construction of ladder stabilizer 10 . The principal components could be constructed of steel or aluminum or a combination of the two materials. For reasons of economy and versatility, plastic is a preferred material.
[0019] With reference now to FIG. 2 , the use of ladder stabilizer 10 may be better understood. Rails 102 of a ladder 100 are leaned against the edge of roof 110 . As mentioned above, the grips 21 of clamp 20 are adapted to engage rail 102 . The angle between arm 30 and clamp 20 may be adjusted by means of adjustment knob 22 to accommodate different roof overhangs, gutters and fascia dimensions. Once the angle of arm 30 has been adjusted, screw 40 is tightened by means of handle 41 until the foot 42 engages the underside of the roof. It will be appreciated that tightening the screw 40 exerts a downward force on arm 30 , which, in turn, applies a clockwise force on clamp 20 to more tightly engage ladder rail 102 . This also forces the ladder against the edge of the roof to firmly secure it in place. Preferably, a stabilizer is used on each of the ladder rails for maximum stabilizing effect.
[0020] It should be noted that stabilizer 10 may also be used with a “parapet” style roof. In this case, the stabilizer is simply inverted and the screw member is tightened against the top of the parapet.
[0021] FIGS. 3-6 show a strap 200 for stabilizing ladder 100 against the edge of roof 110 . The strap may be simply wrapped around the side rails 102 of the ladder and nailed to the roof at each end.
[0022] The construction of strap 200 can be better seen in FIGS. 4 and 5 . The strap comprises a length of flexible material 202 , such as nylon webbing. An end fitting 204 is secured at each end of the strap. Material 202 is looped through a slot 205 in the end fitting and sewn together. Nail holes 206 are provided for securing the ends of the strap to a roof.
[0023] A feature of strap 200 is the provision of means for coupling together two or more of the straps end to end. End fittings 204 have a pair of locking prongs 207 and a pair of locking prong holes 208 . The holes are configured to receive the locking prongs of another end fitting that has been inverted and aligned with the first fitting. The locking prong holes 208 of each end fitting receive the locking prongs 207 of the other end fitting. The locking prongs are shaped so that, once the two end fittings have been placed together, the locking prongs extend over the surface of the adjacent end fitting to secure them together.
[0024] Each of end fittings 204 is provided with a safety clip 210 to prevent unintended uncoupling of coupled end fittings. Safety clip 210 is separated from end fitting 204 on three sides so that it can deflect slightly from the plane of the fitting. The safely clip has a saw-tooth cross-section as illustrated in FIG. 6 . When a pair of end fittings are coupled together, the opposing safety clips engage each other as the locking prongs are slid over the respective locking prong holes. This prevents the unintentional uncoupling of the end fittings since the safety clips must be manually separated before the locking prongs can be removed from their respective locking prong holes.
[0025] FIGS. 7 and 8 show another type of strap assembly 300 for stabilizing ladder 100 against the edge of roof 110 . As shown, a pair of strap assemblies 300 are used, one with each of the side rails 102 of the ladder. The assembly comprises a first strap portion 302 secured at one end to end fitting 304 and at the other end to adjustment clamp 305 . A second strap portion 303 is releasably secured by the adjustment clamp. Strap portions 302 and 303 may be made of nylon webbing as in the previously described embodiment.
[0026] Each of the strap assemblies is secured to the roof at end fitting 304 by nails driven through slotted holes 306 . Strap portion 303 is wrapped around the respective side rail of ladder 100 and threaded through loop 307 like a slipknot in a lasso. The free end of strap portion 303 is then threaded through adjustment clamp 305 and secured taught.
[0027] End fitting 304 is formed with bends so that portion 308 , which connects to strap portion 302 , is raised off of the surface of the roof. The bends also provide an upright surface 310 , which may be struck with a hammer to dislodge the end fitting from the securing nails. End fitting 304 is preferably made of metal strap material, such as steel, which is plated or otherwise treated for corrosion protection.
[0028] When ladder 100 is to be relocated, tension in the strap assemblies is released at the adjustment clamps, and the end fittings are tapped off of the nails and removed.
[0029] It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims. | A device for stabilizing a ladder has a clamp adapted to engage a side rail of the ladder, an arm extending from the clamp and a screw member disposed at the end of the arm. The ladder is leaned against the roof in the conventional manner and the device is positioned on the side rail of the ladder with the arm extending under the eaves. The screw member is then tightened against the underside of the roof (or against the soffit if there is one) to secure the ladder in position. | 4 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention has relation generally to method and apparatus for intraoperative and perioperative pressure gradient regulation, and more particularly to control of pressure gradients across operatively exposed tissues, fluids or other natural or artificial components, including but not limited to the dura and blood vessels, for the reduction of at least one of edema, hemorrhage, and tissue movement.
B. Underlying Physiology and Current State of the Art
This invention relates to several intraoperative and perioperative conditions and complications which may be amenable to treatment or prevention by the controlled application of a pressure gradient across the operatively exposed tissue or structures. This invention has application to neurosurgical procedures, general surgical procedures, orthopedic surgical procedures, and other major and minor surgical procedures in the control of at least one of edema (excessive accumulation of watery fluids is cells, tissues, or serious cavities), hemorrhage, and tissue movement.
B1. Edema, Particularly as Encountered Intraoperatively in Neurosurgery
Edema commonly occurs during and following surgical procedures. Edema in central nervous system (CNS) structures is of particular concern because negligible room for expansion is permitted by the virtually inelastic dura which envelopes the CNS and the bony calvarum to which the dura is attached. For simplicity, "cerebral edema" will be understood to refer to and encompass edema of any and all parts of the CNS and peripheral nervous system (PNS), including but not limited to the cerebrum, cerebellum, brainstem, spinal cord, nerve roots, dorsal root ganglia, spinal nerves, cranial nerves, and peripheral nerves.
Central nervous system tissue is physiologically maintained at a pressure greater than the extracranial pressure, which is typically that of the ambient room pressure. This is influenced by several factors, including rates of production and outflow of cerebrospinal fluid (CSF), carotid arterial and jugular venous pressures, vasomotor tone of CNS arterioles, oncotic and osmotic pressures of the serum, and permeability of the vascular endothelial cells. These factors are further modulated by local and systemic parameters, exemplified by hormones, arterial carbon dioxide partial pressure, inflammatory cytokines, surgical or accidental trauma to vascular endothelial cells, and release of intracellular contents by damaged cells.
The pressure within the normal intact CNS is substantially uniform, and the intracranial-ambient pressure gradient is borne by the dura and surrounding bony structures. During neurosurgical procedures, the dura, subsequent to incision, becomes incapable of maintaining the tension along its curved plane required to balance the pressure difference between its internal and external surfaces. Consequently, this pressure gradient must be borne by a volume of CNS tissue, that including, surrounding, and deep to the exposed surface.
This pressure gradient may cause mechanical deformation of the CNS tissue as well as fluid shifts. from the intravascular space to the extracellular space. Fluid may shift within the extracellular space along this pressure gradient, with flow proceeding from the deeper regions to the more superficial. Furthermore, the hydrostatic-oncotic pressure balance between the intravascular space and the extracellular space is disturbed, and a fluid driving pressure gradient is established from the intravascular to the extracellular space, producing edema from plasma-derived fluid.
These fluid shifts can result in significant accumulation of fluid, i.e. edema, of the exposed and underlying tissue, with several undesirable effects. The excessive fluid volume in the edematous tissue causes compression of the vascular space and can result in ischemia. Ischemia, in turn, by compromising cell metabolism, impairs ionic transport across cell membranes; net sodium influx results, drawing water with it into the intracellular space; this cell swelling further exacerbates the edema. The increase in tissue volume can present a serious problem to the surgeon at the completion of the neurosurgical procedure.
Normally, the virtually inelastic dura is reapposed over the nervous tissue, and the bone flap is replaced prior to skin closure. If the volume of the tissue has increased, as occurs in edema, closure of the increased tissue volume within the unchanged volumes contained by the dura and cranial vault will necessarily result in an increase in intracranial pressure. Postoperative persistence of elevated ICP is associated with increased morbidity and mortality.
Intraoperative options available to the neurosurgeon include (1) resection of otherwise viable nervous tissue to compensate for the volume increase resulting from edema, (2) withdrawal of cerebrospinal fluid (CSF) from the ventricles for the same purpose, and (3) closure of the skin over the dura without replacement of the bone flap. These options are suboptimal, resulting in potentially decreased postoperative neurological function, incomplete decompression, and potential need for reoperation, respectively.
Pharmacological means are used to reduce cerebral edema in an effort to reduce intracranial pressure (ICP) in the preoperative, intraoperative, and postoperative periods. Neurosurgical procedures are not uncommonly delayed while awaiting a drop in the intracranial pressure in response to preoperative administration of pharmacological agents. The major drugs currently used include diuretics, steroids, osmotic agents, and short-acting barbiturates. Other modalities of prevention or treatment include cerebrospinal fluid drainage (via ventricular catheter), hypothermia, assisted ventilation with hyperventilation, dehydration, and avoidance of cerebral vasodilating anesthetics. These agents, though helpful, often provide incomplete reduction of intracranial pressure and may take hours to days to achieve requisite decompression.
B2. CSF Loss Encountered Intraoperatively in Neurosurgery
The intracranial-ambient pressure gradient may cause flow and leakage of CSF through the operative incision. Loss of CSF from the region of the spinal cord can result in caudal shift of the brain with impingement against bony or fibrous structures in the head. These include herniation of the uncus through the tentorium and herniation of the cerebellar tonsils or the brainstem through the foramen magnum. Consequences can range from headache to death, depending on the magnitude of the shift and the structures compromised.
B3. Edema in Other Surgical Procedures
Edema occurs during and following other surgical procedures and may also be undesirable. Edema is a well known complication of general surgical procedures. Intraoperative and postoperative shift of fluid from the intravascular space to the extracellular space is termed "third spacing", and this typically involved several liters of fluid. Consequently, several liters of intravenous fluids are given intraoperatively and in the early postoperative period to minimize hypovolemia and cardiovascular compromise. This edema fluid is subsequently remobilized back to the intravascular space, typically on the third postoperative day, and poses a risk of hypervolemia, including such complications as atrial fibrillation. Careful monitoring of patient fluid status and adjustment of intravenous and oral fluid intake to minimize perioperative and postoperative intravascular volume excursions is the current practice, and this affords a limited control with a slow time response in the fluid management of the surgical patient.
B4. Hemorrhage, Particularly Intraoperative and Postoperative
Intraoperative and postoperative hemorrhage is undesirable yet common. The shift of blood out of the intravascular compartment is driven by the pressure gradient between a combination of the systolic and diastolic blood pressures and the surrounding ambient pressure or that of any body cavity or potential space into which the hemorrhage may occur. Hemorrhage preoperatively or in the absence of surgery is a concern as well, particularly in cases involving trauma. The major methods currently used to control hemorrhage include blood vessel ligation and electrocautery. Tourniquets may also be used to arrest hemorrhage from distal portions of the body.
B5. Tissue Movement, Particularly that of the Nervous System
During neurosurgical procedures, the exposed brain or spinal cord is observed to move in a cyclical manner with respiration or mechanical ventilation. This movement limits the accuracy and expediency of microsurgical procedures. Fine surgical manipulation can be compromised by movement of the tissue, focal plane of the surgical microscope. Changes in intrathoracic pressure are transmitted via the vascular system to the CNS tissue; this is evidenced by the cyclic fluctuation of the intracranial pressure, as measured through a ventricular catheter in an otherwise intact subject, in association with the respiratory cycle. Intraoperatively, when a portion of the CNS is exposed to ambient pressure, the ICP pressure gradient effects movement of the CSF and the CNS tissue. The edematous effects of the static component of the pressure gradient are described previously. This static component also causes a shift in the position of the tissue, particularly in spinal surgery. The dynamic component of this pressure gradient effects intraoperative movement of CNS tissue in association with respiration and to a lesser extent with the cardiac cycle. This presents difficulty in surgical manipulation, tissue visualization, placement of implanted electrodes or other devices, and in positioning of neurophysiological electrodes. These problems are encountered in human and animal procedures, in both clinical evaluation and research experimentation.
C. Summary of the Prior and Related Art
The prior art includes several different methods and apparatuses for the application of hyperbaric and hypobaric pressure to a subject. Such devices include so called depurators which apply a hypobaric pressure to the body of the subject; these systems are claimed to treat various diseases for which high altitude environments are claimed to be therapeutic. Other devices which apply pressure to regions of the body include enclosures designed to provide a sterile surgical field within a contaminated environment such as a battlefield. Yet other devices facilitate the application of pressure at the site of a wound for the purposes of hemostasis.
Despite the technology taught by such inventions, there remains a need for an invention which creates controlled pressure gradients across relevant anatomy to facilitate control of the movement of fluids and tissues while simultaneously permitting surgical intervention. A pronounced need for such a device exists in the field of neurosurgery. The edema which results from such uncontrolled fluid shifts causes postoperative elevation of intracranial pressure, a postoperative condition directly associated with increased morbidity and mortality. Other surgical procedures, particularly general surgical operations, have a need for intraoperative and postoperative control of fluid shifts. Considerable effort in the postoperative management of general surgical patients is directed toward the monitoring and control of intravascular and extracellular fluid volumes. These is a need for an invention which allows for intraoperative and postoperative control of these fluid shifts. Intraoperative, postoperative and post traumatic hemorrhage is a problem which remains in want of a better solution. Arrest of blood flow from compromised vessels may be technically difficult due to limited exposure of bleeding vessels, and the localization of the source of blood loss may be limited by the impaired visualization inherent in a bloody field. A clear need exists for an invention which facilitates manipulation of the intravascular-ambient pressure gradients and thereby allows for control or elimination of blood loss.
BRIEF DESCRIPTION OF THE INVENTION
A. Objects of the Invention
The present invention relates to the control of pressure gradients involved in the shift of CSF, intravascular fluid, extracellular fluid, blood, or other fluids. By controlling, reducing, eliminating, reversing, or modulating these pressure gradients, edema, hemorrhage, CSF loss, and tissue movement may be controlled and reduced. It is a general object of the present invention to provide a method and requisite apparatus for the manipulation of pressure gradients to effect control of the many types of fluid shifts that occur intraoperatively, preoperatively, postoperatively, or post-traumatically. It is a related general object of the present invention to provide a method and necessary apparatus for the performance of surgical procedures in which manipulation of pressure gradients is used to effect control of the many types of fluid shifts that occur intraoperatively, preoperatively, postoperatively, or post-traumatically.
A1. Objects Pertaining to Neurosurgery
It is an object of the present invention to provide a method and apparatus for performing a neurosurgical procedure with reduced or absent edema of the nervous tissue. It is another object of the present invention to provide a method and apparatus for performing a neurosurgical procedure with reduced or absent hemorrhage. It is yet another object of the present invention to provide a method and apparatus for performing a neurosurgical procedure with reduced or absent loss of cerebrospinal fluid. It is still another object of the present invention to provide a method and apparatus for performing a neurosurgical procedure with reduced or absent intraoperative movement of the nervous tissue.
A2. Objects Pertaining to Surgery in General
It is an object of the present invention to provide a method and apparatus for performing a surgical procedure with reduced or absent edema of the tissue within, surrounding, and remote from the operative zone. It is another object of the present invention to provide a method and apparatus for performing a surgical procedure with reduced or absent hemorrhage. It is still another object of the present invention to provide a method and apparatus for performing a surgical procedure with reduced or absent intraoperative movement of the operative tissue.
Other objects and advantages will be in part indicated in the following description and in part rendered apparent therefrom in connection with the annexed drawings.
B. Summary of the Invention
The present invention is a method and apparatus involving manipulation of pressure gradients to control the intraoperative, perioperative, or post-traumatic shifts of bodily fluids and tissues, including but not limited to the CSF, intravascular fluid, extracellular fluid, blood, and nervous tissues. By reducing, eliminating, reversing, modulating, or otherwise regulating these pressure gradients, edema, hemorrhage, CSF loss, and tissue movement may be controlled and reduced.
The method and apparatus of the present invention prescribe and effect, respectively, control of the pressure gradient between that of the bodily tissues and the ambient environment. The pressures within bodily fluids and tissues, exemplified by blood pressure and intracranial pressure, exceed that of the ambient environment. When the mechanical or functional integrity of these or the overlying tissues or structures is compromised, as is often the case during the intraoperative perioperative, and post-traumatic intervals, fluids otherwise normally contained by these structures may experience a net flow in response to these pressure gradients. These flows may be reduced, prevented, reversed, or otherwise controlled by the manipulation of these pressure gradients, as put forth in the method and effected by the apparatus of the present invention.
The method includes the application of this pressure gradient control to all bodily tissues, fluids, and natural or artificial structures, including but not limited to the nervous system, heart, limbs, thorax, abdomen, and implanted or explanted devices.
This method and requisite apparatus have application in neurosurgical procedures, in which incision of the dura exposes the nervous tissue to ambient, typically atmospheric, pressure. The nervous tissue is normally maintained at the intracranial pressure (ICP), typically 14 mmHg, and upon incision of the dura, this pressure gradient is borne by the nervous tissue. The resulting mechanical distension and edema are described previously. By the method of the present invention, this manipulation of this pressure gradient affords control, including reduction and elimination, of these untoward processes. Elimination of this pressure gradient, according to the method of the present invention, could be effected by increasing the ambient pressure to that of the ICP, by decreasing the ICP to ambient pressure, or a combination of ambient pressure and ICP manipulation.
This method and essential apparatus further have application in the control of hemorrhage in other surgical procedures. Hemorrhage results when the integrity of the vascular walls is compromised such that the vascular structures are incapable of sufficiently resisting the flow of blood along the intravascular-ambient pressure gradient. By the method of the present invention, manipulation of this pressure gradient affords control, including reduction and elimination, of hemorrhage. Elimination of this pressure gradient, according to the method of the present invention, could be effected by increasing the ambient pressure to that of the systolic, diastolic, or a function involving the two blood pressures, by decreasing any of these blood pressures to ambient pressure, or a combination of ambient pressure and blood pressure manipulation.
This method and required apparatus have further application in the intraoperative control of tissue or fluid movement. The oscillating pressure gradient associated with the respiratory cycle is transmitted from the thoracic cage via vascular structures to generate an oscillatory component of the intracranial pressure. During intraoperative exposure of the nervous system, this oscillating intracranial-ambient pressure gradient causes movement of the nervous tissues and the cerebrospinal fluid. By the method of the present invention, manipulation of this oscillatory pressure gradient affords control, including reduction and elimination, of this movement of tissues and fluids and other natural or artificial structures. Elimination of this pressure gradient, according to the method of the present invention, could be effected by cyclically increasing the ambient pressure to that of the intracranial pressure or the oscillating component thereof, by decreasing the intracranial pressure or the cyclical component thereof to ambient pressure, or a combination of ambient pressure and intracranial pressure manipulation. Elimination of this pressure gradient, according to the method and achieved by the apparatus of the present invention, is accomplished by manipulating at least one of the ambient pressure or the intracranial pressure to cancel or reduce at least one of the static (steady) or dynamic (oscillating) components of the intracranial-ambient pressure gradient.
The apparatus according to the present invention accomplishes at least one of the previously described methods. The present invention is characterized by an apparatus which controls the tissue-ambient pressure gradient by applying elevated pressure to a region including the zone of operation or trauma. The present invention is similarly characterized by an apparatus which controls the tissue-ambient pressure gradient by effecting reduced pressure in the tissue underlying, surrounding, or comprising a region of tissue excluding the zone of operation or trauma. The present invention is further characterized by an apparatus which controls the tissue-ambient pressure gradient by a combination of applying elevated pressure to a region including the zone of operation or trauma and effecting reduced pressure in the tissue underlying, surrounding, or comprising a region of tissue excluding the zone of operation or trauma.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be more clearly understood from a reading of the following detailed description in conjunction with the accompanying drawings wherein:
FIG. 1 is a coronal cross section of the brain and a craniotomy.
FIG. 2 is a horizontal cross section of the spinal cord and a laminectomy.
FIG. 3 is a cross section of a skin incision and underlying subcutaneous tissue.
FIG. 4 is a cross section of a limb undergoing amputation.
FIG. 5 is a sagittal cross section of an incised and opened abdomen.
FIG. 6 is a sagittal cross section of an incised and opened thorax.
FIG. 7 is a coronal cross section of the brain with an operative zone ambient positive pressure applying apparatus in position about a craniotomy.
FIG. 8 is a lateral view of a non-operative zone ambient negative pressure applying flexible apparatus in position about a craniotomy.
FIG. 9 is a lateral view of an operative zone ambient positive pressure applying apparatus in position about a spinal procedure.
FIG. 10 is a lateral view of a non-operative zone ambient negative pressure applying flexible apparatus in position about a spinal procedure.
FIG. 11 is a lateral view of a non-operative zone ambient negative pressure applying flexible apparatus in position about a thoracotomy.
FIG. 12 is a lateral view of a non-operative zone ambient negative pressure applying flexible apparatus in position about an abdominal procedure.
FIG. 13 is a lateral view of the apparatus system including the non-operative zone ambient negative pressure applying flexible apparatus and operative zone ambient positive pressure applying apparatus in position about a craniotomy.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 through 6, the underlying methods of the present invention are described, and in FIGS. 7 through 13, the apparatus by which the methods are conducted are described.
In FIG. 1, the anatomy pertinent to a craniotomy is shown and is used to illustrate the limitations of the current techniques. The operative zone ambient environment 1 typically consists of air at atmospheric pressure. The scalp 2 is the outer covering of the head. The calvarum 4 is deep to the scalp and forms the protective rigid covering of the brain. The dura 3 is the next layer deep to the calvarum 4. The arachnoid 6 is the next deep layer, enclosing the subarachnoid space 74. Deep to the arachnoid 6 is the normally unexposed cortical surface 8. The cortical surface is intimately lined by the pia layer which is not depicted here. The operatively exposed cortical surface 7 is deep to the region of the craniotomy 5 in which the calvarum 4 has been removed to permit entry to the underlying structures. The internal portion of the brain or brain parenchyma 9 lies deep to the cortical surface 8 and surrounds the fluid filled ventricles 10. The cerebrospinal fluid 75 is produced within the ventricles 10 and flows to the subarachnoid space 74.
All the structures deep to the calvarum 4 are normally maintained at the intracranial pressure (ICP), which is typically 14 mmHg above the ambient pressure. The calvarum 4 and dura 3 normally provide the mechanical tension to contain the neural tissue against the said pressure gradient. When the cortical surface 7 is exposed during a neurosurgical procedure or trauma, the pressure gradient is borne by the exposed cortical surface 7 and a portion of the underlying brain parenchyma 9. As described in previous sections, this hydrostatic pressure gradient drives fluid shifts from the intravascular space and the deeper extracellular space in the deeper regions of the brain parenchyma 9 to the extracellular space in the exposed cortical surface 7 and other exposed portions of the nervous tissue.
These fluid shifts commonly encountered in neurosurgical procedures result in tissue swelling or edema, and reduction or elimination of this edema is one of the objects of the present invention. The said edema is driven by the pressure gradient between the intracranial pressure and that of the operative zone ambient environment 1. A method of reduction of the said edema according to the present invention is the reduction of the said pressure gradient. This method may be accomplished by at least one of increasing the pressure in the operative zone ambient environment 1, decreasing the intracranial pressure, or a combination.
FIG. 2 is a horizontal cross section of the surface of the spinal cord. The operative zone ambient environment 1 is in contact with the exposed tissues, including most superficially the skin 13, the subcutaneous tissues 14. The bony structure comprised by the vertebral lamina 11 protect the underlying dura 3, arachnoid 6, and spinal cord 76. The vertebral lamina 11 are removed in the region of the laminectomy 12. As is the case in the craniotomy 5 shown in FIG. 1, when the spinal cord surface 77 is exposed to the operative zone ambient environment 1, the normally present pressure gradient can drive fluid from the spinal cord parenchyma 76 to the spinal cord surface 77, causing edema. Additionally, cyclic variation in the pressure of the CSF 75 which bathes the spinal cord surface 77 can cause movement of the spinal cord parenchyma 76 and said spinal cord surface 77 relative to the vertebral lamina 11, making fine surgical manipulation and visualization under a surgical microscope difficult, as described previously.
FIG. 3 is a cross section of an incision onto the skin 13 overlying any portion of the body. The subcutaneous tissue 14 lies deep to the skin 13 and comprises muscle, adipose, or other tissue types. The subcutaneous tissue exposed surface 15 is in contact with the operative zone ambient environment 1. Muscles and other subcutaneous tissue components are maintained at a compartmental pressure in excess of that of the ambient environment. The pressure gradient between the compartmental pressure and that of the overlying operative zone ambient environment 1 are borne by the portions of the subcutaneous tissue 14 deep to and including the subcutaneous tissue exposed surface 15. This pressure gradient can cause fluid shifts from the intravascular space and the deeper portions of the extracellular space to the extracellular space in the region of the subcutaneous tissue exposed tissue 15, resulting in edema.
The pressure differences between the arterial and venous pressures and that of the operative zone ambient environment 1 may be termed the operative zone transarterial pressure gradient and operative zone transvenous pressure gradient, respectively; and these said gradients may be collectively referred to as operative zone transvascular pressure gradients. If the continuity of the vascular walls is compromised, the transvascular pressure gradients will drive blood flow through the damaged vascular walls, resulting in hemorrhage.
FIG. 4 is a cross section of a limb during an amputation procedure. The operative zone ambient environment 1 is in contact with the skin 13 and the other exposed structures, including muscle 16, and the muscle flap 17 overlying the terminal portion of the limb including the bone 18 and bone marrow 19 contained therein. Transection of large and small blood vessels and exposure of the bone marrow 19 to the operative zone ambient environment 1, which is normally at a pressure much lower than the arterial or venous pressures, can result in significant hemorrhage. By controlling the transvascular pressure gradients, by at least one of increasing the pressure of the operative zone ambient environment 1 and decreasing that of the intravascular space, it is an object of the present invention to reduce and prevent said hemorrhage.
FIG. 5 is a sagittal cross section of a body with an abdominal incision 20. The abdominal incision 20 could represent a general surgical abdominal incision or a traumatic wound and is shown to extend through the skin 13 and into the abdominal cavity 27. The walls of the abdominal vessels, including the abdominal aorta 23 and its branches, including the celiac trunk 24, the superior mesenteric artery 25, and the inferior mesenteric artery 26 provide tension to contain the blood against the pressure gradient from the intravascular space to the pressure of the operative zone ambient environment 1, the aforesaid operative zone transarterial pressure gradient. Compromise of the integrity of these or other blood vessels can result in hemorrhage. By controlling the said operative zone transvascular pressure gradients, by at least one of increasing the pressure of the operative zone ambient environment 1 and decreasing that of the intravascular space, it is an object of the present invention to reduce and prevent said hemorrhage. Reduction of the intravascular pressures may be accomplished by applying a reduced pressure to the proximal non-operative ambient environment 79, and this said reduced pressure is transmitted to the structures within the proximal non-operative body segment 84, including the descending thoracic aorta 22. The reduction in pressure of the blood within the descending thoracic aorta 22 is transmitted to the blood within the abdominal aorta 23. This will reduce the operative zone transarterial pressure gradients, facilitating decrease and elimination of arterial hemorrhage. Similarly, a reduction in the operative zone transvenous pressure gradient will result in alleviation or elimination of venous hemorrhage. This effect may be achieved intraoperatively and postoperatively. Additionally this effect may be achieved in preoperative or non-operative conditions, including but not limited to aortic rupture arising from aneurysms or dissections as well as trauma.
To maintain proper circulation and prevent vascular collapse in the portion of the distal body segment 80 which is distal to that exposed to the operative zone ambient environment 1, a negative pressure is applied to the distal non-operative ambient environment 78. This allows the maintenance of a perfusion pressure in the distal body segment 80 including that portion distal to the abdominal cavity caudal border 36. The negative pressure in the distal non-operative ambient environment 78 may be maintained at the same or a different negative pressure as compared to the proximal non-operative ambient environment 79. For example, the negative pressure in the distal non-operative ambient environment 78 may be maintained at a pressure more positive than either of the proximal non-operative ambient environment 79 or the operative zone ambient environment 1 to supplement venous return from the distal non-operative body segment 80. Further, the pressures of the proximal 79 and distal 78 non-operative environments may be cycled synchronously or independently. Additionally, the pressures of the proximal 79 and distal 78 non-operative environments may be maintained near that of the operative zone ambient environment 1 and brought to more negative pressures only as needed for intraoperative, perioperative, or other control of hemorrhage.
The same method of reducing hemorrhage may be achieved by applying a positive pressure to the operative zone ambient environment 1 to oppose hemorrhage driven by the operative zone transvascular pressure gradients present across the walls of the abdominal blood vessels, including those of the abdominal aorta 23 and its branches. Constant, cyclical, or intermittent pressure may be applied to the distal non-operative ambient environment 78 to supplement venous return from the distal body segment 80.
FIG. 6 is a sagittal cross section of a body with a thoracic wall incision, known as a thoracotomy 28. The thoracotomy 28 could represent a cardiothoracic or other surgical thoracic incision or a traumatic wound and is shown to extend through the skin 13 and may extent through the thoracic wall 34 into the thoracic cavity 33. The thoracic cavity 33 contains the lungs 32, heart 30, pericardium 31, ascending thoracic aorta 29, descending thoracic aorta 22, and other structures. The inferior border of the abdominal cavity 36, abdominal cavity 27, abdominal aorta 23, diaphragm 35, and vertebral column 21 are also shown. During thoracic and particularly cardiothoracic surgical procedures, significant hemorrhage may occur. The flow of blood during said hemorrhage is driven by the operative zone transvascular pressure gradients, the most pronounced including those across the walls of the heart 30, ascending aorta 29, and descending aorta 22.
By applying a negative pressure to the proximal non-operative body segment 79 and distal nonoperative body segment 80, the pressure developed by the heart 30 in the intrathoracic arterial structures including the ascending aorta 29 and descending aorta 22 and their many branches is reduced; consequently hemorrhage resulting from damage to any of these structures is lessened. By applying an equivalent positive pressure to the operative zone ambient environment 1, the same operative zone transvascular pressure gradients will be lessened; and the same reduction in hemorrhage is achieved.
FIG. 7 depicts an apparatus for executing the method of performing a craniotomy with reduced cerebral edema, hemorrhage, and movement as illustrated in FIG. 1 by the application of positive pressure to the operative zone ambient environment 1 contained within the pressurized chamber 83. The positive pressure in the operative zone ambient environment 1 may be selected to reduce, eliminate, or reverse the intracranial pressure gradient otherwise born by the exposed cortical surface 7 and the underlying brain parenchyma 9. Although the craniotomy 5 is depicted over the cerebral cortex, the present invention applies to any portion of the central nervous system, including the cerebrum, cerebellum, and brainstem.
A flexible membrane 39 encloses the operative zone ambient environment 1. The flexible membrane 39 could be replaced with a rigid or semirigid structure without departing from the spirit of the present invention. The flexible membrane 39 is attached to the scalp 2 by a flange 37 surrounding the region of the craniotomy 5. The flange 37 may be secured to the scalp 2 by at least one of an adhesive, mechanical force, a combination, or other means. A flange restrainer 38 prevents peeling of the flange 37 away from the scalp 2, particularly in the region where the flange 37 joins the flexible membrane 39. The positive pressure of the operative zone ambient environment 1 within the flexible membrane 39 is maintained by a positive fluid pressure applied to the inflow port 45. An outflow port 46 may be included to permit circulation of fluid within the operative zone ambient environment 1, facilitating control of the state of the fluid, including temperature, humidity, composition, and other variables in addition to pressure.
Glove ports 40 are provided to allow access to the operative zone by the surgeon and other operating room or trauma personnel. The said glove ports 40 may have gloves and sleeves permanently or temporarily attached. Alternatively, the glove ports 40 may include seal means to facilitate insertion of gloved hands. A passage portal 43 is provided to allow insertion and retrieval of instruments, tissues, and other objects between the non-operative zone ambient environment 66 and the operative zone ambient environment 1. A passage portal closure means 44 is attached to the said passage portal 43 and allows for the maintenance of a fluid tight seal surrounding the operative zone ambient environment 1. The flexible membrane 39 may be constructed from a transparent material. A window 42 is constructed from a rigid or flexible transparent material to augment visualization of the operative zone. A multiplicity of windows 42 may be included without departing from the spirit of the present invention. A microscope port 41 is connected to the flexible membrane 39 to facilitate unimpeded visualization of the operative zone via a surgical microscope 65. Also shown are the dura 3, calvarum 4, arachnoid 6, unexposed cortical surface 8, brain parenchyma 9, and the cerebrospinal fluid 75 which occupies the ventricles 10 and subarachnoid space 74 among other structures.
FIG. 8 depicts an apparatus for executing the method of performing a craniotomy with reduced cerebral edema, hemorrhage, and movement as illustrated in FIG. 1 by the application of negative pressure to the non-operative zone ambient environment 66 which is contained within the partially evacuated chamber 60. Application of a negative pressure to the non-operative zone ambient environment 66 effects an absolute decrease in the hydrostatic pressures of all contained bodily regions in communication with the skin exposed to the said non-operative ambient environment 66. By this method, the depicted apparatus allows precise control of the intracranial pressure; the intracranial pressure may be reduced to approach, equal, or fall below the pressure of the operative zone ambient environment 1. Although the craniotomy 5 is depicted over the cerebral cortex, the present invention applies to any portion of the central nervous system, including the cerebrun, cerebellum, and brainstem.
A flexible membrane 47 forms the top and lateral sides of the partially evacuated chamber 60 which contains the non-operative zone ambient environment 66. The flexible membrane 47 is supported against the pressure of the room ambient environment 82 by at least one of a cephalic membrane support 51, caudal membrane support 52, and intermediate membrane supports 48. A membrane to craniotomy operative zone seal means 49 maintains a fluid tight seal between the flexible membrane 47 and the scalp 2 surrounding the region of the craniotomy 5. The partially evacuated chamber caudal side 61 may be a continuation of the flexible membrane 47 and may be constructed from a rigid or semirigid material without departing from the spirit of the present invention.
One or a multiplicity of low pressure gas outflow ports 53 facilitates partial evacuation of gas from the partially evacuated chamber 60. One or a multiplicity of low pressure gas inflow ports 54 may be included to allow circulation of gas in the said partially evacuated chamber 60, facilitating control of the temperature, humidity, composition, and other properties in addition to pressure. One or a multiplicity of injection fluid inflow ports 55 may be included to provide access for intravenous, intramuscular, subdural, epidural, or other fluid lines. One or a multiplicity of bodily fluid outflow ports 56 may be included to provide access for urine, blood sampling, and other lines. The said low pressure gas outflow port 53 and low pressure gas inflow port 54 are shown attached to the partially evacuated chamber caudal side 61; this location is exemplary and could be interchanged with any side of the said partially evacuated chamber 60, including any portion of the flexible membrane 47 or the partially evacuated chamber bottom side 50. Similarly, the locations of the injection fluid inflow ports 55 and bodily fluid outflow ports 56 may be altered without departing form the spirit of the present invention.
The flexible membrane 47 may be supplied as a discrete sheet or continuous roll withdrawn from a membrane dispenser means 59 shown mounted to the partially evacuated chamber bottom side 50. A membrane to chamber bottom seal means 58 provides a fluid tight seal between the flexible membrane 47 and the partially evacuated chamber bottom side 50 and is shown attached to the lateral aspect 57 of the partially evacuated chamber bottom side 50. The said membrane to chamber bottom seal means 58 may equivalently be attached to any aspect of the said partially evacuated chamber bottom side 50, and the said partially evacuated chamber bottom side 50 may include, be attached to, or be separate from the operating room table without departing from the spirit of the present invention.
FIG. 9 depicts an apparatus for executing the method of performing a spinal procedure with reduced spinal cord edema, hemorrhage, and movement as illustrated in FIG. 2 by the application of positive pressure to the operative zone ambient environment 1 contained within the pressurized chamber 83. The positive pressure in the operative zone ambient environment 1 may be selected to reduce, eliminate, or reverse the pressure gradient, substantially identical to the intracranial pressure, otherwise born by the spinal cord surface 77 and the underlying spinal cord parenchyma 76.
The back incision 63 and the underlying laninectomy 12 (see FIG. 2) are in contact with the operative zone ambient environment 1 which is contained within the pressurized chamber 83 and maintained at a pressure greater than that of the non-operative zone ambient environment 66. The flange 37 is affixed to the back skin 62 by at least one of an adhesive, mechanical pressure, clamps, or other means. The flange restrainer 38 prevents peeling of the flange 37 away from the back skin 62 which might otherwise occur at the junction of the flange 37 and the flexible membrane 39. The flange 37 is depicted as flexible and the flange restrainer 38 as rigid; however, this is exemplary, and the said flange 37 and flange restrainer 38 may be combined into a single flexible or rigid flange means without departing from the spirit of the present invention.
The remaining components of the said pressurized chamber 83 of FIG. 9 are substantially equivalent to those described in detail in the description of FIG. 7. The patient is shown lying prone atop the operating table 67; blankets, pads, and other operating room accessories are omitted for clarity.
FIG. 10 depicts an apparatus for executing the method of performing a spinal procedure with reduced spinal cord edema, hemorrhage, and movement as illustrated in FIG. 2 by the application of negative pressure to the non-operative zone ambient environment 66 contained within the partially evacuated chamber 60.
Application of a negative pressure to the non-operative zone ambient environment 66 effects an absolute decrease in the hydrostatic pressures of all contained bodily regions which are in communication with the skin exposed to the said non-operative zone ambient environment 66. By this method, the depicted apparatus allows precise control of the intracranial pressure, which is substantially equivalent to that of the spinal cord parenchyma 76 and the cerebrospinal fluid 75. The intracranial pressure may be reduced to approach, equal, or fall below the pressure of the operative zone ambient environment 1. The pressure gradients driving edema formation, hemorrhage, and spinal cord tissue movement may thus be eliminated. Modulation of the negative pressure within the partially evacuated chamber 60 in relation to the respiratory or ventilatory cycle reduces and prevents the movement of the nervous tissue which is otherwise observed to occur in synchrony with the respiratory cycle.
The membrane to back operative zone seal means 64 provides a fluid tight seal between the flexible membrane 47 and the back skin 62 surrounding the back incision 63. The remaining components of the said partially evacuated chamber 60 of FIG. 10 are substantially equivalent to those described in detail in the description of FIG. 8. The patient is shown lying prone atop the partially evacuated chamber bottom side 50, which may be attached to or identical to the operating table 67. Alternatively, the patient could be lying on the operating table 67 which may be attached to or separate from the partially evacuated chamber bottom side 50; blankets, pads, and other operating room accessories are omitted for clarity.
FIG. 11 depicts an apparatus for executing the method of performing a surgical procedure involving a thoracotomy with reduced hemorrhage as illustrated in FIG. 6 by the application of negative pressure to the non-operative zone ambient environment 66 contained within the partially evacuated chamber 60.
Application of a negative pressure to the non-operative zone ambient environment 66 effects an absolute decrease in the hydrostatic pressures of all contained bodily regions which are in communication with the skin exposed to the said non-operative zone ambient environment 66. By this method, the depicted apparatus allows precise control of the pressure of the venous blood returning to the heart 30 (see FIG. 6) and some control of the back pressure applied to the pumping heart 30 (see FIG. 6) via the arterial blood contained in the ascending aorta 29 (see FIG. 6). The operative zone transvascular pressure gradients driving arterial and venous hemorrhage may thus be reduced or eliminated.
The membrane to thoracotomy operative zone seal means 70 provides a fluid tight seal between the flexible membrane 47 and the thorax skin 68 surrounding the thoracotomy 69. The remaining components of the said partially evacuated chamber 60 of FIG. 10 are substantially equivalent to those described in detail in the description of FIG. 8. The patient is shown lying supine atop the partially evacuated chamber bottom side 50, which may be attached to or identical to the operating table 67. Alternatively, the patient could be lying on the operating table 67 which may be attached to or separate from the partially evacuated chamber bottom side 50; blankets, pads, and other operating room accessories are omitted for clarity.
FIG. 12 depicts an apparatus for executing the method of performing a surgical procedure involving an abdominal incision with reduced hemorrhage as illustrated in FIG. 5 by the application of negative pressure to the non-operative zone ambient environment 66 contained within the partially evacuated chamber 60.
Application of a negative pressure to the non-operative zone ambient environment 66 effects an absolute decrease in the hydrostatic pressures of all contained bodily regions which are in communication with the skin exposed to the said non-operative zone ambient environment 66. By this method, the depicted apparatus allows precise control of the absolute pressure of the arterial blood within the descending thoracic aorta 22 (see FIG. 5) in the proximal non-operative body segment 84 which is contained within the non-operative ambient environment 66. The arterial blood within the descending thoracic aorta 22 (see FIG. 5) passes through the diaphragm 35 (see FIG. 5) into the abdominal aorta 23 (see FIG. 5) within the abdominal cavity 27 (see FIG. 5). The pressure of the blood within the abdominal aorta 23 (see FIG. 5) may be controlled by manipulating the partial vacuum applied to the proximal non-operative body segment 84 to regulate the pressure of the blood within the descending thoracic aorta 23 (see FIG. 5).
Hemorrhage is driven by the operative zone transvascular pressure gradients, such as that between the abdominal aorta 23 (see FIG. 5) and the operative zone ambient environment 1. By regulating the pressure of the blood within these vessels, according to the present invention, hemorrhage may be controlled or eliminated.
The membrane to abdomen operative zone seal means 73 provides a fluid tight seal between the flexible membrane 47 and the abdominal skin 71 surrounding the abdominal incision 72. The remaining components of the said partially evacuated chamber 60 of FIG. 10 are substantially equivalent to those described in detail in the description of FIG. 8. The patient is shown lying supine atop the partially evacuated chamber bottom side 50, which may be attached to or identical to the operating table 67. Alternatively, the patient could be lying on the operating table 67 which may be attached to or separate from the partially evacuated chamber bottom side 50; blankets, pads, and other operating room accessories are omitted for clarity.
FIG. 13 depicts a system according to the present invention for executing the method of manipulating tissue pressure gradients for use in controlling at least one of fluid flow and tissue movement intraoperatively, postoperatively, preoperatively, or post-traumatically. The system controls the pressure gradient between a subject and an environment. The figure provides an example the application of this invention to a neurosurgical procedure involving a craniotomy 5; in this application, the device controls the transdural pressure gradient between the intracranial pressure present in the brain parenchyma 9 (see FIG. 1) and the operative zone ambient environment 1. The said pressure gradient is manipulated by the difference between the pressure of the operative zone ambient environment 1 contained within the pressurized chamber 83 and the pressure of the non-operative zone ambient environment 66 contained within the partially evacuated chamber 60. An obvious simplification of this system is the omission of one of the said chambers. In this case, the said pressure gradient is manipulated by the difference between the pressure of the single chamber and the pressure of the room ambient environment 82. Other variations of the present invention include the use of rigid or semirigid materials in the construction of either of the said hermetic chambers. Further, the said hermetic chambers could be constructed as portable devices, fixed stations, as regions within the operating room separated by at least one partition, as separate rooms, or other variation of the present invention.
Pressure sources 85 and 86 separately provide fluid at a pressure, said pressure may be but is not restricted to be set according to: a predetermined value, a predetermined time-varying profile, a timevarying profile determined in real-time, a manually determined value or profile, a dynamic profile determined as a function of variables including but not limited to vital functions and pressure gradients.
In the application depicted, pressure source 85 applies a partial vacuum or hypobaric pressure, and pressure source 86 applies a hyperbaric pressure. Pressure source 85 is connected via fluid outlet hose 91 to low pressure gas outflow port 53. Outflow fluid sensor 87 is connected via fluid sensor hose 93 to fluid outlet hose 91 and senses pressure and other fluid characterization values of the fluid emanating from the partially evacuated chamber 60. Inflow fluid sensor 89 is connected via fluid inlet hose 95 to low pressure gas inflow port 54. Inflow fluid sensor 89 can be employed to sense characteristics if inflowing fluid; alternatively, if inflow is blocked, said inflow fluid sensor 89 can be employed to sense the pressure within partially evacuated chamber 60. Pressure source 86 is connected via fluid inlet hose 92 to fluid inflow port 45. Inflow fluid sensor 88 is connected via fluid sensor hose 94 to fluid inlet hose 92 and senses pressure and other fluid characterization values of the fluid flowing into the pressurized chamber 83. Outflow fluid sensor 90 is connected via fluid outlet hose 96 to fluid outflow port 46. Outflow fluid sensor 90 can be employed to sense characteristics if outflowing fluid; alternatively, if outflow is blocked, said outflow fluid sensor 90 can be employed to sense the pressure within pressurized chamber 83.
The pressure gradient between the exposed cortical surface 7 (see FIG. 1) of the operative subject 81 and the operative zone ambient atmosphere 1 is controlled by controller 103. The controller 103 is connected to at least one of pressure source 85 via data link 97, pressure source 86 via data link 98, outflow fluid sensor 87 via data link 99, inflow fluid sensor 88 via data link 100, inflow fluid sensor 89 via data link 101, and outflow fluid sensor 90 via data link 102. The said controller 103 may include a means to estimate the operative tissue-ambient pressure gradient, for example the transdural pressure gradient as illustrated in FIG. 13. The controller 103 may maintain the operative tissue-ambient pressure gradient according to any constant or time-varying profile, including but not restricted to a preset value or series thereof, a single or series of values determined intraoperatively, a manually set value or series thereof, a single or series of values which are a function of a combination of at least one of measured or estimated values, a single or series of values determined according to bodily parameters or functions, and a series of values determined according to a control law.
Furthermore, as applied to all methods and apparatus discussed heretofore, including the partially evacuated chambers 60 and the pressurized chambers 83, intermittent variation in the pressures within the respective said chambers will facilitate intermittent hemorrhage. This may be desired to enable the surgeon to identify and correct potential intraoperative or postoperative sources of hemorrhage.
It is understood that modifications to the invention as described may be made, as might occur to one with skill in the field of the invention, within the intended scope of the claims. Therefore, all embodiments contemplated have not been shown in complete detail. Other embodiments may be developed without departing from the spirit of the invention or from the scope of the claims. | An intraoperative and perioperative method and several representative apparatus designs therefor for the reduction of fluid and tissue movement, where said fluid includes but is not limited to plasma, extracellular fluid, intracellular fluid, cerebrospinal fluid, and blood; and said tissue includes but is not limited to central nervous system tissue. An application of particular import in neurosurgical procedures is the intraoperative control of cerebral and spinal cord edema and the reduction of respiration-induced tissue movement. The method of the present invention, as applied to neurosurgical edema reduction, involves control of the pressure gradient between the central nervous system (CNS) and the ambient pressure. The physiologic pressure gradient between the CNS and the ambient pressure is termed the intracranial pressure (ICP) and is normally maintained at approximately 14 mmHg. The ICP may be decreased, normal, or increased as a result of any of various pathologic conditions which may indicate neurosurgical intervention. A significant complication of neurosurgical procedures is edema of the exposed nervous tissue. Control, including reduction and/or reversal, of the CNS-ambient pressure gradient eliminates the hydrostatic contribution to the generation of cerebral edema. By appropriate modulation of the applied pressure gradient, the dynamic component of the intracranial-ambient pressure gradient associated with respiration is canceled, reducing or eliminating intraoperative tissue movement. This is of particular utility in microneurosurgical procedures and in neurosurgical procedures involving placement of electrodes. The apparatus facilitates the control of the pressure gradient between the CNS and the ambient pressure and may be implemented as any of numerous possible equivalent designs, two representative embodiments including (1) a hypobaric chamber applied to a section of the unopened portion of the calvarum and extending to include the entire caudal portion of the body and (2) a hyperbaric chamber affixed to the head to apply pressure to the exposed cerebral surface. The method and apparatus of the present invention are additionally efficacious in the control of edema in other surgical procedures. Furthermore, the method and apparatus of the present invention are effective in the control of hemorrhage. | 0 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to simple transmissions utilizing compound countershafts and, in particular, relates to simple transmissions of the type utilizing a multiplicity of substantially identical compound countershafts and a rotatable mainshaft which is arranged substantially parallel to the countershafts with means provided for pivotally supporting the output end of the mainshaft and means provided for guiding the input end of the mainshaft in free floating relation relative to the axis of the countershafts and wherein the mainshaft gear closest the pivot point of the mainshaft is radially and axially fixed relative to the mainshaft while all or substantially all of the remaining mainshaft gears are located generally concentric of the mainshaft and in constant meshing engagement with and supported solely by the countershaft gears and wherein the countershafts are each comprised of portions which are in constant meshing engagement through an idler gear assembly which is concentric with but freely floating relative to the mainshaft.
Simple transmissions, that is, transmissions utilizing a one piece mainshaft, are well known in the prior art. Transmissions utilizing either simple or compound mainshafts in connection with multiple countershafts wherein either the mainshaft gears or the countershaft gears are mounted in a radially floating manner relative to the other gears are well known in the prior art. Examples of such transmissions may be seen by reference to U.S. Pat. Nos. 3,105,395; 3,255,644; 3,283,613; 3,335,616; 3,349,635; 3,378,214; 3,500,695; and 3,648,546.
The prior art transmissions, particularly those transmissions utilizing a floating mainshaft and/or floating mainshaft gears in connection with multiple countershafts, have proven to be highly acceptable. However, to achieve a sufficiently large range of available gear ratios, it has generally been necessary to utilize a compound transmission. Such transmissions generally comprise a main transmission and an auxiliary transmission of either the "range" type or the "splitter" type or a combination thereof as is well known in the prior art. Such transmissions are highly effective and commercially successful, especially for use in heavy duty vehicles wherein a large range of ratios is required and a large number of individual gear ratios is required. Such heavy duty compound transmissions typically have 9, 10, 12, 13 or more forward gear ratios.
There has, however, developed a need for transmissions having a greater range of ratios and a greater number of ratios than is normally available in a simple transmission as the centerline distances required in prior art simple transmissions to provide same would become too great while not justifying the somewhat expensive structure and controls required for a compound transmission. The prior art devices have been unable to satisfactorily fill this need.
Simple transmissions utilizing multiple compound countershafts have been proposed wherein all mainshaft gearing was floating relative to the mainshaft and wherein the idler gear assembly was substantially rigidly mounted to the mainshaft to prevent the countershaft portions most distant the input gear from counter rotating at rest conditions which would tend to cause the mainshaft gears to sag or bottom out on the mainshaft which in turn would result in misalignment of the clutches and subsequent shifting difficulties. This was not a totally satisfactory design as the idler assembly defined a substantially rigid coupling between the front and rear portions of the countershafts and tended to transmit timing or indexing errors from the front countershaft portions to the rear countershaft portions.
SUMMARY OF THE INVENTION
In accordance with the present invention, a simple transmission which minimizes center distances, i.e., the distance between the mainshaft and the countershaft axis, minimizes the axial length of the countershaft portions and/or provides a greater range and/or number of available gear ratios than has heretofor been available is provided. The transmission preferably utilizes a mainshaft which is pivotably guided at the output end and floatingly guided at the input end in connection with substantially identical multiple countershafts, each of said countershafts being compounded to provide an extended range of ratios with a minimal center distance and a minimum axial length of countershaft portion. The countershafts are compounded by the use of a countershaft idler assembly concentric with the axis of the mainshaft and radially movable relative thereto. The mainshaft gear closest the pivot point of the mainshaft is axially and radially fixed relative to the mainshaft, as by a bearing or the like, while all or substantially all of the remaining mainshaft gears are concentric with but radially movable relative to the mainshaft.
Accordingly, it is an object of the present invention to provide an improved simple transmission having an extended range and number of available gear ratios with a minimal centerline distance and/or axial length of countershaft portions.
Another object of the present invention is to provide a simple transmission utilizing at least two substantially identical compound countershafts.
A further object of the present invention is to provide an improved floating mainshaft, multiple countershaft transmission wherein each of the countershafts is compounded to provide an extended range and/or number of available gear ratios within a predetermined centerline and wherein the transfer of timing errors from the front countershaft portions to the rear countershaft portions is reduced or eliminated.
These and other objects and advantages of the present invention will become apparent from a reading of the detailed description of the preferred embodiment taken in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the preferred embodiment of the present invention.
FIG. 2 is a sectional view of the transmission schematically illustrated in FIG. 1.
FIG. 3 is a schematic illustration of the shift pattern for the transmission of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In this disclosure, certain terminology will be used for convenience in reference only and will not be limiting. For example, the terms "forward" and "rearward" will refer to directions forward and rearward of the vehicle in which the transmission is installed. The terms "rightward" and "leftward" will refer to directions as taken in the drawings in connection with which the terminology is used. The terms "inward" and "outward" will refer to directions toward and away from, respectively, the geometric center of the apparatus. All foregoing terms mentioned include the normal derivatives and equivalents of each thereof.
For convenience of identification, the shaft 12 has throughout been called the input shaft, and the shaft 18 has been called the main shaft and output. This terminology has, however, been used for convenience in reference and is to be given no limiting significance inasmuch as the apparatus will operate with the direction of power flow reversed.
A schematic illustration of the preferred embodiment of the transmission of the present invention may be seen by reference to FIG. 1. The transmission 10 schematically illustrated is of the twin countershaft type, it being understood, however, that multiple countershaft transmissions utilizing any number of substantially identical countershafts may utilize the features of the present invention. The transmission 10 comprises an input shaft 12 designed to be driven by the prime mover of the vehicle and carrying a drive gear 14 thereon. A pair of compound countershafts 16 and 16A and a "floating" mainshaft 18 are provided. It is understood that the term "floating" includes shafts having one end pivotally mounted and the other end floatingly guided as well as shafts wherein both ends are floatingly guided. The axes of the mainshaft 18 and the compound countershafts, 16 and 16A, are substantially parallel. The axis of input shaft 12 is substantially concentric with the axis of mainshaft 18. The compound countershafts, 16 and 16A, are substantially identical. Each of the compound countershafts, 16 and 16A, comprises a forward portion 20 and 20A and a rearward portion 22 and 22A, respectively. Forward countershaft portions, 20 and 20A, are separately rotatable and may be substantially coaxial with the rearward countershaft portions 22 and 22A respectively. The forward portions 20 and 20A of the compound countershafts, 16 and 16A, carry gears 24, 26, 28, 30, 32 and 24A, 26A, 28A, 30A, and 32A, respectively. The rearward portions 22 and 22A of the compound countershafts 16 and 16A, carry gears 34, 36, 38, 40 and 34A, 36A, 38A, 40A, respectively.
Gears 42, 44, 46, 48, 49, 50, 52 and 54 encircle the mainshaft 18 and are constantly engaged with and supported by the countershaft gears 26, 26A, 28, 28A, 30, 30A, 32, 32A, 34, 34A, 36, 36A, 38, 38A, 40, 40A, respectively, as is well known in the art. Gear 54 is radially fixed to the mainshaft 18 by means of an antifriction bearing 72. Axially slidable clutches 56, 58, 60 and 62 are splined to the mainshaft for rotation therewith in a known manner. Clutch 56 may be selectively engaged to rotationally fix either the input shaft 12 or the gear 42 to the mainshaft. Clutch 58 may be selectively engaged to fix gear 44 or gear 46 to the mainshaft. Clutch 60 may be selectively engaged to fix gear 49 or gear 50 to the mainshaft. Clutch 62 may be utilized to fix gear 52 or gear 54 to the mainshaft.
The operation and structural features of the "floating" mainshaft, "floating" mainshaft gear, multiple countershaft type of transmission described above is well known in the prior art and a more detailed description thereof may be seen by reference to U.S. Pat. Nos. 3,105,395; 3,237,472, 3,335,616; and/or 3,500,695, all of which are assigned to the assignee of this invention and all of which are hereby incorporated by reference. In the preferred embodiment, mainshaft 18 is pivotally mounted at the rear or output end thereof and floatingly guided at the front or input end thereof, as may be appreciated in greater detail by reference to above-mentioned U.S. Pat. No. 3,500,695.
In operation, the input shaft 12 drives a gear 14 which is constantly engaged with gears 24 and 24A to drive the compound countershafts 16 and 16A and the countershaft gears mounted thereon. The countershaft gears are constantly engaged with the gears encircling the mainshaft and thus mainshaft gears 42, 44, 46, 49, 50, 52 and 54 and mainshaft idler gear 48 are constantly rotating whenever the input shaft is rotating. The operator of the vehicle may, for example, simply move sliding clutch 62 to the right to rotationally couple gear 54 to the mainshaft to achieve a reverse rotation. Similarly, sliding clutch 62 may be moved to the left to couple gear 52 to the mainshaft 18 for operation in the fast forward speed. Similarly, sliding clutch 60 may be utilized to engage gear 50 with the mainshaft for second speed or gear 49 with the mainshaft for third speed. In a similar manner clutch 58 may be utilized to engage gear 46 with the mainshaft for fourth speed or gear 44 with the mainshaft for fifth speed. Clutch 56 may be utilized to engage gear 42 with the mainshaft for sixth speed or to engage the input shaft 12 directly with the mainshaft 18 for seventh speed operation.
Reference to FIG. 3 will illustrate the shift pattern followed by the operator.
Countershaft gears 32 and 32A meshingly engage and drive mainshaft idler gear 48 as may be seen. The mainshaft gear 49 also surrounds mainshaft 18 and is splined or coupled to idler gear 48 for rotation therewith. The gear 49 drivingly engages countershaft gears 34 and 34A which are rotationally fixed to rearward countershaft portions 22 and 22A, respectively, to drive the rearward portions 22 and 22A of the countershafts. Mainshaft idler gear 48 has an axis of rotation generally concentric with the axis of rotation of the mainshaft 18. Idler gear 48 is coupled to mainshaft gear 49 by means of a coupling 70 which surrounds mainshaft 18 and is free to move radially relative thereto. Coupling 70 may be mounted to gears 48 and 49 by a splined connection or the like. Preferably, the spline connection is crowned and/or of greater than normal backlash allowing gears 48 and 49 to rotate on different axes of rotation.
FIG. 2 illustrates the structural embodiment of the transmission 10 schematically illustrated in FIG. 1. Elements of the transmission structure illustrated in FIG. 2 corresponding to those elements schematically illustrated in FIG. 1 will be assigned like numerals.
The multicountershaft transmission 10 includes a horizontally split housing H, only a portion of which is shown. The housing H has a forward end wall 102 and a rearward end wall 103. Each of said endwalls is provided with openings for receipt of the various shaft bearings. The input shaft 12 is supported by bearing 104 and carries an enlarged splined head 106 on the rearward end thereof. The head 106 carries splines 107 which support the annular drive gear 14. The drive gear 14 has external teeth 108 and internal clutch teeth 110. The input shaft 12 is also provided with a recess 150 having a rearwardly facing opening in which the front or input end 152 of the mainshaft 18 is loosely received allowing the mainshaft to float freely relative to the input shaft.
The transmission 10 includes two substantially identical or twin compound countershafts 16 and 16A, only one of which, 16, is illustrated in FIG. 2. Countershaft 16 comprises a forward portion 20 and a rearward portion 22. Forward portion 20 of compound countershaft 16 is supported by bearings 112 and 114. Rearward portion 22 of countershaft 20 is supported by bearings 116 and 118. The forward portion 20 of countershaft 16 carries thereon and fixed for rotation therewith countershaft gears 24, 26, 28, 30, and 32. The rearward portion 22 of countershaft 16 carries thereon and fixed for rotation therewith countershaft gears 34, 36, 38, and 40. Countershaft gear 24 is in constant mesh with the input or drive gear 14.
The mainshaft 18 comprises the output unit of transmission 10. The mainshaft is arranged substantially coaxially with the input shaft 12 and is mounted for a degree of radial movement or floating movement relative to the countershafts 16 and 16A. In the embodiment illustrated, the forward end 152 of the mainshaft 18 is loosely received in an annular recess 150 at the rearward end of input shaft 12. The rearward end 124 of mainshaft 18 is pivotally supported by a bearing 126. Further details as to the mounting of the mainshaft may be seen by reference to U.S. Pat. No. 3,500,695.
Mainshaft gears 42, 44, 46, 49, 50 and 52 and mainshaft idler gear 50 encircle the mainshaft 18 for constant engagement with and are supported solely by the countershaft gears as is well known in the prior art. Clutch units 56, 58, 60 and 62 are utilized to selectively clutch one of the mainshaft gears to the mainshaft. Mainshaft gear 54, the reverse drive gear, is radially fixed on the mainshaft by bearing 72.
By way of example, mainshaft clutch unit 56 is slidingly mounted on the forward end of the mainshaft 18 on splines 128 and carries clutch teeth 130 which are engageable with the clutch teeth 110 on the input drive gear 14 upon leftward movement of said clutch unit 56. Clutch unit 56 also carries clutch teeth 132 which are engageable with suitable internal clutch teeth 134 in the mainshaft gear 42 upon rightward movement of the clutch unit 56. The remainder of the mainshaft clutch units, 58, 50, and 62, operate in a similar manner and will not be described in further detail. Shift forks 136, 138, 140, and 142 are utilized to selectively move mainshaft clutch units 56, 58, 60 and 62, respectively, either to the right or to the left as is well known in the art.
Each of the gears 42, 44, 46, 49, 50, 52 and 54 may be collectively termed "mainshaft gears" since they are all capable of drivingly engaging the mainshaft. However, it is emphasized that gears 42, 44, 46, 50 and 52 are all supported on and by the countershaft gears and that they merely surround and at times engage the mainshaft but are not supported on or by the mainshaft. Rather, the mainshaft will move both rotatably and about the pivot axis with respect to those of the mainshaft gears with which it is not clutched at a particular moment. Mainshaft idler gear 48 is supported in a similar manner.
Synchronizers and/or blocking rings can, if desired, be provided between the interengageable teeth associated with the various clutch units and the internal clutch teeth associated with the various mainshaft gears.
Surrounding the mainshaft but not supported thereby is a coupling member 70. Coupling member 70 is rotationally coupled to mainshaft idler gear 48. It is noted that coupling member 70 is also affixed for rotation with mainshaft gear 49, and thus gear 49 is driven by countershaft gear 32 on the forward countershaft portion 20 of countershaft 16. Mainshaft gear 49 is in constant engagement with countershaft gear 34 on the rear countershaft portion 22 of countershaft 16 and thus a substantial gear reduction between the forward countershaft portion 20 and the rearward countershaft portion 22 of countershaft 16 is achieved without the necessity of increasing the center distance 150 which is the distance between the centerline of the countershaft 16 and the mainshaft 18. A spacer, 144, may be utilized between gears 48 and 49.
It is noted that countershaft gear 40 and mainshaft gear 54 are not in direct meshing engagement but rathr each mesh with a reverse idler (not shown) as is well known in the art. Although gears 40 and 54 mesh through an idler, they are considered to be constantly meshed as each is in constant meshing engagement with the idler.
Mainshaft gear 54, the reverse drive mainshaft gear, is mounted on the mainshaft 18 by means of an antifriction bearing, such as ball bearing 72, and thus is radially fixed thereto. As the mainshaft will pivot at its rearward end 124 generally about the bearing 126, mainshaft gear 54 is the mainshaft gear closest the pivot point of the mainshaft 18.
Applicant has found that by mounting the mainshaft gear closest the pivot point of the mainshaft radially fixed to the mainshaft, a floating coupling between the front and the rear portions of the compound countershafts may be utilized to isolate timing errors between the countershaft portions while preventing sagging of the mainshaft gears supported by the rear countershaft portion countershaft gears as a result of counter-rotation of the rear countershaft portions and still retaining most of the features of the floating mainshaft, floating mainshaft gear transmission. Counter rotation of the front countershaft portions, 20 and 20A, is, of course, prevented by the engagement of countershaft gears 24 and 24A with fixed input gear 14.
Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed. | An improved simple change gear transmission having an extended range and/or number of gear ratios and minimized center distance and/or axial countershaft portion length is provided. The improved transmission utilizes a single main shaft which is pivotally mounted at one end and guided for free floating movement at the other end and at least two substantially identical countershafts which are compounded. Each countershaft has a plurality of ratio gears mounted therein which are grouped with identical ratio gears on the other countershafts. A plurality of mainshaft gears are disposed generally concentric of the mainshaft, but radially movable relative thereto and are in constant meshing engagement with and supported by the countershaft gears. Preferably, the mainshaft is floatably retained at the end thereof closest the input of the transmission while the other end thereof is mounted in a pivotal manner. The improvement comprises mounting the mainshaft gear closest the pivot point of the mainshaft, preferably the reverse mainshaft gear, radially and axially fixed relative to the mainshaft for rotative motion relative thereto, as by an anti-friction means such as a bushing or a bearing, and utilizing an idler gear assembly which is concentric with but freely floating relative to the mainshaft. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of DE 10 2016 110 054.4 filed on May 31, 2016. The disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present disclosure concerns an illuminating device, and an interior part for a vehicle, which comprises an illuminating device of this type. The illuminating device provides an unobtrusive illumination of vehicles, particularly motor vehicles, aircraft, streetcars, railway cars, and ships, among others.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0004] In aircraft cabins, it is customary to install illuminating elements as separate units, which consist of lamps, decorative elements, and switches. The lamp typically backlights a transparent plate, onto which lettering or characters are attached, such that information is also visible in the dark.
[0005] A further option for communicating information is touchscreens that are only illuminated when needed, then displaying the required information.
[0006] Furthermore, it is known practice to arrange lights in aircraft such that indirect illumination is created. Surfaces are lit by a concealed light, which illuminates the interior of the aircraft.
[0007] DE 10 2014 003 527 A1 describes an aircraft illuminating device with a light distribution body made of flexible plastic, into which light from multiple LEDs is directed, and distributed over the surface. DE 10 2013 202 224 A1 specifies an interior part for an aircraft, which provides for a light guide behind a perforated decorative element, where a spacer is used to adjust the distance between the light guide and the decorative element. DE 197 24 486 A1 and FR 2 927 859 A1 specify interior parts, in which a rope-like (restiform) light guide is inserted into the surface of a decorative element using a textile loop. US 20150251594 A1 describes an illuminating device for an aircraft cover, which provides for multiple additional lighting elements behind a flat, transparent light source.
SUMMARY
[0008] There are frequently multiple operating and display elements for various functions at each aircraft seat, which additionally should be illuminated permanently or during certain phases of the flight or trip. As a result, there is more demand for improved illumination solutions, which provide for light sources that can be controlled independently in a common field-of-view, and which can be easily installed on a carrier.
[0009] According to the present disclosure, an illuminating device for an aircraft comprises a carrier module, a flat light guide attached to the carrier module with a plurality of emitting points, and multiple light sources for illuminating the light guide. The flat light guide is covered with a translucent haptic layer, which is attached to a visible side of the light guide. The translucent haptic layer in turn is covered by a decorative layer. As an additional illuminating element, the illuminating device comprises a rope-like (restiform) light guide, which has an inherent (separate) light source and is connected to the decorative layer via a retaining device. This results in a flat arrangement, which can be easily integrated into interior parts and simultaneously enables the illumination of large areas. In doing so, additional light effects can be integrated by means of the rope-like light guide. The illuminating device is not visible while switched off, as the illuminating device is covered by the decorative layer.
[0010] In this context, a rope-like light guide can be understood as a light guide that is long in length but short in width and height. Here, the rope-like light guide may for example have a round or square cross-section such that the rope-like light guide is in the shape of a bar or a rod, for example. The rope-like light guide may be formed from a highly transparent material such as polycarbonate, but may also function as a diffusing lens in which, for example, scattered particles or light-scattering additives are contained in the rope-like light guides.
[0011] An advantageous further form of the present disclosure states that the rope-like light guide is an optical fiber, which is inserted into a sheath. An optical fiber is typically less than 1 mm in diameter, making it difficult to mount. As a result, the optical fiber can be mounted on the retaining device through the proposed sheath. In this case, the sheath may be a flexible textile strip that clings around the optical fiber and closely to it. This results in the optical fiber being reliably attached to the decorative layer. It is advantageous if the optical fiber is attached to the visible side of the decorative layer in such a way that the light in the optical fiber is barely muted/interfered with, or not at all muted, by the decorative layer and/or the retaining device.
[0012] It is advantageous if the retaining device is formed by two seams of the decorative layer with which the sheath is sewn. This seam then forms the retaining device. Thus, a decorative element of the decorative layer, i.e. a seam, which extends over the flat light guide, is used to attach the rope-like light guide. The additional illuminating element is thus harmonically integrated into the decorative layer.
[0013] The sewing specified above results in seam edges, which extend away from the visible side in the direction of the flat light guide. It is advantageous if these seam edges are kept short. In particular, the seam edges protrude only up to about 3 mm from the decorative layer into the illuminating device. This enables the seam edges to be more easily inserted into the haptic layer.
[0014] According to a further advantageous form of the present disclosure, the sheath is a textile that contains plastic, which is placed around the optical fiber and forms a lug protruding from the optical fiber. This lug is used by the retaining device for attachment to the decorative layer, for example by the lug being sewn to the seam edges.
[0015] The integration of the seam edges of the decorative layer into the haptic layer is advantageous if the haptic layer is composed of multiple sections, the separating line of which runs along the rope-like light guide. The seam edges are then inserted into the gaps between the sections. In other words, the size and edge routing of the sections of the haptic layer follows the sections of the decorative layer. If the width of the seam edges matches the thickness of the haptic layer, then the gap between the sections can be kept small. This is the case when the thickness of the haptic layer is between 1.5 and 5 mm, or in one form 2 to 4 mm, or in still another form approximately 3 mm. To this end, spacer fabric with transparent threads can be selected for the haptic layer. In this case, a haptic layer has two cover layers, which are connected to one another via pile yarns and create a soft, springy impression on the surface.
[0016] It is advantageous if the decorative layer is leather, particularly with a thickness of 0.6 to 1 mm, or in one form 0.7 to 0.9 mm, or in another form 0.8 mm. Real leather, or alternatively artificial leather, gives a particularly appealing impression and, at the thicknesses specified above, enables backlighting, either because the leather is scarfed or skived over the utilized surface of the illuminating device creating a translucent effect, or because the decorative layer is perforated. With these thicknesses, the visibility of the perforation or rather of the light shining through the perforation is only slightly dependent on the viewing position. In order to inhibit the sewing of the decorative layer to the rope-like light guide causing excess stretching of the perforated areas, a distance is retained between the perforation and the retaining device, particularly at least 5 mm, or another form at least 7 mm.
[0017] In one form, the perforation is a micro-perforation, which has individual openings. Here, at least isolated openings have a surface area of at least 0.2 mm 2 in order to enable the permeation of sufficient quantities of light. The illuminating device is particularly appealing when the size of the openings is varied, particularly when the size decreases from the middle of the illuminating device to the edges. This results in a particularly brightly illuminated central area, which harmoniously transitions into the non-illuminated area of the illuminating device at the edges.
[0018] In an advantageous form of the present disclosure, the openings of the perforation are arranged in such a way that the observer is presented with an embellishment. This embellishment may be used for an emergency exit, seatbelt or no-smoking sign, or a company logo. In this case, rather than the openings of the perforation being equally arranged over the area of the embellishment, they form the embellishment.
[0019] A laser can be used to make the openings in the decorative layer. Similarly, a laser can be used to generate the emitting points of the surface of the flat light guide. Alternatively or additionally, a reflective layer can be attached to the flat light guide on the side opposite the emitting points in order to increase the light yield of the illuminating device. This is especially advantageous if the light sources shine into a narrow side of the light guide, i.e. the light guide is not backlit, with the light distributed over the area from one or more narrow sides and then emitted to the visible side.
[0020] For simple production and good integration of the illuminating device into interior parts, it has proven to be advantageous if the carrier module is formed in a box shape, i.e. comprises a base plate with side panels. The light sources, for example LEDs, can then be integrated into the side panels. The light sources are attached onto the carrier modules by means of press fitting, for example.
[0021] A light transmission element can be arranged between the rope-like light guide and the light source provided for the rope-like light guide. The light transmission element is light-conducting and may be produced, for example, from a transparent plastic such as polycarbonate. To this end, the light transmission element can be used to reliably transmit light from the light source to the rod-shaped light guide. The light transmission element is in one form shaped as a rod and/or bar and runs parallel to the rope-like light guide. If a light transmission element is used, it may be advantageous if light-scattering additives are used in the rope-like light guide to better homogenize the light directed in the rope-like light guide. The light source provided for the rope-like light guide is in one form arranged for light conduction on a front edge of the light transmission element, whereby a longitudinal side of the light transmission element is adjacent to the rope-like light guide for light conduction.
[0022] The flat light guide may have at least one throughput through which the rope-like light guide is routed. The throughput is in one form oblong. In this case, the throughput, and in one form the longest side of the throughput, runs parallel to a longitudinal side of the flat light guide. In another form, multiple throughputs are placed parallel to one another in the flat light guide. In one form, the rope-like light guide is inserted into the throughput and protrudes through the flat light guide. Furthermore, the carrier module may also have a throughput, with the result that the rope-like light guide is routed through both the flat light guide and the carrier module. If there are multiple throughputs in the flat light guide, it is advantageous if one rope-like light guide is provided per throughput. The rope-like light guide is in one form square, particularly a bar shape.
[0023] It may furthermore be advantageous if multiple separate light sources are arranged on the rope-like light guide. In this manner, it is possible, for example, to create chase lighting and/or to illuminate various areas of the rope-like light guide differently.
[0024] In this context, it may be advantageous if the light sources provided for the rope-like light guide are arranged in a row. The role of light sources may be represented, for example, by a line of dot-like light sources. These may be monochrome or multi-colored light sources. It is advantageous if all light sources that are arranged in a row are arranged along an area of the rope-like light guide. In this context, the rope-like light guide in one form runs parallel to the row of light sources.
[0025] The carrier module may have recesses through which the rope-like light guide is at least partially routed. The rope-like light guide can either be routed through the recess next to the flat light guide or, alternatively, it is also possible for the flat light guide to have throughputs that are arranged congruently with the recesses in such a that way the rope-like light guide is routed through the recess in the carrier module as well as through the throughput in the flat light guide.
[0026] The inventive interior part for a vehicle is based on the aforementioned illuminating device and additionally comprises a slot on a side panel, which opens a mounting space of the interior part, into which the illuminating device can be inserted and in which the illuminating device can be attached. This type of attachment means is such that the illuminating device can be easily removed, and maintained or replaced.
[0027] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0028] In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
[0029] FIG. 1 shows an illuminating device according to the present disclosure, switched on;
[0030] FIG. 2 shows an interior part with the illuminating device installed;
[0031] FIG. 3 shows a carrier module with LEDs;
[0032] FIGS. 4 and 5 show sectional views of the illuminating devices from the X and Y directions;
[0033] FIG. 6 shows a haptic and decorative layer with the rope-like light guide attached;
[0034] FIG. 7 shows an illuminating device as an embellishment;
[0035] FIG. 8 shows an alternative form of the illuminating device in a sectional view;
[0036] FIG. 9 shows a further alternative form of the illuminating device in a sectional view;
[0037] FIG. 10 shows a further alternative form of the illuminating device in a sectional view; and
[0038] FIG. 11 shows a top view of the illuminating device according to FIG. 10 .
[0039] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
DETAILED DESCRIPTION
[0040] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0041] The illuminating device described in the following is intended for integration into an interior part and only to be visible when switched on, i.e. if the illuminating device is switched off, then only one surface of the illuminating device, which does not differ from the surface of the adjacent areas of the interior part, remains visible to the observer.
[0042] The interior part ( 30 ) shown in FIG. 1 is, for example, a backrest of a group of seats for the passenger cabin of an aircraft in the VIP (Very Important Person) area. An illuminating device comprising a flat light guide ( 2 ), which has, for example, a surface area of 300×500 mm, and three rope-like light guides ( 6 ) arranged parallel to one another and with spacing, is integrated into the interior part ( 30 ). Larger illuminating devices are also conceivable. The illuminating device connects to a side panel ( 21 ) of the interior part ( 30 ). The flat and rope-like light guides ( 2 , 6 ) have different luminosities, with the result that there is a visible distinction between the brightness of each. This results in an optically appealing structure, in which the rope-like light guide ( 6 ) also continues beyond the flat light guide ( 2 ) onto the surface of the interior part ( 30 ).
[0043] FIG. 2 shows the interior part ( 30 ) in a top view, in which cover layers of the interior part have been omitted for purposes of clarity. The illuminating device is arranged on the side panel ( 21 ) of the interior part ( 30 ), because this provides the option of inserting the illuminating device through a slot ( 20 ) in the side panel ( 21 ). According to the dimensions of a carrier module ( 1 ) for the illuminating device, the interior part ( 30 ) provides for a mounting space ( 22 ), i.e. a hollow cavity, into which the carrier module ( 1 ) can be inserted and attached. A side panel of the carrier module ( 1 ) seals the illuminating device against being seen opposite the slot ( 20 ).
[0044] The carrier module ( 1 ) in one form is produced from plastic using the laser sintering method (SLS, Selective Laser Sintering) and contains openings on a side panel for light sources ( 3 ). This can be more easily seen in FIG. 3 . The light sources ( 3 ) are multicolored LEDs, which are connected to the carrier module ( 1 ) by means of press fit into the openings. As the surface of the carrier module ( 1 ) increases, more or stronger LEDs ( 3 ) should be used. Alternatively or additionally, LEDs can also be attached on the opposite side panel or a reflective film can be attached there. This will increase the luminosity of a flat illumination.
[0045] FIG. 4 shows the illuminating device in a sectional view through the side panel of the carrier module ( 1 ) with the LEDs ( 3 ). The illuminating device is surrounded by a structure ( 15 ), which is part of the interior part and leaves free the intended mounting space ( 22 ) (see FIG. 2 ). The carrier module ( 1 ) is placed flush in this mounting space ( 22 ), and a reflector film ( 13 ) is placed on the base (turned away from the visible side (SS)) of said carrier module.
[0046] The flat light guide ( 2 ) is furthermore attached in the carrier module ( 1 ), with a small amount of play on both sides. This space is used on one side to attach the LEDs ( 3 ) which then laterally provide light from a narrow side (S) of the light guide ( 2 ) into it. The light of the LEDs ( 3 ) in the light guide ( 2 ) diffuses due to reflections on the short ends of the light guide ( 2 ). On the underside, any exiting light is cast back into the light guide ( 2 ) by the reflective film ( 13 ). Toward the visible side (SS), emitting points ( 2 ′) placed at the surface of the light guide ( 2 ) provide that light is emitted homogeneously through the use of lasers.
[0047] The flat surface is raised at these emitting points ( 2 ′). The otherwise prevailing dominant refractive index differences between PMMA (which is used for the flat light guide ( 2 ) and is polymethyl methacrylate or acrylic/acrylic glass) and the surrounding air, lead to reflection back into the light guide ( 2 ) with the flat surface. However, at the uneven emitting points, this results in enhanced emission of light beams. The emitting points ( 2 ′) are distributed over the surface of the flat light guide ( 2 ) such that light is emitted evenly over the entire surface of the illuminating device, although the available quantity of light in the light guide ( 2 ) from the LEDs ( 3 ) to the opposite side panel is constantly decreasing.
[0048] A protective layer ( 14 ) is attached over the light guide ( 2 ) and to the structure ( 15 ) and subsequently arranged flush with it with respect to the visible side SS. Said protective layer ( 14 ) made of transparent PMMA is used to separate the flat light guide ( 2 ) in the carrier module ( 1 ) mechanically from the cover layers ( 4 , 5 ) described in the following. This means the protective layer ( 14 ) and the light guide ( 2 ) underneath are not bonded together but rather are detachable from one another.
[0049] Both a haptic layer ( 4 ), formed here by a 3-mm thick spacer fabric made of transparent fibers of two cover layers, which are connected to one another with pile yarn, as well as a decorative layer ( 5 ) made of approximately 0.8-mm thick split and shrink-optimized real leather, extend over the surface of the illuminating device as well as over the adjacent surfaces of the interior part. This causes the illuminating device not to be visible when switched off.
[0050] The representation of the illuminating device according to FIG. 5 has a different intersecting line, selected in this case to be vertical with respect to that according to FIG. 4 . With the same layer structure as in FIG. 4 , the LEDs are not visible. To achieve this, the haptic layer ( 4 ) and the decorative layer ( 5 ) are subdivided into multiple sections—in this case five—which are arranged parallel to one another and aligned with respect to the abutting edges. This results in gaps which are used to place a rope-like light guide ( 6 ), between the sections of the haptic layer ( 4 ). Light is fed into the rope-like light guide ( 6 ) by means of inherent light sources, which are LEDs (not shown here), at the ends thereof. Three parallel rope-like light guides ( 5 ), optical fibers (LWL) here, are arranged precisely at a seam point between the sections of the decorative layer ( 5 ). As shown later in FIG. 6 , the seam edges and a lug of a sheath surrounding the optical fiber (LWL) extend away from the visible side (SS) into the illuminating device.
[0051] FIG. 6 shows a seam point of the cover layers ( 4 , 5 ) enlarged. The optical fiber (LWL) is surrounded by a sheath ( 8 ) made of flexible textile with a plastic portion, in which ends of the sheath ( 8 ) form a lug ( 10 ), which extends parallel to the optical fiber (LWL) and are bonded together by heating both portions of the lug ( 10 ). Thus, the optical fiber (LWL) fits tightly in the sheath ( 8 ).
[0052] The optical fiber (LWL) is arranged in the center in the gap between two sections of the spacer fabric ( 4 ). The real leather is connected to the spacer fabric ( 4 ) by means of a bonded connection, as a decorative layer ( 5 ). The decorative layer ( 5 ) is perforated in advance by means of a laser, in such a way that the perforation ( 11 ) then comprises openings ( 11 ′). The openings ( 11 ′) are between 0.5 and 2 mm wide, whereby the opening ( 11 ′) next to the optical fiber (LWL) is at a distance of 7 mm from it. The thickness (d) of the decorative layer ( 5 ) is 0.8 mm. Ends of the sections of the decorative layer ( 5 ) on the optical fiber (LWL) form seam edges 9 , which connect to the optical fiber (LWL) and enclose the lug ( 10 ) of the sheath ( 8 ). This makes it possible to sew together the lug ( 10 ) and the seam edges ( 9 ). The seam edges ( 9 ) in this case are approximately 3 mm wide, and can therefore be stowed in the gap between the sections of the haptic layer ( 4 ). This sewing forms the retaining device ( 7 ) for the optical fiber (LWL) on the decorative layer ( 5 ).
[0053] Finally, FIG. 7 shows an example of an embellishment ( 12 ), which can be created by means of the illuminating device through backlighting. A seatbelt sign is made visible by the openings ( 11 ′) of the perforation ( 11 ) being arranged only at the locations in the decorative layer ( 5 ) that are required for expressing the shape of the embellishment ( 12 ).
[0054] FIG. 8 shows an alternative form of the illuminating device in a sectional view. In this case, the light is transmitted by the light source ( 6 ′) (not shown) provided for the rope-like light guide ( 6 ) by means of an additional light transmission element ( 31 ). The light transmission element ( 31 ) extends parallel to the rope-like light guide ( 6 ), whereby the light source ( 6 ′) (not shown) provided for the rope-like light guide ( 6 ) is arranged on a front (not shown) of the light transmission element ( 31 ). The light transmission element ( 31 ) is formed in the example embodiment at hand by a highly transparent rod-shaped light guide made of polymethyl methacrylate (PMMA). The light of the light source ( 6 ′) is evenly fed into the rope-like light guide ( 6 ) by the light transmission element ( 31 ) in such a way that an even and homogeneous light pattern is created. Two rope-like light guides ( 6 ) and/or light transmission elements ( 31 ) are arranged above the flat light guide ( 2 ). A third rope-like light guide ( 6 ) is arranged next to the flat light guide ( 2 ), whereby the rope-like light guide ( 6 ) protrudes through a recess ( 33 ) in the carrier module ( 1 ). Furthermore, the scattered particles ( 2 ′) are arranged on a side of the flat light guide ( 2 ) facing away from the haptic layer ( 4 ) and/or the decorative layer ( 5 ).
[0055] FIG. 9 shows a further alternative form of the illuminating device, in which the form according to FIG. 9 differs from the form according to FIG. 8 in that, instead of light transmission elements, a row of light sources ( 6 ′) is arranged directly on the rope-like light guide ( 6 ). The row of light sources ( 6 ′) in the present example form is created by multiple dot-like multicolored LEDs. The light sources ( 6 ′) are directly attached to the rope-like light guide ( 6 ) using a non-adhesive.
[0056] FIG. 10 shows a further alternative form of the illuminating device, in which a throughput ( 32 ) is placed in the light guide ( 2 ) and a recess ( 33 ) is placed in the carrier module ( 1 ). Due to the throughput ( 32 ) and the recess ( 33 ), the rope-like light guide ( 6 ) is arranged in the form of a light strip. A row of dot-like light sources is arranged along the rope-like light guide ( 6 ).
[0057] FIG. 11 shows a top view of the flat light guide according to the form illustrated in FIG. 10 . Three throughputs ( 32 ) have been placed in the flat light guide ( 2 ); a rope-like light guide ( 6 ) is placed in each of these throughputs. The rope-like light guides ( 6 )/the throughputs ( 32 ) are arranged parallel to one another. The light sources ( 3 ) of the flat light guide ( 2 ) are arranged on the narrow side (S) of the flat light guide ( 3 ). The longitudinal side of the throughputs ( 32 )/rope-like light guides ( 6 ) are essentially arranged vertically to the narrow side of the flat light guide ( 2 ). Because the rope-like light guide ( 5 ) is backlit by several light sources arranged in a row, various colors and brightnesses can be represented simultaneously in various areas of the rope-like light guide ( 6 ).
[0058] The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure. | An illuminating device for a vehicle includes a carrier module, a flat light guide attached to the carrier module with a plurality of emitting points, and multiple light sources for illuminating the light guide. The flat light guide is concealed with a translucent haptic layer, which is attached to a visible side of the light guide, which, in turn, is covered by a decorative layer. The illuminating device comprises a rope-like light guide, which has an inherent light source and is connected to the decorative layer via a retaining device. This therefore results in a flat arrangement, which can be easily integrated into the interior parts and simultaneously enables illumination over a large surface area. In doing so, additional light effects can be integrated by means of the rope-like light guide. The illuminating device is not visible while switched off, as the illuminating device is covered by the decorative layer. | 1 |
TECHNICAL FIELD
The present invention relates to an assembly of a one-way clutch and a bearing which is to be attached to a stator of a torque converter, and more particularly to an assembly of a one-way clutch and a bearing in which a thrust bearing (needle bearing), a thrust washer, and the like are not used, and wear of sliding faces of a stator and a bearing support can be reduced.
BACKGROUND ART
A torque converter which is used as an automatic transmission of an automobile is configured so that, as shown in FIG. 9, a pump impeller 2 is rotated by an output shaft 1 of an engine, a turbine runner 4 is rotated by using ATF (Automatic Transmission Fluid), the rotational torque of the turbine runner 4 is increased via a stator 3 , and the power is then transmitted to an input shaft 5 of the transmission. A one-way clutch 6 is attached to the stator 3 . An inner race 6 b of the one-way clutch 6 is non-rotatably placed by spline fitting or the like on a stationary shaft 11 which is placed around the input shaft 5 . Depending on the vane angle of the stator a thrust load is applied to the one-way clutch 6 . In order to absorb the load, therefore, thrust bearings 12 and 13 (or thrust washers) are usually placed on both the sides of the one-way clutch 6 , respectively.
When the thrust bearings 12 and 13 (or thrust washers) are placed on both the sides of the one-way clutch 6 , however, the number of parts is increased, the configuration is complicated, and it is disadvantageous from the view point of space. Consequently, the assignee of the present application has proposed an assembly of a one-way clutch and a bearing in which, as shown in FIG. 6, such a thrust bearing 12 and the like are not used, small gaps 21 and 20 are respectively formed between a flange portion 3 b , that elongates radially inward from a boss portion 3 a of the stator 3 , and a pump-side member 2 a . A bearing support 7 and a turbine-side member 4 a are placed on the opposite side, and dynamic pressure grooves are formed in sliding faces of the flange portion 3 b of the stator 3 and the bearing support 7 (Japanese Patent Publication (Kokai) No. HE18-247251).
As shown in FIGS. 7 (A) and 7 (B), for example, herringbone-like or V-like dynamic pressure grooves 10 , 10 , . . . are formed in the surface of the side face of the flange portion 3 b of the stator 3 , or, as shown in FIGS. 8 (A) and 8 (B), herringbone-like or V-like dynamic pressure grooves 9 , 9 , . . . are formed in the surface of the side face of the bearing support 7 . A dynamic pressure is generated by relative rotation of the stator 3 and the like, so that the thrust load is supported and thrust bearings or thrust washers are not required.
The stator 3 and the bearing support 7 , in which the herringbone-like or V-like dynamic pressure grooves 10 or 9 are formed in the sliding face, are produced from a synthetic resin. The ATF (Automatic Transmission Fluid) which generates a dynamic pressure is sucked into the dynamic pressure grooves 10 ( 9 ) from the inner and outer radial sides of the side faces of the stator 3 and the bearing support 7 to join together in the apexes of the dynamic pressure grooves 10 ( 9 ), i.e., in the center of the sliding faces, with the result that the pressure is raised to exert the dynamic pressure effect. In such pressure rise, however, the pressure is generated at the junctions of the dynamic pressure grooves 10 ( 9 ), but the high-pressure fluid has no way of escape, and hence the fluid temperature is abruptly raised in accordance with the sliding operation of the side faces of the stator 3 and the bearing support 7 . As a result, there arises a problem in that the sliding faces are easily worn.
SUMMARY OF THE INVENTION
The invention has been conducted in view of the above-discussed problem. It is an object of the invention to provide an assembly of a one-way clutch and a bearing in which a thrust load due to a stator can be absorbed, a dynamic pressure can be generated, and, even when the pressure becomes high, the temperature is prevented from being abruptly raised, so that wear and the like of sliding faces can be prevented from occurring.
In order to solve the problem, the present invention provides an assembly of a one-way clutch and a bearing in which a bearing is placed between a one-way clutch attached to a stator of a torque converter, and a pump member adjacent to a flange portion formed on the stator, and a turbine member adjacent to a bearing support which is placed on a side opposite to the flange portion of the stator, and
dynamic pressure grooves ( 3 c ) and an escape groove(s) ( 3 d ) serving as the bearings are formed in at least one of opposing faces of the flange portion formed on the stator and the pump member, or opposing faces of the bearing support which is placed on the side opposite to the flange portion of the stator, and the turbine member.
Furthermore, the present invention provides that the escape groove(s) is a ring-like groove ( 3 e ) which is formed in a circumferential direction of a face, the dynamic pressure grooves being formed in the face.
Moreover, the present invention also provides that the escape grooves are grooves ( 3 f ) which are radially formed at predetermined angular intervals in a circumferential direction of a face, the dynamic pressure grooves being formed in the face whereat the dynamic pressure grooves are not formed.
Furthermore, the present invention additionally provides that a bearing support is placed in place of the flange portion of the stator.
Moreover, the present invention provides that the bearing support is used as the flange portion of the stator, and the flange portion of the stator is used as the bearing support.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 (A) is an axial section view of a stator constituting an assembly of a one-way clutch and a bearing of the present invention, and FIG. 1 (B) is a side view of a flange portion.
FIG. 2 is a side view of a flange portion of a stator constituting an assembly of a one-way clutch and a bearing of the present invention, and showing an embodiment in which dynamic pressure grooves and escape grooves are densely formed.
FIG. 3 is a view showing an example which is a second embodiment of the assembly of a one-way clutch and a bearing of the present invention wherein dynamic pressure grooves formed in a side face of a flange portion of a stator, and a ring-like escape groove that elongates in a circumferential direction in junction points of the dynamic pressure grooves is formed.
FIG. 4 is a view showing an example which is a third embodiment of the assembly of a one-way clutch and a bearing of the present invention wherein dynamic pressure grooves are formed in a side face of a flange portion of a stator, and grooves which interrupt the dynamic pressure grooves are radially formed as escape grooves at predetermined angular intervals in a circumferential direction.
FIG. 5 (A) is a section view of a bearing support constituting the assembly of a one-way clutch and a bearing of the present invention, and FIG. 5 (B) is a side view of the bearing support.
FIG. 6 is an axial section view of an assembly of a one-way clutch and a bearing of the conventional art showing an axial section of an assembly of a one-way clutch and a bearing in which a thrust bearing and a thrust washer are not used.
FIG. 7 (A) is a partial axial section view of a stator constituting an assembly of a one-way clutch and a bearing of the conventional art, and FIG. 7 (B) is a side view of the stator.
FIG. 8 (A) is a partial axial section view of a bearing support which is placed in a stator constituting an assembly of a one-way clutch and a bearing of the conventional art, and FIG. 8 (B) is a side view of the bearing support.
FIG. 9 is an axial section view of an assembly of a one-way clutch and a bearing of the conventional art in which a thrust bearing and a thrust washer are placed on both the sides of a stator wherein the one-way clutch is disposed.
DETAILED DESCRIPTION
Hereinafter, specific embodiments of the invention will be described with reference to the drawings. In the following, description will be made referring to FIG. 6 in order to avoid duplicated description, and the same components will be described by using the identical reference numerals.
FIG. 1 (A) is an axial section view of a stator 3 constituting the assembly of a one-way clutch and a bearing of the invention, and FIG. 1 (B) is a side view of a flange portion of FIG. 1 (A). The stator 3 is configured in the same manner as the stator shown in FIG. 6, and formed by a boss portion 3 a , and a flange portion 3 b formed by elongating radially inward one side of the boss portion 3 a.
An outer race 6 a (see FIG. 6) of the one-way clutch is fitted into the inner side of the boss portion 3 a . The pump-side member 2 a (see FIG. 6) is placed on the side adjacent and opposed to the flange portion 3 b of the stator 3 to form a small gap 21 therebetween. A one-way clutch is placed and the bearing support 7 is placed on the side of the boss portion 3 a opposite to the flange portion 3 b . The turbine-side member 4 a (see FIG. 6) is placed on the side adjacent and opposed to the bearing support 7 and forms a small gap 20 therebetween.
As shown in FIG. 1 (B), herringbone-like or V-like dynamic pressure grooves 3 c , 3 c , . . . are formed in the side face of the flange portion 3 b of the stator 3 at predetermined intervals in a circumferential direction. The dynamic pressure grooves 3 c , 3 c , . . . are formed so that the resistance of the automatic transmission fluid with respect to the relative rotation direction of the stator 3 , indicated by the arrow P, is increased. Namely, the dynamic pressure grooves 3 c , 3 c , . . . are formed so that, during relative rotation of the stator 3 , the automatic transmission fluid is introduced from the inner and outer radial sides and joins in a rear center portion in the rotation direction of the stator 3 . The dynamic pressure grooves 3 c are not limited to a herringbone-like shape or a V-like shape, and may have any other shape such as a triangular shape as long as a dynamic pressure can be generated. During relative rotation of the stator 3 , a high pressure is generated in the gap 21 between the stator and the pumpside member 2 a , and hence such dynamic pressure grooves 3 c , 3 c , . . . have a function of a bearing. Therefore, a thrust bearing or a thrust washer which is necessary in the conventional art is not required.
In the side face of the flange portion 3 b of the stator 3 , the dynamic pressure grooves 3 c , 3 c , . . . are formed, and also escape grooves 3 d , 3 d , . . . for allowing the automatic transmission fluid to escape are formed. In order to allow the automatic transmission fluid to smoothly escape by using a centrifugal force generated during relative rotation of the stator 3 , each of the escape grooves 3 d is formed into a curved shape such as that constituting a part of a volution (spiral) so that the inner radial side is in the forward side and the outer radial side is in the rearward side. When the escape grooves 3 d , 3 d , . . . are formed together with the dynamic pressure grooves 3 c , 3 c , . . . in the side face of the flange portion 3 b of the stator 3 in this way, the dynamic pressure generated in the center of the side face of the flange portion 3 b can be allowed to escape at a certain degree. Therefore, abrupt generation of a high pressure and temperature rise of the automatic transmission fluid which are caused by the rotation can be suppressed.
FIG. 2 is a side view of the flange portion 3 b of the stator 3 in which wide dynamic pressure grooves 3 c , 3 c , are densely formed in the side face. Also in the surface of the flange portion 3 b in which the dynamic pressure grooves 3 c are formed, volute (spiral) escape grooves 3 d are formed so that the inner radial side is in the forward side with respect to the relative rotation of the stator 3 and the outer radial side is in the rearward side, and that the automatic transmission fluid is allowed to escape by using a centrifugal force.
Next, FIG. 3 is a side view of the stator 3 of a second embodiment constituting the assembly of a one-way clutch and a bearing of the present invention. In the stator 3 , a ring-like circular escape groove 3 e having a predetermined width is formed in a circumferential direction in junction points of the dynamic pressure grooves 3 c , 3 c , . . . which are formed in the side face. Namely, the conventional dynamic pressure grooves 10 , 10 , . . . such as shown in FIG. 6 cannot allow a dynamic pressure generated in the center of each groove to escape. By contrast, in the embodiment, between the center circular escape groove 3 e and the outer portion of each of the dynamic pressure grooves 3 c that are positioned more outward than the escape groove, paths are formed so as to connect the grooves. Therefore, the circular groove 3 e functions as an escape groove, so that the high pressure of the automatic transmission fluid which is generated in the center portions of the dynamic pressure grooves 3 c , 3 c , . . . can be allowed to escape to the outside of the stator 3 by a centrifugal force due to the relative rotation.
FIG. 4 is a side view of the stator 3 of a third embodiment of the present invention.
In the embodiment, the dynamic pressure grooves 3 c , 3 c , . . . are formed in the side face of the flange portion 3 b of the stator 3 , and radial grooves 3 f , 3 f , . . . are radially formed at predetermined angular intervals in a circumferential direction. The radial grooves serve as escape grooves which interrupt the dynamic pressure grooves 3 c , 3 c , . . . in four places (at an interval of 90 deg.) in the circumferential direction where at the dynamic pressure grooves are not formed. The dynamic pressure of the automatic transmission fluid which is generated by the relative rotation of the stator 3 can be allowed to escape to the outside of the stator 3 through the radial grooves 3 f , 3 f , . . . . The radial grooves 3 f , 3 f , . . . which interrupt the dynamic pressure grooves 3 c may be formed with reducing their width, and radially increased or reduced.
In the assembly of a one-way clutch and a bearing of the invention, the stator 3 has been exemplarily described. As shown in FIGS. 5 (A) and 5 (B), alternatively, also in a side face of the bearing support 7 , dynamic pressure grooves 7 a may be similarly formed and escape grooves 7 b may be formed, or a circular groove or radial grooves which are similar to the ring groove 3 e or the radial grooves 3 f may be formed.
In addition to the above-described embodiments, dynamic pressure grooves and escape grooves may be formed also in the surface of the pump-side member 2 a which is placed to form the small gap 21 with respect to the flange portion 3 b of the stator 3 , and in that of the turbine-side member 4 a which is placed to form the small gap 21 with respect to the bearing support 7 . In the stator 3 , the flange portion 3 b may not be formed, and a bearing support may be placed. Conversely, a flange portion may be placed on the side of the bearing support 7 of FIG. 1, the flange portion 3 b may be placed on the side of the pump-side member 2 a of the stator 3 , and dynamic pressure grooves and—escape grooves may be formed in the surfaces of the portions.
In the above-described embodiments, the dynamic pressure grooves 3 c ( 7 a ), the escape grooves 3 d ( 7 b ), and the like are formed in the side face of the flange portion 3 b of the stator 3 , and the bearing support 7 . Alternatively, the dynamic pressure grooves 3 c and the escape grooves 3 d ( 3 e , 3 f ) may be formed in the flange portion 3 b of the stator for 3 , and a thrust bearing or a washer may be placed between the bearing support 7 and the turbine-side member 4 a . Alternatively, the dynamic pressure grooves 7 a and the escape grooves 7 b may be formed in the side face of the bearing support 7 , and a thrust washer or a needle bearing may be placed on the side of the flange portion 3 b of the stator 3 .
As described above in detail, according to the assembly of a one-way clutch and a bearing of the present invention, the automatic transmission fluid of elevated temperature can be discharged while maintaining an adequate dynamic pressure between the stator and a pump member, and the stator and a turbine member. Furthermore, cold automatic transmission fluid is sucked from the dynamic grooves to the sliding faces of the stator and the bearing support to exert the dynamic pressure effect, and the automatic transmission fluid of elevated temperature is discharged from the escape grooves. Therefore, also wear of the sliding faces can be reduced. | An assembly of a one-way clutch and a bearing in which a thrust load due to a stator is absorbed and a dynamic pressure is generated is configured to prevent an abrupt temperature rise even when the pressure becomes high so that wear of sliding faces is prevented. The assembly of the one-way clutch and bearing is attached a stator of a torque converter. Dynamic pressure grooves and an escape groove serving as the bearings are formed in at least one of opposing faces of a flange portion formed on the stator and a pump member, or opposing faces of a bearing support which is placed on the side opposite to the flange portion of the stator, and a turbine member. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to batch digestors and more particularly to apparatus for recovering heat from batch digester cooking fluids and a process for use thereof.
2. Description of the Prior Art
Batch digesters are commonly used in industrial applications to liberate fibrous pulp or other desired by-products from woodchips or other fibrous materials by digestion or cooking. The digestion of materials in batch digesters requires the use of heat and a highly corrosive fluid or cooking "liquor", such as sodium sulphite. To effect digestion a quantity of material is placed within a digester. This material may be preheated, exposed to a predetermined quantity of super heated cooking liquor, allowed to soak or "cook" in the cooking liquor at an elevated temperature and pressure for a predetermined time period, and then discharged from the digester and separated into the desired product and spent liquor. The spent cooking liquor is the contaminated cooking liquor which includes residue pulp liberated during the cooking process. Release of the pressure in the digester liberates energy contained in the superheated contents of the digester. Such energy may be subsequently recovered and utilized if desired.
The reclamation of heat from batch digester systems is well known in the prior art. Specifically U.S. Pat. Nos. 1,832,367 issued to T. L. Dunbar, Nov. 17, 1931; 1,860,755 issued to Stevens et al, May 31, 1932; 1,885,561 issued to Stevens et al, Nov. 1, 1932; 1,947,889 issued to C. B. Thorme, Feb. 20, 1934; and 2,216,649 issued to A. D. Merrill, Oct. 1, 1940 all discuss apparatus and processes for such heat recovery. The prior art teaches the use of direct or indirect heat exchange to transfer heat between the cooking and spent liquors. Such a heat exchange is to preheat the cooking liquor prior to its introduction into the digester. Preheating the cooking liquor in such a manner reduces the expense of independently heating the cooking liquor and reduces total processing times.
Direct heat exchange in the prior art between cooking and spent liquors is accomplished by mixing heated spent liquor with unheated cooking liquor. A major drawback to direct heat exchange is the contamination of the cooking liquor by the spent liquor resulting in lengthened cooking times.
The indirect heat exchange between the cooking and spent liquors is the preferred approach of the prior art. The indirect heat exchange between the cooking and spent liquors is accomplished by use of a fluid-to-fluid heat exchanger. Unheated cooking liquor is introduced into one portion of the heat exchanger while heated spent liquor is introduced into a second portion of the heat exchanger. The two liquors are passed near each other inside their respective portions of the heat exchanger. The heat exchange is accomplished through the walls of the heat exchanger. Neither cooking or spent liquor is allowed to contact the other liquor and contamination of the cooking liquor is avoided. Once heated, the cooking liquor is superheated. When superheated, cooking liquor is stored for future use in a pressurized accumulator to prevent release of energy from the superheated liquor.
Conventional fluid-to-fluid heat exchangers have an acccessible fluid system and an inaccessible fluid system. Both systems may be washed or flushed, but only the accessible system may be truly cleaned or descaled in case of blockage. If blockage occurs due to heavy scaling or fouling in the inaccessible portion of the heat exchanger, the heat exchanger must be replaced or rebuilt. Such replacement or rebuilding of a heat exchanger is expensive.
A disadvantage of the prior art is that it requires highly corrosive liquors to pass through the inaccessible portion of the heat exchanger resulting in fouling, scaling and general blockage of that portion of the heat exchanger. Such blocking, scaling or fouling requires the expensive rebuilding, replacement or cleaning of the heat exchanger to restore efficient heat exchanger operation.
Another disadvantage of the prior art is that it requires the use of expensive pressurized accumulators to store heated liquors.
A further disadvantage of the prior art is that it requires the use of expensive pressurized measuring equipment to accurately measure the quantity of preheated cooking liquor introduced into the digester.
SUMMARY OF THE PRESENT INVENTION
It is an object of the present invention to provide apparatus which eliminates the need to replace, rebuild, or frequently clean heat exchangers due to fouling, scaling or blocking of the inaccessible portion of the heat exchanger.
It is another object of the present invention to provide apparatus which eliminates the need for pressurized accumulators to store heated liquors.
It is another object of the present invention to provide a process that eliminates the need for pressurized measuring equipment to measure preheated cooking liquors.
Briefly, a preferred embodiment of the present invention includes apparatus to receive a quantity of corrosive fluid, i.e. a cooking liquor, at least one batch digester, a quantity of live steam, at least two fluid-to-fluid heat exchangers, a quantity of inert non-corrosive non-fouling fluid, a non-pressurized inert fluid reservoir, a non- pressurized cooled inert fluid reservoir, and a non-pressurized cooled spent liquor storage tank. The preferred embodiment further includes an assortment of valves, piping and other plumbing to fluidly interconnect the aforementioned apparatus.
To utilize a preferred embodiment a quantity of material to be digested is deposited in the batch digester. The material to be digested is then exposed to a predetermined quantity of heated cooking liquor. The cooking liquor mixes with the material to be digested. The mixture remains in the digester for a predetermined time until a desired level of digestion of the material has occurred. After digestion, a mixture of spent cooking liquor, digested material and dissolved organic compounds remain within the digester. The mixture of spent cooking liquor and dissolved organic material are collectively referred to as spent liquor. The heated spent liquor is then displaced from the mixture by cooled spent liquor. The super heated spent liquor is exhausted from the digester through a first heat exchanger to a cooled spent liquor storage tank. The cooled spent liquor-digested material mixture is withdrawn from the digester and stored for future processing.
The heated spent liquor displaced from the digester and a quantity of unheated inert fluid are simultaneously passed through the first heat exchanger to heat the unheated inert fluid and cool the heated spent liquor. The heated spent liquor is passed through the accessible portion of the first heat exchanger while the unheated inert fluid is passed through the inaccessible portion of the first heat exchanger. Once cooled, the spent liquor is stored for future use in the cooled spent liquor storage tank. The heated inert fluid is then passed into a second heat exchanger, or stored in the heated inert fluid reservoir if its use is not immediately required. When required, the heated inert fluid is passed through the second heat exchanger simultaneously with a predetermined quantity of unheated cooking liquor. The second heat exchanger cools the heated inert fluid and heats the unheated cooking liquor. The unheated cooking liquor is passed through the accessible portion of the second heat exchanger while the heated inert fluid flows through the inaccessible portion of the second heat exchanger. Cooking liquor heated in the second heat exchanger is then introduced into the digester. The cooled inert fluid is stored in the cooled inert fluid reservoir for future use or immediately passed through the first heat exchanger to start the heat exchange process over again.
The preferred embodiment of the present invention envisions a continuous closed loop system for the inert fluid. The closed system utilizes heat from the heated spent liquor to heat unheated cooking liquor without exposing the inaccessible portions of the heat exchanger to corrosive fouling liquors.
One advantage of the present invention is that the inaccessible portions of the heat exchangers are not exposed to any corrosive liquors, eliminating blockage, fouling, or scaling of the inaccessible portion of the heat exchanger.
Another advantage of the present invention is the possibility of the use of non-pressurized reservoirs to store the inert fluid. When the proper inert fluid is chosen the heated inert fluid is not volatile, eliminating the need for pressurized accumulators, thus minimizing operational costs associated with batch digesting.
Another advantage of the present invention is its use of inert fluid as a means to effectively recover waste heat energy from the spent liquor without heating any cooking liquor until such is required. Thus, exact quantities of unheated cooking liquor may be measured by non-pressurized measurement equipment for use in the digester prior to heating.
These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment which is illustrated in the drawing FIGURE.
IN THE DRAWING
FIG. 1 is a schematic diagram of apparatus for a batch digesting process according to the present invention and further illustrating the batch digesting process according to the present invention segmented into operational cycles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a schematic diagram of a batch digesting system according to the present invention referred to by a general reference character 10. To more clearly illustrate the operation of system 10, system 10 is subdivided, by a series of dashed lines, into seven operations. The operations include a material fill operation 12, a presoak operation 13, a cooking liquor fill operation 14, a cooking operation 16, a displacement operation 18, a discharge operation 20, and a heat exchange operation 22. A number of the elements of system 10 are repeated in operations 12, 13, 14, 16, 18 and 20. Such duplication of the elements is not required for the functioning of the present invention, and is shown merely for ease of description.
System 10 includes a digester 30, a cooking heater 32, a pump 34, a blow tank 36, a cooled spent liquor storage tank 38, a first heat exchanger 40, a second heat exchanger 42, a heated inert fluid reservoir 44, a cooled inert fluid reservoir 46, and a variety of plumbing (not shown) comprising valves and piping to fluidically interconnect the apparatus.
It should be understood that each operation 12, 13, 14, 16, 18, 20 and 22 does not require all of the aforementioned apparatus or distinct apparatus. For example, all the operations may be conducted with one digester 30, and two heat exchangers 40 and 42. Likewise, system 10, depending on its application, may utilize multiples of any of the apparatus, e.g. system 10 may employ a plurality of digesters 30 and cooking heaters 32 if so desired. Additionally, system 10 may function without cooking heater 32 when direct steam (to be discussed hereinafter) is injected into digester 30. Such a system is illustrated by dot-dashed lines (to be discussed hereinafter) in operations 14 and 16.
Each digester 30 includes an upper cylindrical portion and a lower cylindrical portion. The upper portion has an upper opening 50, an upper opening cover 52, and a steam relief conduit 54. Digester 30 further includes a liquor reintroduction passage 55, a liquor displacement conduit 56, a lower opening 57 and a lower opening cover 58, a steam introduction passage 60, a liquor introduction passage 62, a liquor outlet conduit 64, and displacement passage 66. Digester 30 must be capable of enclosing a predetermined quantity of material 70, referenced by line 70, to be digested, such as woodchips or other fibrous material, and a predetermined quantity of cooking fluid (to be discussed hereinafter). Digester 30 is pressurized to prevent spontaneous boiling of heated cooking fluid and material 70.
The cooking fluid used in system 10 may be a corrosive chemical such as sodium sulfide. In system 10 there are two fluids, a cooking liquor 72, and a spent liquor 74. The cooking liquor is referenced by line 72 and the spent liquor by the line 74. The difference between cooking liquor 72 and spent liquor 74 is chemical composition, specifically, the amount of impurities present in each liquor. Cooking liquor 72 is a relatively pure inorganic solution fluid while spent liquor 74 is chemically altered due to chemical reactions that transpire during cooking operation 16 and contains substantial quanities of impurities, such as water, ligin and other non-fibrous waste materials. Spent liquor 74 along with pulp resides in digester 30 after cooking operation 16 is terminated. During cooking operation 16, cooking liquor 72 is transformed into spent liquor 74 as material 70 is digested.
Cooking heater 32, used in operations 14 and 16 may be a conventional industrial design capable of heating predetermined quantities of cooking liquor 72. The exact requirements for cooking heater 32 are dependent on the choice of cooking liquor 72 and material 70. In FIG. 1 cooking heater 32 is a standard steam heater.
Blow tank 36 may also be of a conventional design capable of containing spent liquor 74 and material 70 when such is discharged from digester 30. In blow tank 36 spent liquor 74 may be separated from material 70 if a pulp washing operation (not shown) is utilized.
Cooled spent liquor storage tank 38, heated inert fluid reservoir 44 and cooled inert fluid reservoir 46 may all be of non-pressurized conventional design. Each must be capable of containing a predetermined quantity of liquid. The exact quantity of liquid to be contained is dependent on the design of system 10.
The first heat exchanger 40 and second heat exchanger 42 may also be of conventional fluid-to-fluid heat exchanger design having an accessible region and a inaccessible region through which fluids to be heated and cooled pass. Heat exchangers 40 and 42 function by passing a heating fluid and a fluid to be heated through the heat exchanger simultaneously. Heat exchange between the two fluids is effected through the walls of the heat exchanger. A fluidized bed heat exchanger can also be used for heat exchanger 40 and/or 42. Such a fluidized bed heat exchanger is disclosed in U.S. Pat. No. 4,119,136 issued to Klaren on Oct. 10, 1978.
The aforementioned components of system 10 must be capable of containing and in some instances conveying the liquors without allowing the escape of either cooking liquor 72 or spent liquor 74.
As illustrated in FIG. 1 the operation of system 10 includes seven overlapping operations. For ease of description, each operation will be individually addressed in relation to the other operations. In material filling operation 12, digester 30 is filled with a predetermined amount of material 70. Such filling is accomplished by opening cover 52, passing material 70 through opening 50 and closing and securing cover 52.
After operation 12, presoak operation 13 may be utilized wherein material 70 is presoaked in heated spent liquor 74. Heated spent liquor 74 is introduced into digester 30 via liquor introduction passage 62. Presoak operation 13 is not always required and may be omitted if desired. However, use of presoak operation 13 improves operating economy by conserving use of live steam 80, referenced by line 80, and increasing the yield of material 70. Under certain conditions use of presoak operation 13 may induce changes in the physical properties of material 70 and should be avoided.
Cooking liquor filling operation 14 is commenced after material fill operation 12 or 13 is completed. During operation 14 a predetermined quantity of cooking liquor 72, either preheated by second heat exchanger 42 as shown or unheated, is introduced into digester 30 through liquor introduction passage 62. When operation 14 follows presoak operation 13, cooking liquor 72 displaces spent liquor 74. The introduction of cooking liquor 72 creates a cooking mixture of cooking liquor 72 and material 70. Cooking heater 32 is heated by live steam 80 as illustrated. If cooking heater 32 is not utilized live steam 80 may be directly introduced into digester 80 via steam introduction passage 60 as shown in operrations 14 and 16 by dot-dash line 80. The introduction of cooking liquor 72 displaces an undetermined amount of gases 81 liberated from material 70 by live steam 80, cooking liquor 72 and/or heated spent liquor 74 if operation 13 is utilized. Displaced steam 81 exits digester 30 through steam released conduit 54.
After cooking liquor fill operation 14 is complete, cooking operation 16 is commenced. Operation 16 requires soaking or cooking of material 70 in cooking liquor 72 for a predetermined time at a predetermined temperature and pressure. Cooking time is dependent on temperature and choice of cooking liquor 72 and material 70 as discussed. During cooking operation 16 the temperature of cooking liquor 72 and material 70 is maintained by circulation of cooking liquor 72 through cooking heater 32 or by direct steam 80 injection into digester 30 via steam introduction passage 60. If steam heater 32 is utilized cooking liquor 72 circulates through cooking heater 32 and re-enters digester 30 through liquor reintroduction passage 55. During cooking operation 16 cooking liquor 72 is contaminated by waste by-products of material 70, such as water, ligin, and other non-fibrous components of material 70. Contamination of cooking liquor 72 results in cooking liquor 72 becoming spent liquor 74 upon the completion of cooking operation 16.
After cooking operation 16 is completed, displacement operation 18 is commenced. Displacement operation 18 entails the introduction of a quantity of cooled spent liquor 74 into digester 30. Cooled spent liquor 74 flows into digester 30 through liquor displacement passage 66. Heated spent liquor 74 residing within digester 30, being less dense than cooled liquor 74, and is displaced by cooled liquor 74. The displaced heated liquor 74 rises to the upper portions of digester 30 and exits digester 30 through liquor displacement conduit 56. After heated liquor 74 is removed from digester 30 it is passed through first heat exchanger 40 and/or liquor introduction passage 62 in presoak operation 13.
The functioning of first heat exchanger 40 and second heat exchanger 42 is paramount to the operation of system 10. The operation of heat exchangers 40 and 42 is shown as heat exchange operation 22. In operation 22, an inert fluid as referenced by line 90, is circulated between heat exchangers 40 and 42 to convey heat from heated spent liquor 74 to unheated cooking liquor 72. Inert fluid 90 must be a non-corrosive, non-fouling liquid. Use of a non-volatile liquid for inert fluid 90 is recommended. When such a liquid is chosen for inert fluid 90 the need to store heated fluid 90 in pressurized accumulators is eliminated. Silicone oil or softened water are suitable for use as inert fluid 90. When softened water is utilized as inert fluid 90 reservoirs 44 and 46 should be pressurized. Inert fluid 90 is passed through the inaccessible regions of both heat exchangers 40 and 42 during operation 22.
In conventional batch digesting systems cooking liquor 72 or spent liquor 74 are passed through the inaccessible portions of a heat exchanger resulting in scaling, fouling or blockage of the heat exchanger. Such scaling, fouling or blockage reduces the efficiency of the heat exchanger and requires cleaning and possible dismantling or replacement of the heat exchanger to regain lost efficiency. Use of inert fluid 90 in the inaccessible portions of heat exchangers 40 and 42 eliminate such cleaning, refurbishing or replacement. Scaling, fouling or blockage is alleviated in the inaccessible portions of heat exchangers 40 and 42 as inert fluid 90 is non-corrosive and does not cause heat exchanger scaling. In conventional digester systems frequent cleaning of the inaccessible portions of the heat exchanger is performed in an attempt to prevent such scaling, fouling or blockage. Such cleanings render the heat exchanger temporarily useless for performing its function. Interruption of the digestion process is required when the heat exchanger is cleaned unless backup reserve heat exchangers are utilized or direct steam injection is used. The frequent cleaning of the heat exchanger, the use of backup heat exchangers, or the use of direct steam injection is expensive. System 10 eliminates such interruptions, the need to have backup heat exchangers available or the need to use direct steam injection.
In heat exchange operation 22 the first heat exchanger 40 is used to transfer heat from heated spent liquor 74, displaced from digester 30 during displacement operation 18, to inert fluid 90. Once heated, inert fluid 90 can be stored in heated inert fluid reservoir 44, for future use, or immediately passed through second heat exchanger 42. Simultaneously with the passage of heated inert fluid 90 through second heat exchanger 42, unheated cooking liquor 72 is passed through the accessible portion of heat exchanger 72. Heat is transferred between heated inert fluid 90 and unheated cooking liquor 72 through the walls of the heat exchanger creating a preheated cooking liquor 72. Preheated cooking liquor 72 may be introduced into digester 30 by liquor introduction passage 62 during liquor filling operation 14. While passing through heat exchanger 42 heated inert fluid 90 is cooled. In this cooled state inert fluid 90 can be stored in cooled inert fluid reservoir 46 until required for future use in heat exchanger 40. Heat exchange operation 22 is a closed system not requiring the addition of inert fluid 90 once operation 22 is properly functioning.
An additional benefit of operation 22 is that it does not heat any cooking liquor 72 before such is required in operation 14. Thus, cooking liquor 72 need not be stored in expensive pressurized accumulators to avoid spontaneous boiling. Furthermore, cooking liquor 72 can be premeasured before its introduction into heat exchanger 42 by non-pressurized measurement equipment. The use of such non-pressurized measurement equipment is not possible when certain prior art methods and apparatus for preheating cooking liquor 72 are utilized.
Subsequent to displacement operation 18, discharge operation 20 is commenced. During discharge operation 20 cooled spent liquor 74, used to displace heated liquor 74 in displacement operation 18, and digested material 70 are removed from digester 30 by pump 34 or via compressed air (not shown). The mixture of cooled spent liquor 74 and digested material 70 is deposited in blow tank 36. Digested material 70 can then be removed for further processing to remove spent liquor.
Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention. | Apparatus and method for reclaiming heat from batch digesting operations including two fluid-to-fluid exchangers fluidically interconnected to allow the passage of an inert fluid between the heat exchangers. The inert fluid passes through the inaccessible regions of the heat exchangers promoting the exchange of heat between spent digester cooking fluid and fresh digester cooling fluid without scaling, clogging or blocking the inaccessible regions of the heat exchanger. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
Priority Claim
[0001] This application is a Continuation-in-Part (CIP) application and claims the priority benefit of a co-pending application Ser. No. 13/560,247 filed on Jul. 27, 2012. Application Ser. No. 13/560,247 is a Divisional application of Ser. No. 12/551,417 filed on Aug. 31, 2009 and now issued as U.S. Pat. No. 8,252,647. The disclosures made in application Ser. Nos. 12/551,417 and 13/560,247 are hereby incorporated by reference in the present patent application.
FIELD OF THE INVENTION
[0002] This invention generally relates to the methods and configuration for fabricating a trench semiconductor power device, e.g., a DMOS device, and more particularly to the device configurations and methods for fabricating a trench semiconductor power device with variable-thickness gate oxides.
DESCRIPTION OF THE RELATED ART
[0003] A DMOS (Double diffused MOS) transistor is a type of MOSFET (Metal Oxide Semiconductor Field Effect Transistor) that uses two sequential diffusion steps aligned to a common edge to form a channel region of the transistor. DMOS transistors are often implemented as a high voltage, high current device as discrete transistors or as components in power integrated circuits. The advantage of such applications is because the DMOS transistors can provide high current per unit area with a low forward voltage drop.
[0004] One particular type of DMOS transistor is a trench DMOS transistor. In this type of DMOS transistor, the gate is formed in a trench and the channel is formed around the sidewalls of the trench gate and the channel extends from the source towards the drain. The trench gate is lined with a thin oxide layer and filled with polysilicon. Compared with a planar gate DMOS device, the trench DMOS allows less constricted current to flow and thereby provides lower values of specific on-resistance.
[0005] In order to improve the device performance, it is often necessary to allow flexibility in the manufacturing processes to more conveniently fabricate a trench DMOS transistor to adjust the thickness of the trench oxide. The device performance is improved by strategically adjusting the thickness of the gate oxide at different portions inside the trench. Specifically, a thinner gate oxide is preferred at the upper portion of the trench to maximize channel current. By contrast, a thicker gate oxide is desired at the bottom portion of trench to support higher gate-to-drain breakdown voltage.
[0006] U.S. Pat. No. 4,941,026 discloses a vertical channel semiconductor device including an insulated gate electrode having a variable thickness oxide, but does not illustrate how to make such a device.
[0007] U.S. Pat. No. 4,914,058 discloses a process for making a DMOS, including lining a groove with a nitride to etch an inner groove having sidewalls extending through the bottom of the first groove, and lining the inner groove with a dielectric material by oxidation growth to obtain increased thickness of the gate trench dielectric on the sidewalls of the inner groove.
[0008] US publication No. 2008/0310065 discloses a transient voltage suppressing (TVS) circuit with uni-directional blocking and symmetric bi-directional blocking capabilities integrated with an electromagnetic interference (EMI) filter supported on a semiconductor substrate of a first conductivity type. The TVS circuit integrated with the EMI filter further includes a ground terminal disposed on the surface for the symmetric bi-directional blocking structure and at the bottom of the semiconductor substrate for the uni-directional blocking structure and an input and an output terminal disposed on a top surface with at least a Zener diode and a plurality of capacitors disposed in the semiconductor substrate to couple the ground terminal to the input and output terminals with a direct capacitive coupling without an intermediate floating body region. The capacitors are disposed in trenches having an oxide and nitride lining.
[0009] A difficulty arises during polysilicon gate backfill in the trench if a thick oxide is uniformly formed in the trench, producing a higher trench aspect ratio (ratio of depth A to width B) as shown in the prior art. By way of example, FIGS. 1A-1D are cross-sectional views illustrating a prior art method of forming a single gate of the prior art. As shown in FIG. 1A , a trench 106 is formed in a semiconductor layer 102 . A thick oxide 104 is formed on the bottom and sidewalls of the trench 106 which increases its aspect ratio A/B. Polysilicon 108 is in-situ deposited into the trench 106 . Due to the high aspect ratio of the polysilicon deposition, a keyhole 110 tends to form as shown in FIG. 1B . As shown in FIG. 1C , the poly 108 is etched back followed with an isotropic high temperature oxidation (HTO) oxide etch as shown in FIG. 1D , throughout which a portion of the keyhole 110 remains.
[0010] FIG. 2 is a cross-sectional view of a current shield gate trench (SGT) device 200 having a shield poly gate with an Inter-Poly Oxide (IPO) 202 between a first polysilicon structure that forms a gate 204 and a second polysilicon structure 206 that acts as a conductive shield. According to one prior art process, such a structure is formed by a process that involves two etch-back steps (of the polysilicon layer 206 and of the IPO oxide layer 202 ) in forming the IPO 202 between the two polysilicon structures 204 , 206 . Specifically, the polysilicon that forms the shield 206 is deposited in the trench and etched back and HDP oxide is formed on the shield 206 and etched back to make room for deposition of the polysilicon that forms the gate structure 204 . This approach has the drawback of poor IPO thickness controllability across wafer. The IPO thickness depends on two independent and unrelated etch-back steps, which could cause non-uniform and local thinning of IPO thickness due to either under etch-back of Poly or over etch-back of Oxide or a combination of both.
[0011] Also, in the methods discussed above the thickness of the gate trench dielectric on the thick portion of the side wall versus the thickness at the bottom of the trench are linked together. One thickness cannot be altered without affecting the other thickness.
[0012] For the above reasons, there is a need to provide new device configurations and new manufacturing methods for the semiconductor power devices to provide more convenient manufacturing processes to more flexibly adjust the gate oxide thickness along different parts of the trench gates such that the above discussed technical difficulties and limitations can be resolved.
SUMMARY OF THE PRESENT INVENTION
[0013] It is an aspect of the present invention to provide a new and improved device configuration and manufacturing method for providing a semiconductor power device with reduced gate to drain capacitance by adjusting the gate oxide thickness, especially, the thickness of the trench bottoms for trenches with a high aspect ratio.
[0014] Another aspect of the present invention is to provide a new and improved device configuration and manufacturing method for providing a semiconductor power device with reduced gate to drain capacitance for high density transistor cells manufactured with trench gates having high aspect ratios. The improved processes provide simplified and low cost processing steps to fabricate thicker bottom oxide (TBO) trenches for high density transistor cells such that the difficulties and imitations encounter by the conventional manufacturing processes can be resolved to produce improved device performance.
[0015] Briefly in a preferred embodiment this invention discloses a semiconductor power device formed on a semiconductor substrate having a plurality of trench transistor cells each having a trench gate. Each of the trench gates having a thicker bottom oxide (TBO) formed by a Poly REOX process on a polysilicon layer deposited on a bottom surface of the trenches.
[0016] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment, which is illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1A-1D are cross-sectional schematic diagrams illustrating trench gate fabrication according to the prior art.
[0018] FIG. 2 is a cross-sectional schematic diagram of a trench gate including an inter-poly oxide (IPO) between Poly1 and Poly2 of the prior art.
[0019] FIGS. 3A-30 are cross-sectional views illustrating a process of fabricating a trench DMOS with variable-thickness gate trench oxides for single poly gate case according to an embodiment of the present invention.
[0020] FIGS. 4A-4M are cross-sectional views illustrating a process of fabricating a trench DMOS with variable-thickness gate trench oxides for shield poly gate case according to an embodiment of the present invention.
[0021] FIGS. 5A-5F are cross-sectional views illustrating an alternative process of fabricating a trench DMOS with variable-thickness gate trench oxides for shield poly gate case according to an embodiment of the present invention.
[0022] FIGS. 6A to 6F are cross-sectional views illustrating an alternative process of fabricating a trench DMOS with a thicker bottom oxide (TBO) for shield poly gate according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] In embodiments of the present invention as illustrated below, separated processing steps are applied to make the bottom dielectric layer to have a greater thickness than the dielectric layer on the trench sidewalls A thicker bottom dielectric layer reduces the capacitance between the trench gate and the drain of the DMOS transistors.
[0024] FIGS. 3A to 3O are cross-sectional views illustrating the fabrication process steps for manufacturing a trench DMOS with variable-thickness trench gate oxides for a single polysilicon (poly) gate of the type depicted in FIG. 1D according to an embodiment of the present invention.
[0025] As shown in FIG. 3A , a trench 306 of width A is formed in a semiconductor substrate 302 . By way of example and not by way of limitation, the trench 306 is formed by applying a hard mask (not specifically shown), e.g., oxide or nitride, which may then be removed or left in place. Alternatively, the trench 306 may also be formed by applying using a photoresist (PR) mask (not shown). An oxide 304 (or other insulator) is deposited to fill the trench 306 . A chemical mechanical planarization (CMP) is carried out on the oxide 304 followed by an etching back to recess the oxide 304 in the trench 306 as shown in FIG. 3B , leaving an thick block of the oxide 304 filling a substantially portion of the lower part of the trench and exposing the silicon sidewall of upper portion of the trench. In FIG. 3C , a thin oxide 308 is then grown on the exposed sidewall of the trench 306 and on the top surface of the semiconductor substrate 302 . By way of example, and not by way of limitation, the thickness of the thin oxide 308 has a range between about 50 Angstroms to 100 Angstroms.
[0026] FIG. 3D shows a step of depositing a layer of oxide etch resistant material, such as nitride 310 , on top of the oxide 308 and the oxide 304 . In an exemplary embodiment, the nitride 310 may composed of a silicon nitride. Alternatively, the etch resistant layer 310 may compose of a polysilicon layer since the polysilicon layer also has high etch resistance during subsequent oxide etch. The thickness of the nitride 310 determines the bottom oxide sidewall thickness T 1 , which may be between about 500 angstroms and about 5000 angstroms. The nitride 310 is then anisotropically etched back leaving one or more oxide etch resistant spacers 311 on the sidewall of the trench 306 as shown in FIG. 3E . The thick oxide block 304 may then be anisotropically etched to a predetermined thickness T 2 at the bottom of the trench 306 as shown in FIG. 3F . The thickness T 2 may be between about 500 angstroms and about 5000 angstroms. The material such as a nitride material that forms the spacer(s) 311 is preferably resistant to the process used to etch the oxide 304 . The spacer(s) 311 therefore act as an etch mask to define a width A′ of a trench etched into the oxide 304 . In this method, the thicknesses T 1 and T 2 are decoupled, i.e., the thickness T 1 does not depend on the thickness T 2 . In general, it is desirable for T 2 to be greater than T 1 . This may be accomplished more easily if the thicknesses T 1 and T 2 are decoupled. After etching, the spacers 311 and thin oxide 308 may be removed leaving behind a trench with a top portion of width A and a narrower bottom portion of width A′ lined by the remaining portion of oxide 304 as shown in FIG. 3G .
[0027] Gate oxide (or dielectric) 314 may then be grown on top of the semiconductor substrate 302 and on portions of the sidewall of the trench that are not covered by the remaining oxide 304 leaving the top portion with a width A″ that is greater than the width A′ of the bottom portion as shown in FIG. 3H . The trench “aspect ratio” is effectively reduced for easier filling due to the wide trench top portion having width A″. Conductive material, such as doped polysilicon may then be deposited to fill the trench. FIG. 3I shows the polysilicon gap fill 316 in a narrow trench case, e.g., where the width A″ at the top of the trench is about 1.2 microns, where the doped polysilicon can easily fill up the trench completely. The polysilicon 316 is then etched back to form a single gate poly as shown in FIG. 3J . The polysilicon 316 acts with the gate dielectric 314 as the gate electrode for the device.
[0028] Alternatively, FIG. 3K shows the poly gap fill 318 in the wider trench case, e.g., the diameter A″ at the top of the trench is about 3 microns, where poly cannot easily fill up completely, which leaves a gap 319 . A filler material, such as an HDP oxide 320 , may then be deposited to fill the gap 319 and on top of the poly 318 as shown in FIG. 3L . The filler material 320 may then be etched back as shown in FIG. 3M followed by an etching back of the poly 318 and filler material 320 to form a single gate poly 318 as shown in FIG. 3N . The device may be completed by a standard process e.g., involving ion implant into selected portions of the semiconductor substrate 302 to form a body region 330 and source regions 332 , followed by the formation of a thick dielectric layer 360 on top of the surface and open contact holes through dielectric layer 360 for depositing a source metal 370 to electrically connect to the source and body regions as shown in FIG. 3O .
[0029] There are a number of variations on the process described above that are within the scope of embodiments of the present invention. For example, FIGS. 4A-4M illustrate a process to fabricate a trench DMOS with variable-thickness gate trench oxides for a shield poly gate of the type depicted in FIG. 2 according to an embodiment of the present invention. In this embodiment, a composite insulator in the form of an oxide-nitride-oxide (ONO) structure is formed on the sidewall and the bottom of the trench.
[0030] As shown in FIG. 4A , a trench 401 is first formed in a semiconductor substrate 402 . A thin oxide layer 404 is formed on the sidewall of the trench 401 . The thickness of the oxide layer 404 may be between about 50 Angstroms and 200 Angstroms. Nitride 406 is then deposited on top of the oxide layer 404 . Thickness of the nitride layer 406 may be between about 50 Angstroms and 500 Angstroms. The trench 401 may then be filled with oxide 408 , e.g., using LPCVD and high density plasma. The oxide 408 may then be etched back leaving a trench of width A with thick oxide block substantially filling the tower portion of the trench as shown in FIG. 4B .
[0031] A thin oxide layer 410 (e.g., a high temperature oxide (HTO)) may optionally be deposited on top of the oxide 408 , on the sidewall of the trench 401 and on top of the nitride 406 as shown in FIG. 4C . The thickness of the oxide 410 may be between about 50 Angstroms and 500 Angstroms. Conductive material, such as doped polysilicon 412 may then be deposited on top of the oxide 410 (or on the nitride 406 if the oxide 410 is not used). The thickness of the poly 412 depends on the desired bottom oxide sidewall thickness T 1 , which may be between about 500 angstroms and about 5000 angstroms. The poly 412 may then be anisotropically etched back to form the poly spacers 413 as shown in FIG. 4D .
[0032] The oxide 408 is then anisotropically etched to a desired thickness T 2 at the bottom as shown in FIG. 4E . The thickness of T 2 may be between about 500 angstroms and about 5000 angstroms. The polysilicon that forms the spacers 413 is preferably resistant to the etch process used to anisotropically etch the oxide 408 . The thickness of the poly spacer 413 on the sidewalls of the trench determines the thickness T 1 therefore determines the width A″ of a trench etched into the oxide 408 by the anisotropic etch process. After etching, the spacer 413 may be removed as shown in FIG. 4F . The “aspect ratio” is effectively enlarged over the top portion of trench for easier gap fill than if a thick oxide were uniformly formed on the bottom and sidewalls of the trench. It is further noted that the bottom thickness T 2 may be determined independently of the sidewall thickness T 1 by simply varying the duration of the anisotropic etch. In general, it is desirable to form T 2 >T 1 .
[0033] Conductive material, such as polysilicon 414 may be deposited to fill the trench in the oxide 408 as shown in FIG. 4G . The polysilicon 414 may then be etched back to below the top surface of the thick oxide 408 , e.g., by about 1000 Angstroms to 2000 Angstroms to form a gap 416 as shown in FIG. 4H . The remaining polysilicon 414 may act as a shield electrode for the finished device. An insulator, such as poly reoxidation (reox) 418 may be formed to fill the gap 416 as shown in FIG. 4I . The thickness of the poly reoxidation 418 may be about 2000 Angstroms to 3000 Angstroms. As the upper portion and the top surface are covered by nitride layer 406 , no oxidation occurs in this area.
[0034] The optional thin oxide 410 may be etched following by etching off the exposed portions of nitride 406 and oxide 404 as shown in FIG. 4J .
[0035] Gate oxide 420 may then be grown on the sidewall of the trench and on top of the semiconductor substrate 402 as shown in FIG. 4K . Finally, conductive material, such as doped polysilicon 423 may be deposited to fill the top portion of the trench 401 and then etched back to form an active gate as shown in FIG. 4L . The thickness of the gate oxide 420 on the sidewalls of the top portion of the trench 401 determines a width A′ of a top portion of the active gate that is formed by the polysilicon 423 . In general gate oxide 420 is much thinner than T 1 and T 2 , in the range of tens to hundreds of Angstroms. Further the top surface of poly 423 may be recessed below oxide layer 420 .
[0036] The fabrication of the device may continue with standard processes to implant body regions 430 and source regions 432 , followed by the formation of a thick dielectric layer 460 on top of the surface and open contact holes through dielectric layer 460 for depositing a source metal 470 to electrically connect to the source and body regions. The device 400 resulting from this process as shown in FIG. 4M is constructed on a substrate 402 which comprising a lightly doped Epitaxial layer 402 -E overlaying a heavily doped substrate layer 402 -S. In the embodiment shown in FIG. 4M , gate trench 401 extends from the top surface of Epitaxial layer 402 -E through the entire 402 -E layer reach into substrate layer 402 -S. Alternatively the bottom of trench 401 may stop within Epitaxial layer 402 -E without reaching substrate layer 402 -S (not shown). The trench 401 has a poly gate electrode 423 disposed in the upper portion of the trench and a poly shielding electrode 414 disposed in the lower portion of the trench with an inter poly dielectric layer 418 in between insulating the two. To optimize the shielding effect, the bottom shielding electrode may electrically connect through layout arrangement to the source metal layer 470 where a ground potential is usually applied in applications. A thin gate oxide layer 420 insulates the gate electrode from the source and body regions in the upper portion of trench. To minimize the gate to drain capacitance of the device therefore to improve the device switching speed and efficiency, body regions 430 is carefully controlled to diffuse to substantially the bottom of gate electrode 423 to effectively reduce the coupling between gate 423 and drain region disposed below the body regions. The bottom shielding (or source) electrode 414 is surrounded by a thick dielectric layer 424 along the lower sidewalls and the bottom of trench to insulate from the drain region. Preferably the dielectric layer 424 is much thicker than the thin gate oxide layer 420 and has a variable thickness that is T 2 on the trench bottom and T 1 on trench sidewalls, whereas T 1 <T 2 . As shown in FIG. 4M , dielectric layer 424 may further comprise a nitride layer 406 sandwiched between oxide layers 404 and 408 .
[0037] FIGS. 5A to 5F illustrate another alternative process of fabricating a trench DMOS with variable-thickness gate oxides for a shield poly gate of the type depicted in FIG. 2 according to an embodiment of the present invention.
[0038] As shown in FIG. 5A , a trench 501 of width A is formed in a semiconductor substrate 502 . A thin insulator layer such as an oxide layer 504 is grown or deposited on the surfaces of the trench 501 and on the top surface of the semiconductor substrate 502 . A thickness of the oxide 504 may be about 450 Angstroms. A layer of material such as a nitride 506 is then deposited, e.g., to a thickness between about 50 Angstroms and about 500 angstroms, on top of the oxide 504 followed by deposition of another oxide, e.g., HTO (high temperature oxide) oxide 508 , on top of the nitride 506 . The thickness of the nitride 506 may be about 100 Angstroms and the thickness of the HTO oxide 508 may be about 800 Angstroms. In this example, the combined thickness of the oxide 504 , nitride 506 and HTO oxide 508 determines a width A′ of a narrowed trench 501 . In-situ doped polysilicon 510 may then be deposited into the narrowed trench 501 and then etched back to a predetermined thickness of, e.g., between about 500 angstroms and about 2 microns to form a shield electrode. Arsenic may be optionally implanted into at least an upper portion of the polysilicon 510 remaining in the trench to enhance a re-oxidation rate of the polysilicon in a subsequent oxidation step.
[0039] Specifically, as shown in FIG. 5B , an insulator such as a poly reox layer 512 may be formed by the oxidation of a top portion of the polysilicon 510 . The thickness of the poly reox 512 may be about 3000 Angstroms. The nitride layer 506 ensures that oxide layer 512 is only formed on top of the polysilicon 510 . The HTO oxide 508 may then be removed by an etch process that stops on the nitride layer 506 as shown in FIG. 5C . This protects the underlying oxide 504 from the etch process that removes the thicker HTO oxide 508 . The nitride 506 may then be removed leaving an upper portion of the trench with a width A″ that is wider than A′ as shown in FIG. 5D . In this example, the width A″ of the upper portion is determined by the thickness of the thin oxide 504 on the sidewalls of the trench. The thickness uniformity of the inter-poly oxide 512 across the wafer may be improved by use of a thermal oxide. This is because a thermal oxide process oxidizes the top portion of the poly in the trench as opposed to depositing and etching back the oxide on the poly in the trench.
[0040] The oxide can be preserved during the nitride removal process due to high nitride to oxide wet etch selectivity.
[0041] Gate oxide 514 may then be formed (e.g., by growth or deposition) on the thin oxide 504 as shown in FIG. 5E . The thickness of the gate oxide 514 may be about 450 Angstroms. Alternatively, the thin oxide 504 may first be removed before growing the gate oxide 514 . Finally, a second conductive material, such as doped polysilicon 516 , may be deposited into the remaining portions of the trench over the gate oxide 514 . The polysilicon 516 may be etched back to form a shield gate structure, in which the polysilicon 516 is the gate electrode and the polysilicon 510 is the shield electrode.
[0042] It should be clear to those skilled in the art that in the embodiments described above, only a single mask—an initial mask used to define the gate trenches is required in the formation of the gate trench, gate trench oxides, gate poly, and shield poly.
[0043] FIGS. 6A-6F are cross-sectional views illustrating the fabrication process steps for manufacturing a trench DMOS with variable-thickness trench gate oxides according to an embodiment of the present invention.
[0044] As shown in FIG. 6A , an ONO (oxide-nitride-oxide) hard mask 601 is formed on top of a semiconductor substrate 602 , which includes a bottom oxide layer 601 - 1 , a middle nitride layer 601 - 2 and a top oxide layer 601 - 3 . By way of example and not by way of limitation, the bottom oxide layer 601 - 1 may be approximately 200 angstroms, the nitride layer 601 - 2 may be 3500 angstroms, and the top upper oxide layer 601 - 3 may be 1400 angstroms. In FIG. 6B , a trench mask (not shown) is applied to carry out a hard mask etch and silicon etch to form a trench 606 in the semiconductor substrate 602 . In an exemplary embodiment, the trench etching process is carried out with a ratio of depth B, including the thickness of the hard mask 601 , to width A, i.e., aspect ratio, B/A>3. A trench etching process may first comprise an etchant to remove the ONO hard mask 601 , in order to expose the top surface of the semiconductor substrate 602 and a second etching process to form the trench 606 . Then a thin gate oxide layer (or other insulator) 608 is grown along the sidewalls and on the bottom surface of the trench 606 . In an exemplary embodiment, the thickness of the thin oxide 608 has a range between about 100 Angstroms to 600 Angstroms.
[0045] FIG. 6C shows a step of depositing a thin layer of polysilicon layer 610 over the gate oxide layer 608 that may have a thickness ranging between 100 to 800 Angstroms on the sidewalls and the bottom surface of the trench 606 . Then a nitride layer 612 is deposited over the polysilicon layer 610 . In an exemplary embodiment, the nitride layer 612 has a thickness ranging between 50 to 300 Angstroms. The nitride layer 612 on the bottom surface of the trench is removed with an etching process, for example a nitride dry etch process, to form a nitride spacer 612 along the sidewalls of the trench 606 . In FIG. 6D , the manufacturing process proceeds with a polysilicon re-oxidation process, i.e., poly REOX, to oxidize the exposed bottom polysilicon layer 610 to form a bottom poly-REOX oxide layer that combines with the gate oxide layer 608 forming a thick bottom oxide layer 611 on the bottom surface of the trench 606 .
[0046] In FIG. 6E , the nitride spacer 612 on the sidewalls of the trench 602 is removed by a wet dip and then the trench 606 is filled with a conductive material such as a polysilicon layer 616 for example through chemical vapor deposition (CVD). Excess polysilicon layer 616 is removed and planarized with the surface of the hard mask 601 by a chemical-mechanical planarization (CMP) process. In FIG. 6F , an poly etch back process is carried out to etch back the polysilicon layer 612 to the surface of the semiconductor substrate 602 , for example with a dry etching process, to generate a poly-recess that is then filled with an oxide layer 618 . Excess oxide layer 618 on top of the polysilicon layer 616 and the top oxide layer 601 - 3 of the hard mask 601 is then planarized by a CMP process to the surface of the nitride layer 601 - 2 of the hard mask 601 . The device may be completed by a standard process to form a trench MOSFET that has a thick bottom oxide (TBO).
[0047] Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. For these embodiments, it is possible to use various alternatives, modifications and equivalents. Therefore, the scope of the present invention should be determined not with reference to the above description but should, instead, be determined with reference to the appended claims, along with their full scope of equivalents. Any feature, whether preferred or not, may be combined with any other feature, whether preferred or not. In the claims that follow, the indefinite article “A”, or “An” refers to a quantity of one or more of the item following the article, except where expressly stated otherwise. The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for.” | Semiconductor device fabrication method and devices are disclosed. The semiconductor power device is formed on a semiconductor substrate having a plurality of trench transistor cells each having a trench gate. Each of the trench gates having a thicker bottom oxide (TBO) formed by a REOX process on a polysilicon layer deposited on a bottom surface of the trenches. | 7 |
This is a division of application Ser. No. 095,506 filed on Sept. 10, 1987 now U.S. Pat. No. 4,842,510.
SUMMARY OF THE INVENTION
The present invention relates generally to electronic controls for burners, furnaces and the like, and more particularly to an integrated control for such burners in the illustrative environment of a gas-fired furnace.
Older furnace control systems have taken a modular approach with separate controls for functions such as gas ignition, a blower fan, the gas valve or valves, induced draft sensing, and thermostat setback operations. The integrated furnace control has taken many of the furnace control functions and combined them into one main control module and may also include such features as a thermostat setback function. The combining of all these functions into one complete module has made the system more cost effective than using separate components, allows many additional features, and provides a safer control.
Integrated furnace control units, or units having at least some of the attributes of integrated control systems have also been known for some time. Illustrative of these known arrangements are the following U.S. Patents. U.S. Pat. No. 4,402,663 which provides for the detection of a flameout or low gas line pressure and suggests indicating the status of other possible malfunctions within the system. U.S. Pat. No. 3,781,161 which pretests a plurality of components by mimicing the start-up and shut-down processes. U.S. Pat. No. 4,444,551 which provides for a flame detector and light emitting diodes for visual indicators of a malfunction. This patented arrangement also allows three retrys or attempts at ignition and then shuts the system down. U.S. Pat. No. 4,295,129 which monitors main and pilot fuel flows and shuts down in response to an abnormal condition. U.S. Pat. No. 3,576,556 which discloses a flame detector circuit along with circuitry for pretesting the detector circuitry for component malfunctions. Finally, U.S. Pat. No. 4,243,372 teaches an arrangement for checking to see that an air flow sensor is operating properly as well as a purge cycle to clear the combustion chamber of accumulated gas prior to an ignition attempt. The air flow sensor in this patented arrangement has a single set of contacts which are checked to see that they are open immediately upon energization of the fan and prior to the air flow being established.
These prior attempts to integrate furnace control typically fail to adequately check for false information and, in particular, fail to combine testing of safety sensors for false indications both while the sensor should be detecting a particular burner parameter and when the sensor should not be sensing that parameter, and are generally wanting in versatility.
In copending application Ser. No. 095,508 assigned to the assignee of the present application, entitled INTEGRATED FURNACE CONTROL AND CONTROL SELF TEST in the names of Mierzwinski, Grunden and Youtz filed on even date herewith now U.S. Pat. No. 4,872,828, there is disclosed a companion integrated furnace control system sharing some features with that disclosed herein and the entire disclosure thereof is specifically incorporated herein by reference.
Among the several objects of the present invention may be noted the provision of a versatile and economical integrated furnace control system; the provision of a furnace control system which interrogates certain furnace components and checks for receipt back of a proper response; the provision of a furnace control system in accordance with the previous object which issues a safety interrupt and lockout command to preclude further furnace operation in a potentially unsafe manner in the event of either an improper response to the interrogation or the receipt of a response in the absence of any interrogation; and the provision of an integrated furnace control system which confirms proper operation of a variety of furnace components both prior to furnace ignition and during furnace operation. These as well as other objects and advantageous features of the present invention will be in part apparent and in part pointed out hereinafter.
In general, an integrated burner control for a gas burner of the type having at least one gas valve control relay operable upon command from the integrated burner control to open a gas valve and supply gas to a burner combustion chamber, an inducer fan for supplying air to the burner combustion chamber, and an air flow sensor for sensing air flow caused by operation of the inducer fan has an arrangement operable upon command for sending an interrogation signal to the air flow sensor. The sensor selectively provides a return signal to the integrated burner control indicative of the presence of adequate air flow or air pressure and the gas valve control relay is enabled only upon receipt of the return signal. The air pressure sensor is monitored during burner operation, and burner operation is interrupted and the gas valve closed upon an indication of inadequate air flow. In particular, the present inventive arrangement checks for a change in the state of the air sensing switch between the time before the inducer fan is enabled and after it is enabled, and will proceed with an attempt at ignition only if the appropriate change in state is sensed.
Also in general, and in one form of the invention, an integrated burner control for a gas burner of the type having at least one gas valve control relay operable upon command from the integrated burner control to open a gas valve and supply gas to a burner combustion chamber, and an inducer fan for supplying air to the burner combustion chamber has an air flow sensor for sensing air flow caused by operation of the inducer fan, the sensor having first contacts which are open when air flow is inadequate for proper burner operation and closed when the air flow is adequate, and second contacts which are open when the air flow is adequate and closed when the air flow is inadequate. The control includes an arrangement for sending a signal to the sensor and responsive to a reply signal from the sensor indicating the second contacts are closed for enabling the inducer fan preparatory to burner ignition.
Still further in general, an integrated burner control for a gas burner of the type having at least one gas valve control relay operable upon command from the integrated burner control to open a gas valve and supply gas to a burner combustion chamber has a flame sensor for sensing for the presence of a flame in the combusion chamber, and an arrangement for sending a sequence of pulses to the flame sensor and for receiving back from the flame sensor the same sequence of pulses indicating the presence of a flame. The arrangement is responsive to the reception from the flame sensor of a sequence of pulses in the absence of any sequence having been sent for providing a fault indication and precluding ignition attempts. The arrangement is also responsive to the sending of the sequence to the flame sensor and lack of reception back of the same sequence of pulses for disabling the gas valve control relay and closing the gas valve. The control is also adapted to send the sequence of pulses to the flame sensor when no flame is present and, in response to the reception from the flame sensor of a sequence of pulses, to provide a fault indication and preclude ignition attempts.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1A-1C, when joined, form a schematic diagram of an integrated furnace control illustrating the present invention in one form;
FIG. 2 is a schematic diagram illustrating a control according to one form of the invention; and
FIGS. 3-9 are system logic flow diagrams for the control systems of FIGS. 1 and 2.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawing.
The exemplifications set out herein illustrate a preferred embodiment of the invention in one form thereof and such exemplifications are not to be construed as limiting the scope of the disclosure or the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 2, an integrated burner control for a gas burner is illustrated. The system includes a gas valve control relay 11 which is operable upon command from the integrated burner control microprocessor 13 to open a gas valve and supply gas to a burner combustion chamber. The microprocessor issues a command to open the gas valve on line 15 which passes through driver transistor 17 to energize the relay coil 19 closing normally open contacts 21 and opening the normally closed contacts 23. The furnace or burner includes an inducer fan for supplying air to the burner combustion chamber and a pressure sensor of a conventional diaphragm type for sensing air flow caused by operation of the inducer fan. The sensor includes a switch 25 having first contacts 27 and 29 which are open when air flow is inadequate for proper burner operation and closed when the air flow is adequate, as well as second contacts 29 and 31 which are open when the air flow is adequate and closed when the air flow is inadequate. A signal in the form of the 24 volt alternating current for opening and closing the gas valve is sent to the switch 25 of the sensor and the microprocessor is responsive to a reply signal from the sensor on line 33 indicating the second contacts are closed for enabling the inducer fan preparatory to burner ignition. The inducer fan is enabled by a signal on line 35 which, by way of the driver transistor 37, energizes relay coil 39 and closes contacts 41.
Subsequent to the enabling of the inducer fan, a signal (which again is the presence of the 24 volt alternating current signal on line 43 in the embodiment illustrated in FIG. 2) is sent to the sensor switch 25 and in response to a reply signal from the sensor by way of normally closed contacts 23 and Schmitt trigger 45 indicating the first contacts are closed, the microprocessor issues a command on line 47 to enable relay 49 for initiating burner ignition. In the illustrated embodiment, actuation of the relay 49 activates a hot surface igniter. After a preset time adequate to allow the hot surface to reach an adequate combustion temperature, the microprocessor issues a command on line 15 to enable the gas valve. The sequence of events as thus far described is illustrated in FIG. 8. During burner operation, the status of the switch 25, and, therefore, the presence of an adequate air flow, is monitored because the gas valve enabling current flows through the contacts 27 and 29. Should the switch status change, the voltage supply is interrupted thereby disabling burner operation and closing the gas valve. Thus, an indication that the first contacts are open shuts down the burner.
The burner control system may also include a flame sensor in the form of a probe which forms part of a flame rectification type flame sensor for sensing for the presence of a flame in the combustion chamber. During normal operation, the microprocessor sends a sequence of pulses to the flame sensor and receives back from the flame sensor the same sequence of pulses on line 51 indicating the presence of a flame. The microprocessor is also adapted to be responsive, for example, prior to the flame having been established, to the reception from the flame sensor of a sequence of pulses in the absence of any sequence having been sent for providing a fault indication and precluding ignition attempts. In the event of the sending of the sequence to the flame sensor and lack of reception back of the same sequence of pulses, the microprocessor recognizes this as a dangerous lack of flame condition and disables the gas valve control relay thus closing the gas valve. The microprocessor is also capable of sending the sequence of pulses to the flame sensor when no flame is present and, in response to the reception from the flame sensor of a sequence of pulses, providing a fault indication and precluding any ignition attempts. This flame sensing sequence is illustrated in FIG. 9 and will be more completely understood from the subsequent discussion of an analogous operation in the circuit of FIG. 1.
In FIG. 1, the power supply portion of the circuit receives a 24 volt alternating current as its call for heat indication from a thermostat on line 61 which appears by way of fuse 63 on line 55 and further provides a 34 volt direct current supply on line 57 and a 5 volt direct current supply on line 59. The power supply 53 of FIG. 2 was not discussed, but its operation is conventional. The applied thermostat voltage is half-wave rectified by diode 65 and the ripple reduced by capacitor 67. Resistor 69 discharges capacitor 67 when the call for heat is removed. The 5 volt line 59 is regulated by Zener diode 71 and capacitor 73 with excess voltage drop occurring across resistor 75 and Zener diode 77. If the input terminal 61 is being controlled by an electronic thermostat, this last Zener diode and a resistor 79 ensure that the microprocessor 81 is not powered by any leakage current when the system is in the off state. Such an off-state voltage will be pulled down to about 7 volts by the resistive connection to ground and the approximately 9.1 volt Zener diode 77 prevents any voltage from appearing on line 59. The capacitor 83 and metal oxide varistor 85 in parallel with resistor 79 and capacitor 87 are present to reduce any noise in the power supply voltages.
The 24 volt alternating current call for heat signal on terminal 61 provides a 60 Hertz interrupt signal to the microprocessor 81 by turning on transistor 89 during the positive half-cycle. Resistor 91 limits the base current in transistor 89 and the diode 93 prevents excessive reverse bias on the base of that transistor during the negative half-cycle. During the negative half-cycle, the resistor 95 pulls the microprocessor input up to the 5 volt supply level and transistor 89 shorts that input during positive half-cycles. The resistor 97 and capacitor 99 delay the interrupt slightly to allow similar circuitry in the gas valve sensing circuit to settle before the microprocessor 81 reads it.
A pressure switch, which confirms proper operation of the air flow inducer fan, closes when the inducer motor has created sufficient draft to activate it. The pressure switch for the circuit of FIG. 1 differs from switch 25 illustrated in FIG. 2 in that only a single set of contacts is used. When the pressure switch closes, a connection is made between terminals 101 and 103 supplying the 34 volts to terminal 101. Capacitor 105 reduces noise. Switch closure is transmitted to the microprocessor when transistor 107 conducts. Resistor 111 functions to limit the base current to transistor 107 and resistor 113 grounds the base of transistor 107 when the air pressure switch is open to ensure that the transistor is off. When the switch is closed, the transistor conducts, grounding the pressure sensor input line 115. When the switch is open, the transistor 107 is nonconducting and resistor 119 pulls the voltage on line 115 up to the 5 volt level.
The flame sensing method used is flame rectification. The microprocessor may receive flame sensing signals from a remote sensor or from the hot surface igniter element. Jumper 117 is present when the hot surface igniter is used. The numerous other unnumbered jumpers depicted in FIG. 1 are present to allow use of the same basic circuit in different versions with a minimum of changes. For example, the system may be used in an environment where an inducer fan and sensor are not required in the operation of the burner. A 24 volt alternating current signal is applied through capacitor 119, and resistors 121 and 123. If the jumper 117 is not present, a separate probe is connected to terminal 125. The capacitor 119 acts as an isolator allowing a negative direct current voltage to appear across capacitor 127 and resistor 129 when a flame is present. The flame has the characteristics of a leaky diode thereby causing the rectification. Capacitor 127 reduces the ripple in the rectified direct current while resistor 131 matches the impedance of the flame to the rest of the circuit. Resistors 121 and 123 provide isolation between the low voltage portion of the circuit and the 120 volt alternating current that is present when jumper 117 is installed and the igniter relay 133 is enabled. Resistor 129 discharges capacitor 127 when the flame is removed. The presence of a flame is sensed by the microprocessor when gate 135 is enabled to discharge capacitor 137 through the base of transistor 139 thereby applying a pulse to line 141. The gate 135 may, for example, be a programmable unijunction transistor or PUT. Depletion of the charge on capacitor 137 is limited by resistor 143. The gate 135 is turned on by a 30 hertz square wave signal from the microprocessor 81 on line 145 which is passed through the capacitor 147 as a spike at the transitions in the square wave. Each negative spike turns on the gate 135 for about 40 microseconds. The gate terminal 149 of gate 135 is pulled to ground between pulses by resistor 151. When a flame is present, there is a negative two volts across gate 135. Resistor 153 functions to keep transistor 139 off between pulses while resistor 155 pulls up the input to the microprocessor on line 141 to the 5 volt level. The pulses to gate 135 turn on the transistor 139 for about 17 microseconds. The microprocessor samples the input on line 141 before and during the pulses to make sure that component failure is not falsely recognized as a flame present signal.
The gas valve relay 157 is sensed to determine if the contacts 159 have welded or stuck in the closed position. Line 161 has a 60 Hertz square wave on if the contacts 159 are closed and a 5 volt direct current bias when the contacts are open. The sense circuit operates much the same as the interrupt discussed earlier in conjunction with the 24 volt alternating voltage call for heat signal, but without the time delay provided by the resistor 97-capacitor 99 circuit. Resistor 163 limits base current in transistor 165 during the positive half-cycle of the square wave and when that transistor is conducting and line 161 is at zero volts. Diode 167 prevents excess emitter-base voltage during the negative half-cycle when the transistor is off and the microprocessor input on line 161 is at 5 volts as supplied by resistor 169. Resistor 171 tends to reduce noise going into the microprocessor.
If the gas valve relay contacts 159 do weld in a closed position, the fuse 63 which provides power to the gas valve through those closed contacts will be blown, thus closing the gas valve in a fail-safe manner as described in greater detail in copending application Ser. No. 095,507 assigned to the assignee of the present invention, entitled GAS VALVE RELAY REDUNDANT SAFETY and filed in the name of Stephen E. Youtz on even date herewith now U.S. Pat. No. 4,828,484. This is accomplished by a microprocessor output of 5 volts on line 173 which triggers the gate of a silicon controlled rectifier 175. When on, the silicon controlled rectifier draws current from the source terminal 61 through the fuse 63 to ground which exceeds the fuse limit blowing the fuse. Gate current from the microprocessor is limited by resistor 177. Resistor 179 keeps the gate at ground potential in the absence of a signal on line 173. Capacitor 181 is present to reduce noise induced triggering.
Ignition of the burner begins when the microprocessor issues the command in the form of a 5 volt output on line 183 actuating relay 133 and applying a 120 volt alternating current to the hot surface igniter. The command turns on field effect transistor 185 supplying current to the relay coil. Resistor 187 is present to act as a voltage divider in circuit with the coil to limit the power dissipated by the coil. When the relay is intended to be off, there is no voltage on line 183 and the resistor 189 pulls the gate of 185 to ground. As an aid in enabling the relay 133, capacitor 191 is charged up to the 34 volt level by way of diode 193 with that diode helping to maintain the voltage level during low points caused by ripple. Resistor 195 drains the charge on capacitor 191 after a demand for heat voltage on line 61 has been removed to prevent any spurious enabling of the relay. Diode 197 reduces the kickback voltage which appears when 185 is turned off thus protecting the field effect transistor 185. Such use of diodes across relay coils is commonplace throughout this and its companion applications. Relay 133 has two sets of contacts, i.e., it is a DPST relay, to facilitate use of the hot surface igniter as the flame sensing element by isolating that igniter from the 120 volt source when it is not energized. The igniter element is connected to terminals 199 and 201.
The circuit for enabling the gas valve relay 157 uses a 30 to 2000 Hertz alternating current signal from the microprocessor on line 207 which alternately turns field effect transistor 203 on and off. A 1700 Hertz signal was employed in one specific implementation. This circuit is described in greater detail in copending application Ser. No. 095,507 assigned to the assignee of the present application, entitled FAIL SAFE GAS VALVE DRIVE CIRCUIT and filed in the names of Victor F. Scheele and Stephen E. Youtz on even date herewith, now U.S. Pat. No. 4,865,538. This signal on line 207 is passed through an ac-dc converter or rectifier including capacitor 209, diode 211, diode 213 and capacitor 215 to also turn field effect transistor 205 on. This provides a volt bias in the range of 4 to 20 volts between the source and gate of 205 when the alternating current signal is present on line 207. Resistor 217 is present to turn off 205 when the signal on line 207 is removed. The capacitors 209 and 215 are selected so that the signal on line 207 must be at least 600 Hertz to enable 205. Diodes 221 and 223, and capacitors 219 and 225 provide another ac-dc converter for supplying negative 12 volts to the coil of relay 157 and the Zener diode 227 functions to both regulate this voltage and to limit the power dissipated by the coil when it is turned off. Current flow through the Zener diode 227 is limited by resistor 229. Resistor 231 ensures that 203 is off when the microprocessor is not driving its gate and the current through it when it is on is limited by resistor 233. The values of resistor 233 and capacitors 219 and 225 are selected to provide efficient transfer of power to the coil of relay 157. The gas valve is connected to terminals 235 and 237, the latter being the furnace chassis.
The inducer fan relay 239 when enabled, supplies 120 volt alternating current to the fan motor connected to terminal 241. The microprocessor enables this relay 239 by providing a 5 volt signal on line 243 which turns on transistor 245. Resistor 247 limits base current in that transistor and resistor 249 ensures that it is off when the signal on line 243 is absent. The fan relay circuitry functions in much the same way as that associated with the igniter relay 133. The capacitor 251 charges up to the peak voltage on line 57 and that peak voltage is maintained during ripple by diode 253. Resistor 255 functions as a voltage divider with the coil of relay 239 to limit the power dissipated by that coil while it is enabled. Resistor 257 discharges the capacitor when 245 is off to make sure that the relay is not enabled by a spurious signal.
The microprocessor 81 provides the timing for each of the functions of the integrated control while monitoring the appropriate inputs for unsafe conditions. Resistor 259 is the oscillator resistor setting the frequency of processor operation at about 2 MHz. Resistor 261 and capacitor 263 provide a 20 microsecond delay to the reset input of the microprocessor to allow for oscillator stabilization. Resistors 265 and 267 are present to pull down unused processor inputs while resistor 269 pulls up the active low test input to the processor which is used to speed up timing sequences during factory testing. The resistors 271 and 273 are used in the alternative to select either a 4 or a 6 second ignition attempt interval.
In one particular implementation of the present invention, an eight bit, MC68HCO5C4 microprocessor having four kilobytes capacity, three tri-state programmable ports and an additional output port was used.
The algorithm for processor operation is illustrated in the flow charts of FIGS. 3-7. Reference to model 10 and model 20 in these flow charts corresponds to the positioning of the jumpers of FIG. 1 and to the particular installation. The jumpers positioned as shown in FIG. 1 correspond to the model 20. The flame sensing circuitry is designed so that any single component failure will prevent the microprocessor from receiving a signal which indicates a detected flame. The flame sense circuit is checked during a purge period for flame and if such a flame is sensed, the control will lock out. Flame failure during steady state burner operation will cause the control to execute a re-ignition cycle with a maximum of three attempts to ignite during each ignition cycle and a maximum of five re-ignition cycles for each call for heat. Each attempt for ignition begins with a call for heat followed shortly by activation of the inducer fan and then a test to see that the inducer fan is providing the required draft. If adequate draft is sensed, the hot surface igniter is energized and after sufficient time for the surface to reach ignition temperature, the gas valve is enabled.
When the thermostat closes and applies the 24 volt signal to terminal 61, the control does a power up reset which turns all outputs off and initializes all inputs. This reset also occurs after a loss of power. The 60 Hertz input on line 275 from which primary timing is clocked is also checked before the control begins its operating sequence.
In FIG. 4, the inducer pressure is sensed both before and after the inducer fan is turned on. This gives an opportunity to be sure the status of the pressure switch has changed and to proceed with the ignition attempt only if a change in switch state has been recognized. Upon a request for heat, the inducer motor is turned on and remains on until either the thermostat demand has been satisfied or a purge is required prior to another ignition attempt. The inducer motor is turned off between ignition attempts to allow the pressure switch to open and the microprocessor will check for switch operation before the inducer is turned on again.
The igniter is timed using three separate timers, one primary timer and two secondary timers. The redundant safety features of these timers is discussed in greater detail in copending application Ser. No. 095,505 assigned to the assignee of the present invention, entitled CONTROL SYSTEM WITH TIMER REDUNDANCY and filed in the name of Stephen E. Youtz on even date herewith, now U.S. Pat. No. 4,832,594. The main timer is a down counter and is referenced to the line synchronization interrupt line 275. The first backup timer is also a down counter referenced to this same line, however, it is offset from the primary timer by one second. The second backup timer is an up counter referenced to the microprocessor internal clock. Timing is considered valid when the backup timers are within certain windows relative to the primary timer. If the timers are out of synchronization, the control goes into a lockout mode. The purge timer may operate in this same redundant manner.
The gas valve relay 157 and the igniter relay 133 are both energized during a trial for ignition. There is no sensing for a flame during this sequence. The igniter is turned off two seconds after the gas valve comes on during a try for ignition. The flame is otherwise checked thirty times per second during operation. If an ignition attempt is unsuccessful, the control will make another attempt up to a maximum of three attempts and flame failure during steady state operation will cause a re-ignition attempt.
From the foregoing disclosure, those skilled in the art will devise many adaptations, modifications and uses for the present invention beyond those herein disclosed yet within the scope of the present invention as set forth in the claims which follow. | An integrated electronic control arrangement is disclosed in the illustrative environment of burner such as in a gas-fired furnace. The control incorporates a self-test feature which shuts down the furnace in the event of any one of a number of possible sensed faults. Self-testing occurs automatically before an attempt at ignition and during furnace operation. Proper functioning of the sensor which senses for induced air flow through the burner combustion chamber is tested prior to enabling a fan which causes that induced air flow. Air flow is confirmed by sending to and receiving back from the sensor a sequence of pulses. Should air flow not be sensed during a combustion period, combustion is terminated. A flame sensor is provided for determining the presence of a flame in the combustion chamber. During times when a flame should be present, pulse sequences are sent to and received back from the flame sensor to confirm that a flame is present. When it is known that no flame is present, if sent pulses are received back, a fault has occurred and the system locks out. If, at any time, any pulses are received when none were sent the system also locks out. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrically operated toothbrushes, and more particularly to an improved electrically operated toothbrush having multiple rotary brushes for simultaneously cleaning and massaging multiple tooth and gum surfaces.
2. Description of the Prior Art
Various devices for cleaning and treating the oral cavity have been proposed in which one or more power driven rotary brushes are provided for massaging the gums and cleaning the teeth. Many of these prior art devices have employed a brushing action transversely of the teeth, or generally parallel to the gum line, although it has long been recognized that a brushing action longitudinally of the teeth and away from the gum line is preferred to the exclusive use of a transverse brushing action.
It is also known, for example from U.S. Pat. No. 2,628,377, to provide a driven rotary toothbrush assembly wherein three rotary brushes are mounted for rotation about parallel axes in position to simultaneously engage inner, outer, and bite surfaces of the teeth, with a gear drive arrangement being provided to rotate the brushes engaging the side tooth surfaces in a direction to brush each surface longitudinally of the teeth and away from the gums. However, the toothbrush disclosed in this patent is very bulky and difficult to maneuver in the mouth. Further, the apparatus does not readily lend itself to use by a plurality of persons in that the brushes and brush supports require tools for removal and the brushes are each supported for separate replacement.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide an improved driven rotary toothbrush assembly which will rapidly and effectively clean multiple surfaces of teeth in an efficient and hygenic manner.
Another object of the invention is to provide an improved power driven multiple brush rotary toothbrush apparatus which may readily be used by a plurality of persons by the attachment of personal brush heads and support stems.
Another object of the invention is to provide such a multiple brush power driven rotary toothbrush assembly employing a plurality of rotary brushes rotatably supported in a brush head which is releasably mounted on a support stem which, in turn, is readily removably from a sealed handle containing a drive motor.
In the attainment of the foregoing and other objects and advantages of the invention, an important feature resides in providing a rotary drive motor mounted within a sealed housing providing a handle for the toothbrush assembly with the motor support housing having one end adapted to receive and frictionally retain one end of a removable, elongated brush head support system. The rotary motor drives a gear train which, in turn, drives three shafts each having one end projecting through one end wall of the housing to engage and drive suitable coupling means, on the ends of three elongated flexible drive shafts mounted on the support stem when the stem is mounted on the end of the motor housing. The flexible shafts have their other ends journaled for rotation in bearings on the distal end of the support stem, and coupling means on the flexible shafts are adapted to cooperate with and drive the rotary brushes supported in a detachable brush head. Cooperating bracket means on the end of the support stem and the brush head mounts the brush head in position to accurately align and engage the coupling means on the flexible shafts with rotary brushes when the brush head is mounted on the stem.
The arrangement just described permits easy snap-on mounting and dismounting of the brush head on the support stem whereby the brushes may be readily changed. At the same time, the snap-on mounting of the support stem enables the apparatus to be used by a plurality of people each utilizing a personal support stem and brush head. The mounting of the brushes in the support head and the arrangement of the gears in the gear train is such that two of the rotary brushes may be used to simultaneously brush the inner and outer surfaces of a person's teeth in a direction longitudinally of the teeth away from the gum while the third brush engages and brushes the end or bite surfaces of the teeth. Preferably the brush head is disposed at a slight angle with respect to the longitudinal axis of the motor housing and drive shaft support stem, and the support stem and brush head are designed to facilitate use of the apparatus without interference from or contact with teeth.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent from the detailed description contained hereinbelow, taken in conjunction with the drawings, in which:
FIG. 1 is a side elevation view, partially in section, of a toothbrush according to the present invention;
FIG. 2 is a top plan view of a rotary brush head used on the apparatus shown in FIG. 1;
FIG. 3 is a bottom plan view of the brush head shown in FIG. 2;
FIG. 4 is an exploded perspective view showing the manner of assembling the brush head and support stem of the toothbrush shown in FIG. 1;
FIG. 5 is a side elevation view of the brush head shown in FIGS. 2 and 3;
FIG. 6 is an end view schematically illustrating the apparatus being employed to brush teeth;
FIG. 7 is an end view of the apparatus being employed to simultaneously clean the corresponding surfaces of both upper and lower teeth and illustrating the brushing action away from the gums;
FIG. 8 is an enlarged fragmentary sectional view taken on line 8--8 of FIG. 1;
FIG. 9 is a further enlarged sectional view taken on line 9--9 of FIG. 8; and
FIG. 10 is an enlarged sectional view taken on line 10--10 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, a rotary toothbrush assembly according to the present invention is designated generally by the reference numeral 10 in FIG. 1, and includes an elongated, generally cylindrical molded handle and motor housing 12 having a hollow interior 14 within which is mounted a small electric motor 16. Motor 16 may be battery operated, in which case the batteries would be mounted in the motor cavity 14 of the handle, but preferably an external source of electric current is supplied as through the cord 18 extending out of the rear sealed end of the handle.
A support wall 20 extends transversely of the housing 12, in inwardly spaced relation to the forward end thereof. Wall 20 may be integrally formed with the sidewalls of the housing 12 or, alternatively, may be separately formed as a disc and subsequently rigidly fixed in position within the hollow interior 14 as by bonding. A second transversely extending wall 22 is mounted on and closes the open forward end of housing 12, with wall 22 being rigidly fixed in parallel spaced relation relative to wall 20 to provide a gear chamber 24. If desired, the transversely extending wall 22 can be formed as the end wall of a shallow cylindrical cup, with the sidewalls 26 of the cup acting to accurately align and spaced walls 20 and 22 with respect to one another.
As best seen in FIG. 8, motor 16 has its shaft 28 extending through and journaled in openings in the walls 20, 22, and a small spur gear 30 is mounted on shaft 28 within the gear chamber 24 to be driven by the motor 16. A pair of stub shafts 32, 34 are also journaled in openings in the walls 20, 22 in spaced parallel relation to the motor shaft 28, one on each side thereof as viewed in FIG. 10, and a pair of gears 36, 38 are mounted one on each stub shaft for rotation therewith. Gears 36, 38 mesh with gear 30 so that shafts 32 and 34 are each rotated in a direction opposite to that of shaft 28.
An elongate brush support stem 40 has one end mounted on the forward end of motor housing 12 and is adapted to support a rotary brush head 42 on its other end. The support stem includes an elongated central beam portion 44 having an integrally formed cup-shaped portion 45 on one end for mounting on the motor housing. The cup-shaped portion includes an annular skirt 46 adapted to be telescoped over and frictionally retained on the forward end of the cylindrical housing 12, with a generally cone-shaped transition wall 48 joining the beam 44 and skirt 46. The opposite end of the beam 44 has integrally formed thereon a pair of laterally spaced, downwardly and outwardly diverging legs 50, 52 (see FIG. 4) and a longitudinally extending, generally rectangular slot 54 formed in an enlarged section 56 on its top surface.
Three flexible drive shafts 58, 60 and 62 are rotatably supported on the support stem 40, with the respective flexible shafts each having one end journaled for rotation about a fixed bearing in the conical wall 48. Thus, as shown in FIG. 8, flexible shaft 58 has one end journaled in the wall 48 by a sleeve bearing and coupling assembly 64 described more fully hereinbelow with respect to FIG. 9. Similarly, flexible shaft 60 has one end journaled by sleeve bearing and coupling assembly 66 and flexible shaft 62 is journaled for rotation by sleeve bearing and coupling assembly 68. The forward ends of the respective flexible shafts are also journaled by similar sleeve bearing and coupling assemblies 70, 72 and 74. Thus, shaft 58 is supported in coupling assembly 70 mounted in and extending through the bottom end of leg 52, shaft 60 is supported by assembly 72 mounted in and extending through a downwardly extending flange on the end of the enlarged head 56, and shaft 50 is supported by assembly 74 mounted on and extending through the bottom end of leg 50.
Sleeve bearing and coupling assemblies 64-74 are substantially identical and accordingly only one will be described in detail with reference to FIG. 9, it being understood that the description and reference numerals apply equally to the remaining assemblies. Thus, by way of example, the flexible shaft 60 has its end rigidly retained within a bore in one end of a substantially cylindrical connector member 76. The connector member 76 is journaled for rotation about its longitudinal axis by a bearing sleeve 78 which is rigidly fixed in an opening in the conical end wall 48. The connector 76 has a substantially square, axially extending opening 80 in its other end dimensioned to receive a substantially square end portion 82 on the shaft 28. The opening 80 and square end 82 of the shaft 28 are positioned such that, when the support stem is mounted on the handle, the square end 82 of the shaft 28 will be telescoped into the opening 80 and drive shaft 60. Rotation of the shaft 28 will, of course, also drive all of the flexible shafts through the gear train and the associated couplings described. An axially extending slot 84 formed in the skirt 46 engages a guide 86 on housing 12 as the cup-shaped end of the support stem is mounted on the handle to accurately align the respective couplings with the shaft to be connected thereto.
The brush head assembly 42 is releasably mounted on the distal end of the support stem 40 and includes three rotary brushes 90, 92, 94 supported in driving engagement one with each of the coupling assemblies 70, 72 and 74. The brush head includes a molded A-frame like structure 95 having a generally flat top 96 with an opening 98 formed therein and four integrally formed legs 100, 102, 104, 106 extending downward one from each corner of the top. A substantially flat tongue-like projection 108 is integrally formed on one edge of the top 96 in position to be received within the rectangular recess or slot 54 to releasably mount the brush head on the support stem. The legs on the brush head are arranged so that legs 100, 102 extend in parallel abutting relation to the legs 50, 52, respectively, on the stem.
The rotary brushes 90, 92 and 94 are substantially identical, although preferably the brush 92 is provided with shorter bristles as pointed out below. Each brush comprises an elongated central twisted wire core 110 (see FIG. 10) supporting a plurality of elongated bristles or filaments 112, with the bristles extending radially outward from the wire core to form a substantially cylindrical brush. However, bristles 112 are preferably of various lengths, with the different lengths being intermixed throughout the length of the brushes in order to provide a more uniform and effective brushing action over irregular surfaces of the teeth and gums.
A short cylindrical bearing element 114 is rigidly formed on each end of the twisted wire core 110 in position to be recieved in and supported by aligned pairs of openings in the brush head. Thus brush 90 is supported in openings in legs 100, 102 and brush 94 is supported on the bottom ends of legs 104, 106, while brush 92 is mounted in openings one at each end of the rectangular opening 98 in the flat top portion of the brush head. One end 116 of the twisted wire core 110 of each brush extends outwardly past its bearing 114 and is shaped into a rectangular or square cross section to fit within the correspondingly shaped opening 80 of the coupling member 76 on the forward end of the mating drive shaft.
To manually install the brush head on the support stem, the tongue 108 is inserted into the groove 54 and pushed firmly until the upwardly projecting protuberance 118 on the top surface of the tongue engages a corresponding depression (not shown) in the adjacent surface of the slot 54. In this position, the rearwardly projecting rectangular drive extension 116 on the respective cylindrical brushes will project into and mate with the rectangular opening 80 in the sleeve bearing and coupling assemblies on the forward end of the flexible drive shafts. The tongue 108 and groove 54 as dimensioned so that the brush head is firmly but releasably retained in position, with the protuberance 118 acting to provide a snap-on or detent feature. Further stability for the brush head is provided by the legs 50, 52 extending in abutting relation to the legs 100, 102 and the interfitting connection between the connectors 70 and 74 and the ends of the rotary brushes 90, 94 connected thereto. The support stem 40 can then be mounted on the handle to provide driving engagement between the rearwardly projecting ends of the flexible shaft and the drive motor, thereby providing direct driving connection between the motor and the three rotary brushes. Suitable switch means, not shown, controls operation of the motor.
After using the apparatus, the brushes may be readily cleaned, either with or without removing the brush head from the elongated support stem. Also, the support stem can be removed from the handle if desired to permit another similar support stem and brush assembly to be mounted thereon so that the toothbrush may be used by any number of people, it only being necessary for each user to have a personal support stem and rotary brush head.
The structure of the rotary brush head enables easy access to all teeth in the mouth without interference from the rigid structure of the brush head or of the drive stem. Also, if desired, a stationary, relatively thin-walled flexible tube or housing 120 may be employed to enclose the flexible rotary shafts so that the shafts turn inside the tubular structure. This arrangement may present a more pleasing and hygenic appearance although it is not required for operation of the apparatus. Preferably, the flexible shafts extend through and are supported by a suitable guide 122 at a point intermediate the ends of the beam 44.
As illustrated in FIGS. 6 and 7, the A-frame support structure 95 supports the rotary brushes 90, 92, 94 for rotation about parallel axes in position to provide space therebetween to receive the teeth of a user between the opposed legs of the A-frame. In this position, the brushes 90, 94 simultaneously brush the inner and outer face surfaces of the teeth while the brush 92 engages and brushes the biting surface. Spacing between the brushes 90, 94 and the length of the bristles 112 are such as to enable complete brushing of the surface of either incisors 124 or molars 126 both being illustrated schematically in FIG. 6. Further, by employing bristles of various lengths in each brush, the complete tooth surface will be adequately brushed regardless of surface irregularities. Note, also, that the position of the central brush 92 is such as to enable the brushes 90, 94 to engage and brush or massage the gums at the gum line. Preferably, the bristles of brush 92 are somewhat shorter than those of brushes 90, 94 to thereby provide maximum reach for the brushes 90, 94 onto the gums.
As best seen in FIGS. 1 and 5, the support legs 50, 52 are inclined so that their bottom, or distal ends are spaced slightly farther from the handle than their top ends. This angle of inclination corresponds to the angle of inclination of the support tongue 108 with respect to the top 96 of the brush head so that the support stem is inclined at an acute angle with respect to the rotary axis of the brushes. This angle is preferable within the range of about 8°-15° in order to provide maximum maneuverability of the brush head in the mouth with minimum interference from the support stem and flexible drive shafts. This angle is particularly advantageous when employing the brush to simultaneously brush the corresponding surfaces of both the upper and lower teeth in the manner illustrated in FIG. 7, especially when brushing the inner surfaces of the teeth.
It is also pointed out that the skeletal A-frame structure of the brush head greatly facilitates use of the toothbrush in that only a minimum of rigid structure is required in the mouth. Further, the rigid structure of the brush head is substantially shielded by the projecting bristles of the rotary brushes. In this regard, however, it is pointed out that the relatively straight line angular construction of the brush head in the drawings is for convenience of illustration only and in practice the brush head is constructed to eliminate sharp corners and edges. Similarly, the relatively wide, angular construction of the support stem, and of the releasable support means for mounting the brush head on the support stem are substantially enlarged and schematically illustrated in the drawings for convenience of illustration.
While I have disclosed and described a preferred embodiment of my invention, I wish it understood that I do not intend to be restricted solely thereto, but rather that I do intend to include all embodiments thereof which will be apparent to one skilled in the art and which come within the spirit and scope of my invention. | An improved driven rotary toothbrush has an electric motor enclosed in a handle and driving a plurality of rotary brushes for simultaneously cleaning multiple tooth surfaces. The rotary brushes are mounted in a brush head adapted to be releasably supported on one end of an elongated brush head support stem having flexible drive shafts extending therealong and having its other end adapted to be releasably mounted on the handle to provide rotary driven connection between the motor and brushes. The releasable mounting of the brush head and of the support stem enables hygenic use of the same motor and handle by a plurality of persons through use of personalized snap-on brush heads and support stems, and also makes possible the easy and economical replacement of the brush heads. | 0 |
This is a continuation of application Ser. No. 07/714,943 filed Jun. 13, 1991 now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a concrete injection plug for repairing a concrete construction, and to a method for injecting a remedial concrete material into a portion of the concrete construction.
Degradation of concrete material of a concrete construction is a considerable problem. The degradation may be caused by a secular change in the material per se, neutralization of the concrete due to external circumstance, injury from salt, alkali-aggregate reaction, unsatisfactory work or execution, shrinkage due to drying, generation of crack or peeling-off due to vibration from vehicles or an earthquake. A reduction in the mechanical strength of reinforcements due to their rusting accompanied by the peeling-off is also a source of degration. The degradation of the concrete may also include separation of a furring mortar formed over the concrete body therefrom, which in turn leads to falling of the skin tiles of a building formed over the furring mortar, or separation and falling of an internal concrete wall of a railway tunnel or the like, or water leakage from a dam.
Also, a separation space layer may be formed between an inner concrete body and an outer mortar layer at a position from 2 to 3 cm from a wall surface. A typical thickness of the separation space layer is in a range of from 0.2 to 1 mm. In order to repair a wall containing such a separation space layer, epoxy resin or a cement slurry injection method has been widely carried out in order to fill the space therewith.
According to a conventional epoxy resin injection method, an injection hole having a diameter of about 5 mm and reaching the separation space layer is formed on the wall by means of a drill. Then, a sleeve tip of a grease pump is depressed into the injection hole so as to directly inject the high pressure epoxy resin thereinto. Alternatively, an injection plug formed of a plastic material is adhesively fixed to the injection hole of the wall, and the pressurized epoxy resin is injected by a compressor or a manual pump. In both cases, any crack portions observed on a surface of the wall, other than the injection hole, are sealed by a sealant.
On the other hand, the above described high pressure grease pump cannot be used for the injection of the cement slurry, since the latter has relatively low viscosity. For example, if the grease pump capable of providing high fluid pressure such as 30 kg/cm 2 is used, the cement slurry may be leaked through a minute gap defined between the injection hole and the tip end of the sleeve of the pump, to thereby render the pressurization impossible. To this effect, a low pressure injection method is applied where a pressure of not more than 5 kg/cm 2 is applied for the injection of the cement slurry. Incidentally, this low pressure injection method is also available for the epoxy resin.
In case of the low pressure injection method for injecting the cement slurry or the epoxy resin, the injection hole is formed on the concrete wall by means of a drill, and a flange portion of the plastic plug is adhesively fixed to a position around the injection hole. Further, an injection hose extending from the injection pump is engaged with a rear mouth piece portion of the plastic plug, so that the cement slurry or the epoxy resin is injected under pressure through the injection hole into the desired internal crack portion of the concrete wall.
This plastic plug has a funnel shape having a diameter of about 5 cm and is readily available. Adhesive material is used for fixing the plug to the wall surface. However, since the adhesive force is insufficient preventing the plug from being separated from the wall during pressurized injection, additional operators are required for pressing the plug onto the wall surface in addition to an operator for operating the pressure pump.
In order to dispense with the worker who has to press the plug onto the wall surface, anchor type injection plug (hole-in-anchor type injection plug) have been employed. This plug has an anchoring or wedge function. Therefore, the anchor type injection plug can be fixedly secured to the wall by hammering the plug into the drilled injection hole. Thus, a release of the injection plug from the wall is avoidable even during the injection work.
With the above described low pressure injection method using the conventional injection plug, it would be difficult to perform injection of the cement slurry in comparison with the injection of the epoxy resin. Therefore, in injecting the cement slurry, injection holes are formed at many places corresponding to portions where the separating of the mortar is deemed to occur. Therefore, it requires much labor and time. In the worst case, epoxy resin must be used instead of the cement slurry for the concrete repair, where many injection holes cannot be located.
SUMMARY OF THE INVENTION
The inventors have conducted experiments for acknowledgement of any factor which prevents the cement slurry from being smoothly injected. Firstly, prepared were a mortar plate having a size of 30 cm×30 cm and a thickness of 3 cm, the mortar plate being simulative of a mortar layer, and a transparent acrylic layer having a size of 30 cm×30 cm and a thickness of 1 cm, the acrylic layer being a simulative of an internal concrete wall body. These two plates were opposed to each other with a space of 0.3 mm defined by spacers (the space being simulative of the separation space layer), and four sides of these plates were clamped together. Then, a small bore having a diameter of 6 mm, is simulative of the injection hole, was formed at a central portion of the mortar plate by means of a drill. In this case, immediately before a drill tip reached the acrylic plate, the mortar plate was bored by the drilling force, and observed was a phenomena in which a conical mortar chip having a diameter of about 5 mm and thickness of 3 mm at its central portion was protruded and brought into intimate contact with the acrylic plate, and the drilled mortar chip was interposed at the spaced gap defined between the acrylic and mortar plates.
A cement slurry was injected into the spaced gap through the small bore by using a manual pump. However, it was impossible to inject the slurry into the gap. If these two plates were unclamped from each other for investigation, it was observed that a minute amount of water infiltrated into the mortar chip from its rear surface (a surface opposite the acrylic plate side), and the surface was covered with cement particles.
This phenomena appears to be caused by the following: When forming the bore, the thin mortar drilled chip was formed, and its tip end (a chip surface confronting the acrylic plate) was brought into intimate contact with the acrylic plate. On the other hand, extremely minute gaps were provided between the mortar plate and another end of the mortar chip. This means that the internal gap space was not sufficiently communicated with the drilled bore. Since the injection was made from the mortar plate side, the cement slurry was subjected to filtering at the extremely minute gaps provided at the other end of the mortar chip, so that minute amount of water infiltrated into the drilled mortar chip and the trapped cement particles were accumulated on the other surface of the chip mass and closed or filled up the extremely minute gap. Thus, cement slurry cannot be further injected into the intended gap between the mortar plate and the acrylic plate. In this connection, after the drilled mortar chip was removed, and the two plates were again assembled together, the cement slurry was smoothly injected into the gap through the small bore since the small bore was adequately communicated with the internal gap space.
In an actual application, the cement slurry could be injected through one of the several injection holes. This was due to the fact that the drilled hole was casually communicated with the large space separation layer, so that the drilled mortar mass chip did not substantially largely close the drilled injection hole. Further, the injection with the epoxy resin was still attainable, since the resin does not contain particulate materials. In other words, the resin does not undergo filtering at the other side of the drilled conical mortar chip because of the nonexistence of particulate materials in contrast to the cement slurry.
In order to obviate the generation of the mortar chip mass, various hole forming machines were used such as a well core boring machine. However, it was impossible to eliminate the generation of mortar chips.
Therefore, it is an object of the present invention to overcome the above described drawbacks and disadvantages, and to provide an improved method for injecting repairing material into a concrete construction, the method being capable of eliminating problems attendant to the generation of the mortar chip mass which may close the separation space layer and may block communication between the separation space layer and the drilled injection hole.
Another object of the invention is to provide an injection method in which a labor for the concrete repairing can be reduced, and remedial maintenance to the concrete construction can be achieved with a high reliability and minimized labor and time.
Still another object of the invention is to provide an improved injection plug device for injecting repairing material into the concrete construction, the plug device being particularly available for the injection method of this invention.
Still another object of the invention is to provide such an injection plug device at low cost yet available for the injection method of this invention.
Still another object of the invention is to provide an injection plug device which is fixedly securable to the concrete wall.
These and other objects of the present invention will be attained by providing a plug device for an injecting repairing agent into a concrete construction, the concrete construction being formed with an injection groove having a first width, the plug device comprising a base member to be mounted on an outer surface of the concrete construction and over the injection groove, an injection guide means provided at a center portion of the base member for allowing the repairing agent to be injected into the injection groove, at least two guide posts extending from the base member and at positions around the injection guide means, the guide posts providing through holes and having an inner end portion, an equal plurality of rod members each extending through each of the through holes, each of the rod members being movable inwardly into the injection groove and outwardly from the concrete construction, each of the rod members having inner and outer end portions, and resilient engageable members provided at the inner end portions of one of the rod members and the guide posts, each of the resilient engageable member having a second width smaller than the first width prior to its deformations and a third width larger than the first width for engagement with walls of the injection groove after its deformation.
In another aspect of the invention, there is provided a method for injecting a concrete repairing agent into a concrete construction comprising the steps of forming an arcuate injection groove from an outer surface of the concrete construction, the arcuate groove having a first width and a depth, placing an injection plug device which injects the repairing agent into the concrete construction onto the outer surface of the concrete construction and over the injection groove, fixing the injection plug device to the arcuate injection groove while sealingly covering the arcuate injection groove, and injecting the repairing agent into the injection groove through the injection plug device.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings;
FIG. 1 is a plan view showing a plug device for injecting a concrete repairing material according to a first embodiment of this invention;
FIG. 2 is a cross-sectional view taken along a line II--II in FIG. 1;
FIG. 3 (a) is a side view showing a toothed washer which is one of the components of the plug device of the first embodiment;
FIG. 3(b) is a plan view of the toothed washer;
FIG. 4 is a cross-sectional view showing the plug device according to the first embodiment and showing a concrete wall construction to which the plug device is applied;
FIG. 5 is a cross-sectional view showing the plug device according to the first embodiment prior to its fixed state to the concrete construction;
FIG. 6 is a cross-sectional view showing the plug device according to the first embodiment after its fixed state to the concrete construction;
FIG. 7 is a cross-sectional view showing a plug device according to a second embodiment prior to its fixed state to a concrete construction;
FIG. 8 is a cross-sectional view showing the plug device according to the second embodiment after its fixed state to the concrete construction;
FIG. 9(a) is a plan view of a toothed grip post which is one of the essential components of the plug device according to the second embodiment;
FIG. 9(b) and 9(c) are cross-sectional view and bottom view of the toothed grip post, respectively;
FIG. 10(a) a plan view showing a trapezoidal slide piece which is also one of the essential components of the plug device according to the second embodiment;
FIG. 10(b) and 10(c) are cross-sectional view and bottom view of the trapezoidal slide piece;
FIG. 11 is a plan view showing a plug device for injecting a concrete repairing material according to a third embodiment of this invention;
FIG. 12 is a cross-sectional view taken along a line XII--XII in FIG. 11;
FIG. 13 (a) is a schematic side view showing a tip end portion of a rod member and a toothed washer assembled thereto in the third embodiment of this invention;
FIG. 13(b) is a front view showing the toothed washer shown in FIG. 13(b);
FIG. 13(c) is a front view showing another example of a toothed washer used in the third embodiment;
FIG. 14(a) is a schematic side view showing a tip end portion of a modified rod member and a modified toothed washer assembled thereto in the third embodiment of this invention;
FIG. 14(b) is a front view showing the modified toothed washer after assembling to the modified rod member:
FIG. 14(c) is a front view showing the modified toothed washer prior to the assembly to the modified rod member:
FIG. 15 is a cross-sectional view showing the plug device according to the third embodiment and showing a concrete wall construction to which the plug device is applied;
FIG. 16 is a cross-sectional view showing a part of the plug device according to the third embodiment after its fixed state to the concrete construction;
FIG. 17 is a cross-sectional view showing injection part of the plug device according to the third embodiment; and
FIG. 18 is a perspective view showing a dual blade type concrete cutter for forming an arcuate injection groove in the concrete construction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A plug device for injecting a concrete repairing material according to a first embodiment of the present invention will be described with reference to FIGS. 1 through 6. As best shown in FIG. 2, the plug device generally includes a rectangular base 1, cylindrical hollow guide posts 2, 3, O-rings 4, 5, an injection nipple attachment segment 6, a packing 7, rod members 8, 9, toothed washers 10, 11, wing nuts 12, 13 and a repairing agent injection nipple 14.
The rectangular base 1 has four side portions bent downwardly, so that the base 1 has a bottomless box shape construction. Throughout the description, one side of the base 1 is referred to as an outer side, and another side of the base 1 (the side at which the bent portions extend) is referred to as an inner side. The packing 7 is formed of rubber and is positioned at the inner side of the base 1 and in the vicinity of the side portions thereof. At the central portion of the rectangular base 1, the nipple attachment segment 6 is implanted and welded, and the repairing agent injection nipple 14 is threadingly engageable with the attachment segment 6 for injecting a cement slurry. For example, the injection nipple 14 is connectable with an injection nozzle (not shown) of an injection pump (not shown) for injecting concrete repairing agent such as cement slurry.
On the base 1, two cylindrical hollow guide posts 2 and 3 are implanted and welded. The guide posts are formed of metal, and arrayed in a direction parallel with a major side of the rectangular base 1 and positioned symmetrical with respect to the nipple attachment segment 6. The guide posts 2 and 3 extend inwardly from the base 1. Further, female threads 2a and 3a are formed in inner peripheral surfaces of the hollow cylindrical guide posts 2, 3, respectively, and annular grooves 2b and 3b are formed at the inner portion of the inner peripheral surfaces so as to secure the O-rings 4 and 5, respectively.
The rod members 8 and 9 extend through the hollow spaces of the cylindrical guide posts 2 and 3, respectively. Thus, cylindrical annular spaces defined between the rod members 8, 9 and the guide posts 2, 3 are fluid-tightly sealed by the O-rings 4, 5. Inner end portions of the rod members 8 and 9 further project out of the inner end of the guide posts 2 and 3. Further, the toothed washers 10 and 11 are threadingly engaged with the projected inner end portions of the rod members 8 and 9, respectively. The toothed washers 10, 11 are formed of resilient material such as spring steel. As best shown in FIGS. 3(a) and 3(b), the washers 10, 11 have rectangular configurations, and their two sides are bent so as to constitute anchor portions. When the washers are engaged with the inner ends of the rod members 8, 9, the bent portions are directed outwardly. Another end portions of the rod members 8 and 9 are formed with male threads 8a, 9a so that the wing nut 12 and 13 are threadingly engageable therewith at the outer side.
Next, will be described with reference to FIGS. 4 through 6 a method for injecting the concrete repairing agent into the concrete construction with the employment of the injection plug device described above.
As shown, the concrete construction includes an internal concrete body B and an external mortar layer A. Further, a separation space layer C is provided at a boundary between the concrete body B and the mortar layer A. The repairing agent is to be filled into the space layer C.
Firstly, an injection groove D is formed from the outer side of the concrete construction. The groove D has generally arcuate or semicircular shape and the groove bottom reaches the separation space layer C (see FIG. 4). Further, as best shown in FIG. 5, the groove has a predetermined width slightly larger than a width of the toothed washer 10, 11 and outer diameters of the guide posts 2, 3. In order to form the arcuate or semicircular injection groove D, two cutting grooves extending in parallel with each other are initially formed by a circular concrete saw or blade, and then, the concrete construction is smashed by a hammer so as to smash the mortar layer portion between the two cutting grooves. The smashed pieces or chips are then removed by air suction means. Incidentally, the two cut grooves are formed by operating twice a concrete cutter having a single circular saw. However, a dual blade type concrete cutter as described in a Japanese Patent Application No. Hei 1-274028 is available for facilitating the formation of two cut grooves extending in precise parallelism with each other with a precise spaced distance therebetween.
More specifically, as shown in FIG. 18, the dual blade type concrete cutter includes two circular saw blades 101a, 101b, a spacer 101c, a spindle 102, a flexible shaft 103, a hand held pipe 104, a chip collection cover 105, a chip suction duct 106, and a flexible chip collection hose 107. The hand held pipe 104 is formed of a light weight material such as a light metal and carbon, and the two circular saw blades 101a and 101b are replaceably supported on a tip end portion of the hand held pipe 104. These blades 101a, 101b extend in parallel with each other with a space therebetween defined by the spacer 101c. These blades are accessible in a market as a cutting blades for cutting a surface of a concrete or asphalt road, the blade being a product by Sankyo Diamond Kogyo Kabushiki Kaisha. These cutters are driven through the spindle 102 and the flexible shaft 103 by a portable drive means (not shown). The concrete chips or powders generated during the cutting work are impinged on the cover 105, and is sucked through the hand held pipe 104, the chip suction duct 106 and the flexible chip collection hose 107 into a chip collection bag (not shown) upon energization of a suction blower (not shown).
Next, the guide posts 2, 3 are inserted into the arcuate groove D for setting the plug device to the concrete construction. Prior to the setting, the wing nuts 12, 13 are rotated in one direction (counterclockwise direction) so that the inner ends of the rod member 8, 9 are moved away from the inner ends of the guide posts 2, 3, to thereby move the toothed washers 10, 11 away from the inner ends of the guide posts 2, 3 in order to obtain the washer shape as shown in FIG. 3(a). Accordingly, a width of the toothed washer can be made smaller than that of the arcuate groove D for facilitating insertion of the washer and guide posts into the arcuate groove D.
Upon completion of the insertion of the guide posts 2, 3 into the arcuate groove D, the wing nuts 12, 13 are rotated in opposite direction (clockwise direction) so that the rod members 8, 9 are moved outwardly. Therefore, the bend anchor or toothed portions of the toothed washers 10, 11 are brought into contact with the inner ends of the cylindrical guide posts 2, 3 and are further urged. Thus, the bending angle of the bent portions is decreased so that the toothed washers can have a generally flat shape as shown in FIG. 6. Accordingly, the width of the washers 10, 11 is increased and becomes larger than the width of the arcuate groove D. Consequently, the initially bent portions are thrusted into the side walls of the arcuate groove D so as to perform an anchoring function, and as a result, the plug device can be fixedly secured to the concrete construction. If the wing nuts 12, 13 are further rotated, the packing 7 is firmly urged onto the outer surface of the mortar layer A, to thereby avoid leakage of the concrete repairing agent through the packing portion.
Then, the injection nozzle (not shown) of the injection pump (not shown) is connected to the injection nipple 14 for injecting the concrete repairing agent such as the cement slurry under pressure into the separation space layer C. Upon completion of the injection, the injection nozzle is detached from the injection nipple 14, and the wing nuts 12, 13 are rotated in one direction. By this rotation, the rod members 8, 9 are moved inwardly, so that the toothed washers 10, 11 are also moved inwardly. By this movement, the anchoring portion of the toothed washers 10, 11 are disengaged from the walls of the arcuate groove D, and the washers 10, 11 restore their original bent configurations. Thereafter, the plug device is disassembled from the concrete construction for completing the injection work.
An injection plug device for injecting a concrete repairing material according to a second embodiment of the present invention will next be described with reference to FIGS. 7 through 10 wherein like parts and components are designated by the same reference numerals and characters as those shown in the first embodiment. This plug device is provided with toothed grip posts 20, 30 (30 not shown) instead of the guide posts 2, 3 of the first embodiment, and is also provided with trapezoidal slide pieces 21, 31 (31 not shown) provided at the inner ends of the rod members instead of the toothed washers 10, 11 of the first embodiment. In the depicted drawings, the second toothed grip post 30 and trapezoidal slide piece 31 are not shown for purposes of simplicity.
FIGS. 9(a) through 9(c) illustrate the detailed arrangement of the toothed grip post 20 fixedly connected to the base 1 (see FIG. 7) similar to the first embodiment. The toothed grip post 20 has a square cross-section and is formed with a through hole for allowing a rod member 28 to pass therethrough. The through hole has an outer large inner diameter portion 20a, an intermediate small inner diameter portion 20b and an inner tapered portion 20c. The boundary between the outer and intermediate inner diameter portions 20a and 20b defines a stepped portion 20d, and the intermediate small diameter portion 20b is formed with an annular groove 20e. A ring 29 is fitted with the large inner diameter portion 20a for preventing the rod member 28 from releasing from the grip post 20. The tapered portion 20c is contiguous with the inner end of the small inner diameter portion 20b, and has an increasing inner diameter toward the inner end of the grip post 20.
At the inner portion and at two external sides of the grip post 20, a rack-form surface of irregular portions 20f are formed to be engageable with the side walls of the arcuate groove D. The width of the grip post 20 in a direction parallel with the minor side of the rectangular base 1 is made slightly smaller than the width of the arcuate injection groove D. The grip post 20 is formed of highly resilient material such as spring steel so that it can be resiliently deformable in accordance with the enlarging function given by the trapezoidal slide piece 21 described later.
As shown in FIG. 7, the rod member 28 has an outer end portion to which a wing nut 32 is integrally attached by means of a pin 33. The rod member 28 has an intermediate portion provided with a flanged portion 28a abuttable on the stepped portion 20d. Further, an O-ring 25 is accommodated in the annular groove 20e of the grip post 20 for sealing purpose in connection with the inserted rod member 28. The rod member 28 has an inner end portion formed with a male thread 28b with which the trapezoidal slide piece 21 is threadingly engageable. By the rotation of the wing nut 32, the rod member 28 is rotated about its axis, so that the slide piece 21 are moved in the axial direction of the rod member 28.
The details of the trapezoidal slide piece 21 are shown in FIGS. 10(a) thru 10(c). The slide piece 21 has tapered surface 21a having an inclination identical with that of the tapered portion 20c of the grip post 20. Thus, the trapezoidal configuration is provided. The slide piece 21 has an inner thread bore 21b for threading engagement with the male thread 28b of the rod member 28. In accordance with the axial movement of the slide piece 21, the tapered surface 21a in contact with the tapered surface 21a can expand or reduce the inner end portion of the grip post 20 in a direction indicated by an arrow X in FIG. 9(b).
Next, a method for injecting the concrete repairing agent into the concrete construction with the employment of the injection plug device according to the second embodiment of this invention will be described with reference to FIGS. 7 and 8. Initially, the arcuate injection groove D is provisionally formed as described above.
For assembling the plug device to the concrete construction, as shown in FIG. 7, the wing nut 32 is rotated in a counterclockwise direction for moving the trapezoidal slide piece 21 inwardly. Therefore, distance between the two rack-form deformable portions is made smaller than the width of the injection groove D. Accordingly, the toothed grip post 20 can be inserted into the injection groove D.
Next, the rod member 20 is rotated about its axis in a opposite direction by rotating the wing nut 32 in a clockwise direction. Therefore, the trapezoidal slide piece 21 is moved outwardly while sliding with respect to the tapered portion 20c. Thus, the tapered portion 20 is resiliently deformed in the direction indicated by the arrow X, so that the rack-form surface of irregular portions 20f are brought into biting engagement with the side walls of the injection groove D as shown in FIG. 8. Consequently, the plug device can be fixed to the concrete construction. By further rotating the wing nut 32 in the clockwise direction, the packing 7 is further urged toward the surface of the mortar layer A, to thus avoid leakage of the concrete repairing agent from the packing 7.
A plug device for injecting a concrete repairing material according to a third embodiment of the present invention will next be described with reference to FIGS. 11 through 17. The plug device according to the third embodiment is provided with a metallic rectangular base 41, cylindrical guide posts 42, 43, O-rings 44, 45, an injection nipple attachment segment 46, a packing 47, rod members 48, 49, toothed washers 50, 51, wing nuts 52, 53 and an injection nipple 54.
As shown in FIG. 11, the rectangular base 41 has four sides bent inwardly to provide a bottomless box shape similar to the foregoing embodiments. Further, the nipple attachment segment 46 is implanted to the central portion of the base 41, and the injection nipple 54 is threadingly engaged with the nipple attachment segment 46 similar to the foregoing embodiments for introducing a cement slurry therethrough. Further, the metal guide posts 42 and 43 are arrayed in a direction parallel with major sides of the rectangular base 41 and at positions opposite to each other with respect to the nipple attachment segment 46. The guide posts 42 and 43 are welded to the base 41. The packing 47 is held on the inner side of the rectangular base 41. Contrary to the first embodiment, these guide posts 42 and 43 extend outwardly from the base 41.
As best shown in FIG. 12, the inner end portions of the rod members 48, 49 extend through the guide posts 42, 43 and further extend inwardly through openings 41a, 41b formed in the base 41 and openings 47a, 47b formed in the packing 47, respectively, and protrude inwardly out of the packing 47. The protruded inner end portions of the rod members 48, 49 are detachably provided with toothed washers 50, 51, respectively. On the other hand, outer end portions of the rod members 48, 49 are formed with male threads 48a, 49a with which wing nuts 52, 53 are threadingly engageable, respectively. Further, at the outermost ends of the rod members 48, 49, hand grips 48b and 49b are provided for manually moving the rod members in their axial direction.
Further, as shown in FIG. 12, root or base end portions of the guide posts 42, 43 are provided with annular projections 42a, 43a extending radially inwardly from inner peripheral surfaces of the posts. Thus, annular regions are defined by the combinations of a lower surfaces of the annular projection 42a, 43a, the inner peripheral surfaces of the guide post 42, 43, outer peripheral surfaces of the rid members 48, 49, and a top surface of the base 41. Within the annular regions, seal rings 44 and 45 are interposed, so that the fluid tight construction can be provided in connection with the guide posts 42, 43 and the rod members 48, 49.
FIGS. 13(a) and 13(b) show one example of the toothed washer 50 provided on the inner end portion of the rod member 48, and FIG. 13(c) shows one modification to the toothed washer. As shown in FIG. 13(a), the inner end portion (tip end portion) of the rod member 48 is formed with a spiral groove 48c with which the toothed washer 50 is engaged. The toothed washer 50 shown in FIG. 13(b) has a generally circular shape having a diameter larger than the outer diameter of the rod member 48. The toothed washer 50 has a central portion formed with an opening 100 engageable with the spiral groove 48c, and a hexapetalous teeth 101 through 106 each being bent outwardly (toward the base 41). Such petal form washer 50 is easily accessible in a market.
According to one modification to the toothed washer shown in FIG. 13(c), the washer 50A has a rectangular shape, and three teeth 101a to 103a are formed in one side, and another three teeth 104a to 106a are formed in opposite side.
FIGS. 14(a) thru 14(c) show another example of a rod member 48A and a toothed washer 50c provided to the inner end portion of the rod member 48A. As shown in FIG. 14(a), the inner end portion of the rod member 48A is integrally provided with a small diameter rod 48d and a protrusion 48e extending therefrom for detachably engaging the modified toothed washer 50c. The modified toothed washer 50c has a rectangular shape and is formed with a central circular opening 100a and slits 100b intersecting the central circular opening. Further, three teeth are formed on one side of the washer, and another three teeth are formed on opposite side thereof. For engagement of the toothed washer 50a with the rod portion 48d, as shown in FIG. 14(c), the rod portion 48d and the protrusion 48e are respectively aligned with the central circular opening 100a and the slits 100b, respectively. Thereafter, as shown in FIG. 14(b), the rod member 48A and the toothed washer 50c are relatively angularly rotated by 90 degrees. Therefore, the protrusion 48e supports the plate portion of the washer for holding the washer to the rod member 48A.
A method for injecting the concrete repairing agent into the separation space layer C with the employment of the plug device of the third embodiment will next be described with reference to FIGS. 15 through 17. The plug device is mounted on the concrete wall, and the hand grips 48b, 49b of the rod members 48, 49 are depressed inwardly, so that the tip end portions of the rod members are inserted into the injection groove D. In this case, since the toothed portions of the toothed washers are bent outwardly, and since the width of the washers is made smaller than that of the groove D, the toothed washers 50, 51 can be smoothly inserted into the groove D.
Next, wing nuts 52, 53 are rotated in a clockwise direction, so that the wing nuts 52, 53 are threadingly moved inwardly in the axial direction of the rod members along the threads 48a, 49b. The inward movement (downward movement in FIG. 16) of the wing nuts 52, 53 are prevented when these are brought into abutment with planar outer ends of the guide posts 42, 43. Thereafter, in accordance with the further rotations of the wing nuts 52, 53, the rod members 48, 49 are moved outwardly (upwardly in FIG. 16) along axial direction thereof. In this case, as shown in FIG. 16, the teeth of the toothed washers 50, 51 are gradually threaded into the side walls of the injection grooves with their resilient deformations, since the toothed portions are bent outwardly, and finally, the axially outward movements of the rod members 48, 49 are prevented because of the sufficient engagements of the toothed washers with the groove wall. Thus, the plug device is securely fixed to the concrete wall. By further rotating the wing nuts 52, 53, the base 41 is urgedly moved inwardly, so that the packing 47 is sufficiently compressed. Accordingly, fluid-tight fixing work of the plug device to the concrete wall is completed.
Then, an injection hose (not shown) extending from an injection pump (not shown) is coupled to the injection nipple 54, and low pressure injection of cement slurry is initiated with a state shown in FIG. 17. As a result, the separation space layer C as well as the injection groove D are filled with the cement slurry. Upon completion of the injection work, the rod members 48, 49 are rotated about their axes in counterclockwise direction by manually rotating the hand grips 48b, 49b in this direction. Therefore, the toothed washers 51, 52 are disengaged from the tip end (inner end) portions of the rod members 48, 49. Then, the rod members 48, 48 are pulled outwardly from the injection groove D, while the disengaged toothed washers 50, 51 are remained within the groove D. Thus, the plug device is dismounted from the concrete wall.
While the invention has been described in detail and with reference to specific embodiment thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention. | An injection plug device for injecting a concrete repairing agent into a concrete construction through an arcuate injection groove formed therein. The plug device includes a base member sealingly placed over an open end of the arcuate injection groove, a plurality of guide posts extending from the base member, an equal plurality of rod members extending through the guide posts, and engageable member selectively engageable with side walls of the arcuate injection groove by resilient deformation. The engageable members are provided at an inner end portion of the guide posts, or an external surface of the inner end portions of the guide posts. The engageable members have a width smaller than a width of the arcuate injection groove prior to their deformation and have another width larger than the width of the arcuate injection groove after their deformation to provide engagement with the side wall of the groove. The injection plug device is used for achieving a method for injecting a concrete repairing agent into the concrete construction. The method includes the steps of forming the arcuate injection groove, placing the base member over the open end of the injection groove in placing the injection plug device on the concrete construction, and engaging the engageable member with the groove for fixing the plug device to the concrete construction. | 4 |
TECHNICAL FIELD
[0001] The present invention relates to a self-service terminal (SST), such as an automated teller machine (ATM).
BACKGROUND
[0002] ATMs are public access terminals that provide users with a secure, reliable, and convenient source of cash and other financial transactions in an unattended environment.
[0003] An ATM typically comprises a paneled chassis housing a plurality of interconnected modules for performing user interface, transaction, and management functions for the ATM. Typical user interface modules include a display module, a keypad module, and a card reader module; typical transaction modules include a cash dispenser module, and a statement printer module; and typical management modules include a controller module, a communications module, and a journal printer module.
[0004] The ATM controller module has an ATM controller application program including software drivers for the modules in the ATM, and ATM controller software to manage:
[0005] (1) fault prediction and tolerance (state of health) for the ATM modules;
[0006] (2) secure communications between the controller module and other modules, and between the ATM and both a remote transaction authorization server and a remote state of health management system server;
[0007] (3) transaction flow, business logic, and presentation of information to an ATM user or an ATM server.
[0008] When an ATM device or module changes from a good working state to a problem state where attention is needed immediately or soon a Simple Network Management Protocol (SNMP) agent will send a message to a remote management system which monitors the state of health of the ATM. The signal is sent via the communications module, which is in turn controlled by the controller application. This level of fault/problem reporting is required for efficient management of the ATM. As part of this system each device or module sends sate of health information to the PC core. This is either done in response to a request from the core or automatically in response to an event, the latter utilizing SNMP traps.
[0009] However, when a device or module within an ATM is powered down independently of the PC Core the PC core and its software will still be fully operational. In such a planned and controlled activity, by either a maintenance service engineer or the controller application software, the management system will be flooded with false status messages from the ATM. This will cause the management system to erroneously display these messages as genuine faults and possible dispatch a service engineer if the faults appear to require such a response. This causes unnecessary communications between the ATM and the management system server, as well as problems with error logs and may be very costly and inconvenient to service companies if engineers are sent out erroneously.
[0010] It is among the objects of an embodiment of the present invention to obviate or mitigate one or more of the above disadvantages, or other disadvantages associated with prior art self-service terminals.
SUMMARY
[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, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0012] According to a first aspect of the present invention there is provided a self-service terminal comprising a pc core and at least one module, which can be powered down independently of the pc core; the terminal having a control application and an agent arranged to monitor the fault state of the at least one module and cause a fault signal to be sent from the terminal when the fault state of the at least one module is characteristic of a problem with the at least one module, wherein the agent is arranged to determine if the module has been powered down, whereupon the fault signal is buffered until the module is powered up and a determination as to the fault state of the module is again made and the fault signal is only sent if the fault state is still characteristic of a problem with the at least one module.
[0013] Preferably, there is a plurality of modules and each module has an associated agent.
[0014] More preferably, the agent is an SNMP agent. Still more preferably an SNMP trap.
[0015] Preferably, the at least one module is selected from: a display module, a keypad module, a card reader module, a cash dispenser module, a statement printer module; a controller module, a communications module and a journal printer module.
[0016] Preferably, the fault signal is arranged for detection and decoding by a remote state of health monitoring facility.
[0017] In a preferred embodiment the self-service terminal is an automated teller machine (ATM).
[0018] In one embodiment the control application comprises a plurality of module driver agents, a plurality of module function request agents for requesting functions provided by a module, the module driver agents being operable to co-operate with an associated function request agent to provide module functions.
[0019] In one embodiment the driver agents are organized in a community of agents.
[0020] Preferably, the agent is arranged to determine if the at least one module has been powered down by ascertaining when the terminal is placed in a diagnostic mode; loss of power to the at least one module being classified as a power down when the terminal is in said diagnostic mode.
[0021] As referred to herein the term “powered down” is intended to mean an intentional power down or shut down of the module by the controller application or a field engineer or the like. It is intended to differentiate from an erroneous shut down of the module due to a problem or fault with the module.
[0022] According to a second aspect of the present invention there is provided a method of operating a self-service terminal self-service terminal comprising a pc core and at least one module, which can be powered down independently of the pc core; the terminal having a control application and an agent arranged to monitor the fault state of the at least one module and cause a fault signal to be sent from the self-service terminal when the fault state of the at least one module is characteristic of a problem with the at least one module; the method including: determining if the module has been powered down; if the module has been powered down buffering the fault signal; powering up the module; and determining the fault state of the module again; and sending a fault signal only if the fault state is still characteristic of a problem with the at least one module
[0023] As referred to herein, an “agent” is a software entity comprising code, and optionally data, which can be used to perform one or more operations in a computing environment. An agent performs operations with some degree of independence and autonomy, and presents a consistent interface to other software entities, such as other agents.
[0024] Two agent arrangements are disclosed, however, these are in no way intended to be limiting to the scope of invention and are enclosed as possible explanatory embodiments only.
[0025] Preferably, separate health agents are provided which co-operate with driver and function agents. Health agents are operable to record state of health information, such as the state of sensors in a module. Preferably, the interface between agents is implemented by a broker agent.
[0026] In an alternative embodiment a single agent, associated with a specific module, will perform the roles of each of: the health agent, the driver agent and the function agent in the first embodiment; as will be described in detail below. Other arrangements of agents are conceivable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and other aspects of the present invention will be apparent from the following specific description, given by way of example, with reference to the accompanying drawings, in which:
[0028] FIG. 1 is schematic diagram of the architecture of a self-service terminal in accordance with one embodiment of the present invention;
[0029] FIG. 2 is a schematic diagram showing the software architecture of a control application executing in memory of the terminal of FIG. 1 ;
[0030] FIG. 3 is a schematic diagram of a health agent of the control application of FIG. 2 ;
[0031] FIG. 4 is a flow diagram of the operation of an agent, in accordance with the present invention; and
[0032] FIG. 5 is a schematic diagram of an alternative agent environment.
DETAILED DESCRIPTION
[0033] Reference is first made to FIG. 1 , which is a simplified block diagram of the architecture of an SST 10 , in the form of an ATM.
[0034] The ATM 10 comprises a plurality of modules for enabling transactions to be executed and recorded by the ATM 10 . These ATM modules comprise: a controller module 14 , a display module 20 , a card reader/writer module 22 , an encrypting keypad module 24 , a receipt printer module 26 , a cash dispenser module 30 , a wireless communication module 31 having a Bluetooth (trade mark) transceiver, a journal printer module 32 for creating a record of every transaction executed by the ATM 10 , and a network connection module 34 (in the form of an enhanced network card) for accessing a remote authorization system (not shown) and a remote state of health management system (not shown).
[0035] The controller 14 comprises a BIOS 40 stored in non-volatile memory, a microprocessor 42 , main memory 44 , storage space 46 in the form of a magnetic disk drive, and a display controller 48 in the form of a graphics card.
[0036] The display module 20 is connected to the controller module 14 via the graphics card 48 installed in the controller module 14 . The other ATM modules ( 22 to 34 ) are connected to the ATM controller 14 via a device bus 36 and one or more internal controller buses 38 .
[0037] When the ATM is powered up, a secure booting-up process is performed, in which the main memory 44 is loaded with an ATM operating system kernel 52 and an agent environment manager 54 in a secure manner. Furthermore, the ATM modules ( 20 to 34 ) and other components within the controller module ( 40 , 46 , 48 ) are authenticated.
[0038] As is well known in the art, the operating system kernel 52 is responsible for memory management, process management, task management, and disk management. The agent manager 54 implements a Java Virtual Machine for allowing agents to execute within a controlled agent environment 56 . A first embodiment of a feasible controlled agent environment 56 is illustrated in more detail in FIG. 2 . A further embodiment is disclosed later in this document. Neither embodiment should be considered as limiting the scope of the invention as detailed in the acclaimed appended hereto.
[0039] Referring to FIG. 2 , the agent environment 56 includes three agent communities: a driver agent community 60 , a function request agent community 62 , and a health agent community 64 ; and a logic engine 66 .
[0040] Each community 60 , 62 , 64 contains agents that can interact with other agents within that community, and with associated agents in other communities. Each community 60 , 62 , 64 also contains an agent infrastructure to instantiate agents and to allow agents to execute.
[0041] The Driver Agent Community
[0042] The driver agent community 60 includes a driver agent 70 for each module in the ATM 10 (apart from the controller module 14 ), namely: a dispenser driver agent 70 a , a keypad driver agent 70 b , a card reader driver agent 70 c , a receipt printer driver agent 70 d , a journal printer driver agent 70 e , a network card driver agent 70 f , a display driver agent 70 g , and a gatekeeper driver agent 70 h for the wireless communications module 31 . The driver agent community 60 also includes a small display agent 70 i and a wireless input agent 70 j for outputting information to and receiving information from a wireless device that may be used by an ATM user for entering a transaction at the ATM. The small display agent 70 i renders information for viewing on a small display, such as a display incorporated into a cellular radio-frequency telephone (hereinafter a “cell phone”), a personal digital assistant (PDA), or such like. The wireless input agent 70 j receives user entries from the cell phone or PDA. The gatekeeper driver agent 70 h monitors information transmitted from a user's wireless device.
[0043] Each of these driver agents 70 translates generic commands to hardware-specific low-level commands for operating the associated module. Most of the drivers 70 also report status information from sensors or other indicators in their associated modules.
[0044] The driver agent community 60 accesses a broker agent 76 that performs administrative tasks, as will be described in more detail below. The broker agent 76 is not a driver agent 70 and is not part of the driver agent community 60 , but the broker agent 76 is shown overlapping the community 60 in FIG. 2 because the broker agent 76 stores information about the driver agents.
[0045] The Function Request Agent Community
[0046] The function request agent community 62 includes a function request agent 72 for each module in the ATM 10 (apart from the controller module 14 ), namely: a dispenser function request agent 72 a , a keypad function request agent 72 b , a card reader function request agent 72 c , a receipt printer function request agent 72 d , a journal printer function request agent 72 e , a network card function request agent 72 f , a display function request agent 72 g , and a gatekeeper function request agent 72 h . The function request agent community 62 also includes a function request agent for outputting information to a wireless device, referred to as a small display function request agent 72 i , and a function request agent for receiving information from a wireless device, referred to as a wireless input function request agent 72 j.
[0047] The function request agent community 62 also accesses the broker agent 76 . The broker agent 76 is not a function request agent 72 and is not part of the function request agent community 62 , but the broker agent 76 is shown overlapping the community 62 in FIG. 2 because the broker agent 76 provides information to the function request agents 72 .
[0048] Each of the function request agents 72 translates generic commands from the logic engine 66 to a format suitable for an associated driver agent 70 , so that the function request agents 72 provide a consistent interface to the logic engine 66 . An associated driver agent is a driver agent that provides suitable functions for the function request agent; for example, a dispenser driver agent is an associated driver agent for a dispenser function request agent.
[0049] The function request agents 72 also provide additional features for the logic engine 66 (for example, obtaining information from the driver agents 70 about the capabilities of the modules, the configuration of the modules, and such like).
[0050] The Health Agent Community
[0051] The health agent community 64 comprises a health agent 74 for each module in the ATM 10 (apart from the controller module 14 and the display module 20 ), namely: a dispenser health agent 74 a , a keypad health agent 74 b , a card reader health agent 74 c , a receipt printer health agent 74 d , a journal printer health agent 74 e , a network card health agent 74 f , and a gatekeeper health agent 74 h.
[0052] Each health agent 74 collates and stores status information for its associated driver agent 72 . The health agent community 64 also accesses the broker agent 76 . The broker agent 76 is not a health agent 74 and is not part of the health agent community 64 , but the broker agent 76 is shown overlapping the community 64 in FIG. 2 because the broker agent 76 provides information to the health agents 74 .
[0053] A Health Agent
[0054] A typical health agent 74 is illustrated in FIG. 5 . The agent 74 has an agent interface 110 , an operation program 112 , and a data storage area 114 .
[0055] The agent 74 issues requests for information to, and receives responses and status information from, an associated driver agent 70 via the agent interface 110 . The agent 74 also sends status information to an associated function request agent 72 via the agent interface 110 .
[0056] The operation program 112 operates on the status information, for example, to predict faults and determine the operational status of the associated module.
[0057] Alternatively, SNMP traps can be utilized instead of the agent 74 issuing requests for information, as is known in the art.
[0058] The data storage area 114 stores status information and address information. The status information includes, for example, the state of sensors or other indicators within the module, previous faults, a log of status reports, and such like. The address information stores a contact identifier for the agent (that is, its own contact identifier) and contact identifiers of other agents it communicates with, namely, an associated driver agent 70 and an associated function request agent 72 .
[0059] As mentioned briefly above, in known ATM health monitoring systems, each health agent operates in the background to monitor the functions of the modules. When a module, such as a cash dispenser, operates, sensors are activated in a sequence as notes are transported, shutters are opened and closed, diverter gates are activated, and such like. The dispenser health agent 74 a monitors the operation of these sensors to predict possible failures and to inform a server (such as a replenisher or a technician) when media needs replenished or a reject bin needs emptied. This is analogous to fault prediction and management as is presently implemented by some ATMs.
[0060] If the dispenser health agent 74 a detects that some service work needs to be performed, then the health agent 74 a informs the dispenser function request agent 72 a , which in turn requests the transaction and logic flow agent 78 to request via the network module 34 a service visit.
[0061] The agent environment 56 may include system agents that are not specific to one particular module, but monitor the health of the entire ATM 10 at the system level, and allow fault diagnosis and tests to be executed.
[0062] As illustrated in FIG. 4 , in accordance with the present invention, the SNMP agent is modified to intelligently determine when the software application or service engineer has initiated a module only power down in, for example, in order to recover a failed module.
[0063] When a module only power down is detected, by the terminal being placed in a diagnostic mode by an engineer, then the SNMP agent will record and buffer the change of state messages but will not immediately send them up to the management system. The SNMP agent will wait for the devices to be powered back on, and the terminal to be taken out of the diagnostic mode into a normal operating mode, and will then determine what if any of the buffered state changes require to be sent up to the management system.
[0064] This operation can be explained most clearly with reference to the flow diagram, FIG. 4 , in which the control or system application state is monitored to determine if the system application is in a normal operational or diagnostic state (box 80 ). Once the system is in a diagnostic state, if the application starts the shut down of a module then none of the health signals initiated by the agent are sent to the remote system state of health management server and instead they are buffered (box 82 ). The agent then monitors the activation of the module, and the return from diagnostic state to normal operational state and once the control application reactivates the module the agent again detects the state of health of the module (box 84 ) and compares it with the original state of health prior to power down of the module (box 86 ). If the new state of health of the module is good then no signal is sent to the remote server (box 88 ). However, if the state of health is still characteristic of a fault or problem with the module then the signal is sent to the remote server (box 90 ), whereupon appropriate action is instigated.
Alternative Embodiment
[0065] An alternative embodiment of the present invention will now be described with reference to FIG. 5 , which shows an agent environment 200 . The agent environment 200 is implemented on the same hardware (that is, the ATM modules) as the above embodiment.
[0066] The agent environment 200 has a module control agent community 202 comprising a module control agent 204 for each module in the ATM.
[0067] The environment also has a control agent broker 206 and a logic engine 208 . The logic engine 208 comprises a transaction flow agent 210 and a rules and business logic file 212 .
[0068] In this embodiment, each control agent 204 combines the functions of a driver agent, a function request agent and a health agent, from the previous embodiment.
[0069] The transaction flow agent 210 operates in a similar manner to the transaction flow agent in the first embodiment.
[0070] Various modifications may be made to the above described embodiments within the scope of the invention. For example, instead of detecting the state of the terminal (normal operation or diagnostic mode) sensors on the module may detect if a loss of power at a terminal is a power down by an engineer or the control system or an erroneous loss of power, in much the same way that a pc can determine if a loss of power is intentional. | A self-service terminal comprises a pc core and at least one module, which can be powered down independently of the pc core, the terminal has a control application and an agent arranged to monitor the fault state of the at least one module and cause a fault signal to be sent from the self-service terminal when the fault state of the at least one module is characteristic of a problem with the at least one module. The agent is arranged to determine if the module has been powered down; whereupon the fault signal is buffered until the module is powered up and a determination as to the fault state of the module is again made. The fault signal is only sent if the fault state still indicates there to be a problem with the at least one module. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation application of and claims priority to U.S. Ser. No. 12/569,659, filed on Sep. 29, 2009, now U.S. Pat. No. 8,566,982 which claims benefit under 35 USC §119(e) of U.S. Provisional Patent Application Ser. No. 61/101,049 filed 29 Sep. 2008, which applications are hereby incorporated fully by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fabric systems, and more specifically to bed coverings constructed of high gauge circular knitted fabrics that accommodate and maintain optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
2. Description of Related Art
Sleep problems in the United States are remarkably widespread, affecting roughly three out of four American adults, according to research by the National Sleep Foundation (NSF). Consequently, a great deal of attention has been paid to the circumstances surrounding poor sleep, along with strategies for how to improve it.
The implications are not merely academic. Sleep—not only the right amount of it but also the right quality—impacts not just day-to-day performance, but also “the overall quality of our lives,” according to the NSF. Addressing the causes of poor quality sleep, therefore, has ramifications for millions.
Though many factors contribute to sleep quality, the sleep environment itself plays a critical role, and sleep researchers routinely highlight temperature as one of the most important components in creating an environment for optimal sleep. As advised by the University of Maryland Medical Center, “a cool (not cold) bedroom is often the most conducive to sleep.” The National Sleep Foundation further notes that “temperatures above 75 degrees Fahrenheit and below 54 degrees will disrupt sleep,” with 65 degrees being the ideal sleep temperature for most individuals, according to the NSF.
A lower environmental temperature is not the only thermal factor associated with improved sleep. Researchers have noted a nightly drop in body temperature among healthy, normal adults during sleep. This natural cycle, when inhibited or not functioning properly, can disrupt sleep and delay sleep onset, according to medical researchers at Cornell University. Conversely, the researchers noted, a rapid decline in body temperature not only accelerates sleep onset but also “may facilitate an entry into the deeper stages of sleep.”
Therefore, maintaining an appropriately cool sleep environment and accommodating the body's natural tendency to cool itself at night should be a top priority for individuals interested in optimizing their sleep quality. Performance fabrics crafted into bedding applications would be uniquely capable of promoting cool, comfortable—and therefore better—sleep, as these advanced fabrics maximize breathability and heat transfer. Performance fabrics are made for a variety of end-use applications, and can provide multiple functional qualities, such as moisture management, UV protection, anti-microbial, thermo-regulation, and wind/water resistance.
There has been a long felt need in several industries to provide improved bedding to help individuals get better sleep. Such improved bedding would include beneficial wicking among other properties. For example, in marine, boating and recreational vehicle applications, bedding should resist moisture, fit odd-shaped mattresses and beds, and reduce mildew. Particularly with watercraft, there is a need to protect bedding, and specifically sheets, from moisture and mildew accumulation.
An additional problem with bedding, not just with marine and recreational vehicles, is the sticky, wet feeling that can occur when the bedding sheets are wet due to body sweat, environmental moisture, or other bodily fluids. In particular, when bedding is used during hot weather, or is continuously used for a long time by a person suffering from an illness, problems can arise in that the conventional bed sheet of cotton fiber or the like cannot sufficiently absorb the moisture. All of these issues lead to poor sleep.
To date, performance fabric bedding products are not known. There are width limitations in the manufacturing of high gauge circular knit fabrics, because the finished width of bedding fabrics are dictated by the machine used in its construction. At present, performance fabrics are manufactured with a maximum width of under 90 inches wide, given present manufacturing and technical limitations, along with the inability of alternate manufacturing processes to produce a fabric with identical performance attributes. Yet, normal bed sheet panels can be 102 by 91 inches or larger. Thus, performance fabrics cannot yet be used for bed sheets.
Some conventional solutions for the above issues that hinder a good night's sleep include U.S. Pat. No. 4,648,186, which discloses an absorbent wood pulp cellulose fiber that is provided in a variety of sizes and is placed under a mattress. The wood pulp is water absorbent and acts to capture moisture to prevent such moisture from being retained by the bedding or the bedding sheets. However, this proposed solution does not interact with the bedding or the bedding sheets, but merely acts as a sponge for moisture that is in proximity to the target bedding.
U.S. Pat. No. 5,092,088 discloses a sheet-like mat comprised of a mat cover, the inside of which is divided into a plurality of bag-like spaces, and a drying agent packed into a bag and contained in the bag-like spaces in such a manner that the drying agent cannot fall out of the bag-like spaces. A magnesium sulfate, a high polymer absorbent, a silica gel or the like can be used as the drying agent. As can be seen, this proposed solution to moisture in bedding is cumbersome and chemically-based.
In the athletic apparel industry, moisture wicking fabric has been used to construct athletic apparel. For example, U.S. Pat. No. 5,636,380 discloses a base fabric of CoolmaxQ high moisture evaporation fabric having one or more insulating panels of ThermaxB or ThermastatQ hollow core fiber fabric having moisture wicking capability and applied to the inner side of the garment for skin contact at selected areas of the body where muscle protection is desired. However, this application cannot be applied to bedding sheets due to the limitations of the size of the performance fabrics manufactured. Further, performance fabric such as this type cannot be easily stitched together as the denier is so fine that stitching this fabric results in the stitching simply falling apart.
Circular knitting is typically used for athletic apparel. The process includes circularly knitting yarns into fabrics. Circular knitting is a form of weft knitting where the knitting needles are organized into a circular knitting bed. A cylinder rotates and interacts with a cam to move the needles reciprocally for knitting action. The yarns to be knitted are fed from packages to a carrier plate that directs the yarn strands to the needles. The circular fabric emerges from the knitting needles in a tubular form through the center of the cylinder. This process is described in U.S. Pat. No. 7,117,695. However, the machinery presently available for this method of manufacture can only produce a fabric with a maximum width of approximately 90 inches. Therefore, this process has not been known to manufacture sheets, since sheets can have dimensions of 91 inches by 102 inches or greater.
Further, the machinery that is used for bedding is very different than for athletic wear. For example, bedding manufacturing equipment is not equipped to sew flatlock stitching or to provide circular knitting. Bed sheets typically are knit using a process known as warp knitting, a process capable of producing finished fabrics in the widths required for bedding. This method, however, cannot be employed to produce high-quality performance fabrics. Warp knitting is not capable of reproducing these fabrics' fine tactile qualities nor their omni-direction stretch properties, for example.
Circular knitting must be employed to produce a performance fabric that retains these fabric's full range of benefits and advantages. However, in order to produce a fabric of the proper width for bedding applications, a circular knit machine of at least 48 inches in diameter would be necessary. Manufacturing limitations therefore preclude the construction of performance fabrics at proper widths for bedding. The industry is unsure if it could actually knit and then finish performance fabrics at these large sizes, even if the machinery were readily available.
Further, athletic sewing factories are typically not equipped to sew and handle large pieces of fabrics so that equipment limitations do not allow for the manufacture of bedding sheets.
What is needed, therefore, is a bedding system that utilizes performance fabrics and their beneficial properties, the design of which acknowledges and addresses limitations in the manufacture of these fabrics. It is to such a system that the present invention is primarily directed.
BRIEF SUMMARY OF THE INVENTION
Briefly described, in preferred form, the present invention is a high gauge circular knit fabric for use in bedding, and a method for manufacturing such bedding. The bedding fabric has superior performance properties, while allowing for manufacture by machinery presently available and in use. In order to achieve a finished width of the size needed to create sheet-sized performance fabric, a high gauge circular knit machine of at least 48 inches in diameter is necessary. And while warp knitting machines are available that can produce wider fabrics, this method will not provide a fabric with the tactile qualities required, nor provide a fabric with omni-directional stretch.
In an exemplary embodiment, the present invention is a method of making a finished fabric comprising at least two discrete performance fabric portions, and joining at least two discrete performance fabric portions to form the finished fabric. Forming the at least two discrete performance fabric portions can comprise knitting at least two discrete performance fabric portions, and more preferably, circular knitting at least two discrete performance fabric portions. Joining the at least two discrete performance fabric portions to form the finished fabric can comprise stitching at least two discrete performance fabric portions together to form the finished fabric.
The at least two discrete performance fabric portions can have different fabric characteristics. Fabric characteristics as used herein include, among other things, moisture management, UV protection, anti-microbial, thermo-regulation, wind resistance and water resistance.
The finished fabric can be used in, among other applications, residential settings, or in marine, boating and recreational vehicle environments.
The present sheets offer enhanced drape and comfort compared to traditional cotton bedding, and are as fine as silk, yet provide the benefits of high elasticity and recovery along with superior breathability, body-heat transport, and moisture management as compared to traditional cotton bedding.
Conventional fitted sheets can bunch and slide on standard mattress sizes. Furthermore, if the fitted bed sheets do not fit properly, they do not provide a smooth surface to lie on. The present invention overcomes these issues.
The present high gauge circular knit fabrics stretch to fit and offer superior recovery on the mattress allowing the fabric to conform to fit the mattress without popping off the corners of the mattress or billowing. The performance fabric can include spandex, offers a better fit than conventional bedding products, can accommodate larger or smaller mattress sizes with a single size sheet, and can conform to mattresses with various odd dimensions.
Spandex—or elastane—is a synthetic fiber known for its exceptional elasticity. It is stronger and more durable than rubber, its major non-synthetic competitor. It is a polyurethane-polyurea copolymer that was invented by DuPont. “Spandex” is a generic name, and an anagram of the word “expands.” “Spandex” is the preferred name in North America; elsewhere it is referred to as “elastane.” The most famous brand name associated with spandex is Lycra, a trademark of Invista.
The present high gauge circular knit fabric offers durability in reduced pilling and pulling when compared to other knit technologies, and offer reduced wrinkles and enhanced color steadfastness
In a preferred embodiment, the present performance fabric can allow for a one-size fitted sheet that can actually fit two different size mattresses. For example, the full fitted sheet of the present invention can fit on both the full and queen size bed. The twin fitted sheet of the present invention will also fit an XL twin. In a boating application, the present invention can be produced to fit almost every custom boat mattress.
Testing of the present invention conducted at the North Carolina State University (NCSU) Center for Research on Textile Protection and Comfort confirms that the present performance fabrics provide a cooler sleeping environment than cotton. Performance bedding was tested side-by-side with commercially available cotton bed sheets in a series of procedures designed to measure each product's heat- and moisture-transport properties, as well as warm/cool-to-touch thermal transport capabilities.
Across all tests, the present performance fabrics in bedding outperformed cotton, demonstrating the performance fabric's superiority in establishing and maintaining thermal comfort during sleep. This advantage is evident to users from the very onset, as NCSU testing indicates that, on average, performance bedding of the present invention offers improved heat transfer upon initial contact with the skin, resulting in a cooler-to-the-touch feeling.
During sleep, high gauge circular knit performance bedding of the present invention helps to maintain thermal comfort by trapping less body heat and breathing better than cotton. Testing has demonstrated that performance bedding made out of performance fabrics transfers heat away from the body up to two times more effectively than cotton. This is critically important not only for sustained comfort during sleep, but also in terms of enabling the body to cool itself as rapidly as possible to facilitate sleep onset. In addition to trapping less heat, performance bedding breathes better than cotton—up to 50% better, giving performance bedding a strong advantage in terms of ventilation and heat and moisture transfer.
The performance advantage over cotton holds true for simulated dry and wet skin conditions, confirming that certain performance fabrics in bedding are better suited than cotton at managing moisture (e.g., sweat) to maintain thermal comfort. In addition to wicking moisture away from the skin through capillary action, the performance fabric's advanced breathability further enables heat and moisture transfer through evaporative cooling. As a result, the user is kept cooler, drier and more comfortable than with cotton.
The present performance bedding holds a distinct advantage over cotton in enabling, accommodating and maintaining optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a preferred embodiment of the present invention.
FIG. 2 illustrates another preferred embodiment of the present invention.
FIG. 3 illustrates a further preferred embodiment of the present invention.
FIG. 4 illustrates another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Although preferred embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the preferred embodiments, specific terminology will be resorted to for the sake of clarity.
It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to a sheet or portion is intended also to include the manufacturing of a plurality of sheets or portions. References to a sheet containing “a” constituent is intended to include other constituents in addition to the one named.
Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value.
By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a fabric or system does not preclude the presence of additional components or intervening components between those components expressly identified.
Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, the present invention of FIGS. 1 and 4 provides a sheet 10 shown having dimensions of 102 inches in length and 91 inches in width. The material is manufactured from performance fabric, which can include, for example, varying amounts of one or more of Lycra, Coolmax, Thermax and Thermastat. In a preferred embodiment, the fabric is treated so that the fabric has antimicrobial properties. By using circular-knit performance fabric, the fabric is able to provide elasticity in all four directions. This property allows for the sheet to fit extraordinary mattress, cushion and bedding shapes, as well as providing better fits for traditional rectangular sheets. By using performance fabrics, the sheet has elastic properties that allow stretching in the directions shown as 30 . In addition, by using circular-knit performance fabric, the resulting bedding retains an exceptionally fine tactile quality critical for providing maximum levels of enhanced comfort.
An alternative to circular knitting is non-circular knitting—for example, warp knitting. This method can achieve widths greater than circular knitting. Industrial warp knit machines, for example, can produce tricote warp knit fabrics up to 130-140 inches in width. Circular knitting, however, is less expensive, as it requires less set-up time. Circular knitting also provides greater multidirectional stretch.
In order to provide a sheet that exceeds the maximum dimensions of fabric that can be produced by available circular knitting machines, flat lock stitching 12 is used to join a plurality of portions resulting in a sheet that is 91 inches wide (as shown). In an exemplary embodiment, piping 11 can be included in close proximity to the stitching. The stitching can be the same color as the fabric of the sheet portions, or different color(s). The piping can be ¾ inch straight piping without a cord or other filler. In one preferred embodiment, the stitching is 16 stitches per inch. Piping 11 can be included at one end of the sheet and can be the same or a different color as the sheet fabric.
For a fitted sheet, the sheet can include an elastic portion surrounding the edge of the fitted sheet to better keep the fitted sheet in place when placed on a mattress or other sleeping surface. A cord can be sewn into the edge of the fitted sheet and cinched around the mattress or other sleeping surface to better hold the fitted sheet in place.
Referring to FIG. 2 , a sheet is shown having dimensions of 91 inches wide and 102 inches in length. In this embodiment, stitching 14 is shown 34 inches from an interior edge 18 of a main portion 16 and another stitch 14 at edge 20 of the sewn-on portion. Flat lock stitching can be used for the stitching. Piping can be applied at or in proximity to the stitching.
Referring to FIG. 3 , a non-rectangular shaped sheet is shown. In this exemplary embodiment, elastic can be included around the edge of the fitted sheet to better maintain the fitted sheet in position when placed on a sleeping surface. In one embodiment, pull ties 24 can be installed at various locations around the edge of the fitted sheet in order to assist in maintaining the fitted sheet secured to the sleeping surface. The pull tie can be cinched to increase tension around the edge of the fitted sheet as shown by 26 .
Stitching used for securing the portions of the sheet together can include that shown as 28 a . In another embodiment, the stitching used for securing the portion of fabric together is shown as 28 b.
Referring to FIG. 4 , yet another preferred embodiment of the invention is shown. In this embodiment, the sheet can be assembled through stitching of differing fabrics for generating performance zones in the sheet. For example, zone 32 can have higher wicking properties than the other zones since this area is where the majority of the individual body rests. Areas 34 a through 34 d can have higher spandex or other elastic fabric properties so that the fit around a sleeping surface is improved. Area 36 may have thermal properties such as increased cooling since this area is generally where the individual's head lies. In an exemplary embodiment, the pillow covers of pillows used by the individual also have differing properties from the remainder of the sheet, e.g., thermal properties.
The present invention encompasses the construction of bedding materials that have superior performance properties while allowing for manufacture by machinery presently available and in use. More specifically, the invention is related to a new method for fabricating a covering and or sheets in bedding. When using the circular knitting machine, the high gauge performance fabrics can only be made to a maximum size of 72.5 inches without losing the integrity of the spandex in the fabric. Yet, normal sheet panels are 102×91 inches. This presents problems when manufacturing sheets from performance fabrics.
Additionally, special stitching techniques must be used given the thread density of the fabric. Using this special stitching, panels are sewn together to produce bedding or a sheet that is the proper size for standard bed sheets. Because discrete portions/panels are used in the manufacture of the present fabrics, panels can be selected that provide different properties for different areas of the bedding ( FIG. 4 ). Stitching or seams on the sheet can also allow for the ease of making the bed. Because the bedding is made from performance fabric with spandex, it stretches to permit multiple and custom sizing for applications in cribs, recreational vehicles and boats.
Circular knitting machines used for high gauge performance bedding fabrics are called high-gauge circular knitting machines, because of dense knitting with thin yarn. High gauge generally denotes 17 gauges or more. Seventeen gauges indicate that 17 or more cylinder needles are contained in one inch. Circular knitting machines of less than 17 gauges are referred to as low-gauge circular knitting machines. The low-gauge circular knitting machines are often used to knit outerwear.
“Yarn count” indicates the linear density (yarn diameter or fineness) to which that particular yarn has been spun. The choice of yarn count is restricted by the type of knitting machine employed and the knitting construction. The yarn count, in turn, influences the cost, weight, opacity, hand and drape of the resulting knitted structure. In general, staple spun yarns tend to be comparatively more expensive the finer their count, because finer fibers and a more exacting spinning process are necessary in order to prevent the yarn from showing an irregular appearance.
A top width in the 90-inch range is currently possible using a circular knit fabric formed on a 36-38-inch diameter machine, although higher levels of spandex in the performance fabric tend to pull the width in. In just one example, on a 30-inch diameter machine, the spandex can reduce an otherwise 94-inch circumference fabric tube to one with a 60-65 inch finished width.
A major limitation in finished width is not strictly a knitting concern but also concerns finishing. With performance fabric, it tends to sag in the middle—increasingly so with greater widths—making finishing difficult to impossible above a certain threshold. A possible 90-inch finished width is contingent upon having a good finishing set-up capable of handling the present performance fabric. This potential for difficulties would only become compounded at the larger widths required for bed sheets.
In a preferred process, the present fabric undergoes a heat setting finishing process. Applying a moisture-wicking finish to another fabric—like cotton—that can be produced at larger widths appears unlikely to match the moisture-control properties of the present fabric, as polyester itself is naturally moisture-resistant and there are physical actions (e.g. capillary action) at play. Further, the use of cotton comes at the expense of breathability and heat-transfer capabilities (as confirmed by laboratory testing) and stretchability.
Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. While the invention has been disclosed in several forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions, especially in matters of shape, size, and arrangement of parts, can be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. Therefore, other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the breadth and scope of the claims here appended. | Bedding material including a first fabric section manufactured from performance fabric and having a first and second side; and, a second fabric section attached to the first side of the first fabric section. Additionally, a third fabric section can be attached to the second side of the first fabric section. The first fabric section can be attached to the second fabric section through a flatlock stitch. The first fabric section can include a first zone and a second zone wherein the first zone contains different performance properties from the second zone and the first zone can have thermal or moisture wicking properties. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to data processing systems and more particularly to sequencers for microprogrammed control units. A sequencer is a means such as a set of circuits which determines the orderly read out of the microinstructions stored in a control memory.
2. Description of the Prior Art
It is known that data processing systems generally comprise a central unit, a main memory and a plurality of peripheral units connected to the central unit by means of a plurality of input/output channels for the exchange of information. The data processing system functions by processing data according to well defined program instructions. From the logical point of view the central unit comprises a control unit and an operative unit. The program instructions are interpreted and executed by means of microprograms, that is, microinstruction sequences that the control unit reads out from a control memory, one microinstruction at a time. Through suitable decoding the microinstructions generate a set of elementary commands, or microcommands, which cause the working of the several logic networks of the central unit in the manner required by the several program instructions. The operative processes performed by the system may be internal, that is, executed within the central unit with possible data exchange with the working memory, or external, that is, requiring the intervention of peripheral units.
In the second case they require an information transfer between some peripheral units and the central processing unit through input/output channels which connect the peripheral units to the central processing unit. The operative processes which develop within the peripheral units are not synchronized among themselves nor with the processes which develop within the central unit. Therefore, the whole system monitoring is not carried out by one program, univocally determined as to the timing, but it is rather performed with "interruptions" which require the execution of predetermined services. The "interruptions" can be caused by interrupt requests coming from peripheral units. Owing to an interrupt request, the central unit must interrupt the execution of an internal process in progress in order to execute the service required by the peripheral unit. As already mentioned, the "interruptions" are asynchronous events which may occur at any time and phase of the internal processes and which, generally, require the immediate interruption of the process in progress and the immediate execution of the required service. This is particularly true in case the interrupt requests come from fast peripheral units, such as disk units. In microprogrammed central units, this involves the interruption of microprograms in progress, through which the program instructions of the internal process are executed, and the start of microprograms executing the services required by the interruption. However, when an interruption occurs, information about the status of the internal interrupted process must be saved in order to resume such process once the required service has been executed.
This problem has been solved, in the prior art, by a multiplication of resources, particularly of registers, devoted to the storing of the microprogram address and determined states of the several overlapping processes. For instance, in U.S. Pat. No. 4,001,784, the control unit of a data processing system comprises three microprogram address registers. A first register is used to store the addresses of the microprogram which performs the program instructions of the internal processes; a second register is used to store the addresses of the microprogram executing the services required by interruptions have a certain priority level; a third register is used to store the addresses of the microprogram executing services required by interruptions have another priority level. Such structure allows the system to save microprogram addresses which, otherwise, would be lost owing to the interruptions, but it is not effective for the "saving" of addresses which should be saved within the same program. Such concept may be explained by referring to microprogram structures. It is known that the several program instructions of an operative process are executed by microprograms consisting of a set of microinstructions stored in a control memory. The microinstructions are preferably arranged in sequence to form a microprogram. In other words, a microinstruction stored in a memory address n is followed by the microinstruction stored in address n+1, and so on. In such a way, the memory addressing operation may be carried out by a network which increments the preceding address by one unit and the network is simple and inexpensive. However, such a design cannot always be utilized. First of all, during the execution of a microprogram, it is often necessary to choose between two possible paths according to particular conditions which occur and, for at least one of such paths, the sequential addressing is no longer possible. Further, the several microprograms, each one allowing for the interpretation of a well determined program instruction, may contain portions formed by identical microinstruction sequences. To avoid a memory waste, it is suitable to store such microprogram portions in the control memory only once so as to avoid duplications. Such microinstruction portions or sequences, identical for several microprograms, are named "subroutines" and it is clear that, for all the microprograms which use them, possibly with the exception of one, the access to such subroutines cannot follow the general criterium of sequential addressing. During the microprogram execution jump microinstructions, that is, unconditioned jump microinstructions, are therefore provided. The execution of such jump microinstructions causes the interruption of the sequential addressing operation and the jump to a microinstruction whose address is determined by the information contained in the jump microinstruction. If all of the subroutines were final portions of the microprograms, their execution would complete the microprogram which has called for one of them and there would be no further problems. On the contrary, a subroutine may also form an intermediate portion of a microprogram. It is therefore necessary, at the end of the subroutine, to return to the specific microprogram by which the subroutine has been called. The subroutine is not able by itself to specify to which of the several microprograms it has to go back to and which must be the subsequent return address in the microprogram basic sequence. Therefore, the return address necessary to go back to the main microprogram after the execution of a subroutine must be saved in a suitable register before starting the subroutine. Generally, the address to be saved is the jump microinstruction address, which calls for the subroutine, incremented by one. The last microinstruction of the subroutine must contain a command information which controls the return, that is, the addressing of the subsequent microinstruction by using the saved address. However, it cannot contain information concerning the specific register where the address has been saved, but the read out from the register of address to be used must be automatically obtained. Generally, a subroutine may also contain, in its turn, microprogram portions common to other subroutines or microprograms, which will be considered subroutines of second level or of subsequent level. It will be therefore necessary to provide a number of address saving registers equal to the subroutine levels which are foreseen and an automatic mechanism of return, that is, of selection of one of these registers. A particularly effective solution of such problem is described in U.S. Pat. No. 3,909,797. According to the solution suggested by such patent, the registers devoted to save the several return addresses from a stack where the output order of the information stored therein is opposite to the input order, that is, information is handled on a last in, first out basis (LIFO). In other words, the last recorded information is always the first one to be read out. This allows the "nesting" of subroutines of different levels, the one inside the other, and the orderly return to the several subroutines up to the internal computation microprogram. However, such solution does not consider the problems rising from a microprogrammed system where a microprogram interruption may be caused by external events. In fact, the above solution does not satisfy the requirements of a control unit which jointly uses microprograms comprising common subroutines and interruption mechanisms.
One solution to such problem may be the combination of the addressing circuits described in the two mentioned patents, that is, a number of register stacks may be provided equal to the microprogram levels which may be executed, suspended or started owing to an interruption. Such a solution would however be complex and expensive.
SUMMMARY OF THE INVENTION
The present invention overcomes these disadvantages. According to the invention, a unique sequencer is provided for a microprogrammed control unit. The sequencer comprises one register stack, which includes a loading/unloading mechanism of the LIFO type (last in, first out) and is used to store both addresses of return from subroutines within the same microprogram, and microprogram addresses which must be saved owing to an interruption. The sequencer further comprises a +1 counter or incrementer and a summing unit, as well as a present address register and a microprogram counter register. The sequential increment of the addresses is obtained through a looped communication path which comprises a counting network and a microprogram counter in series. Such path comprises an input/output node for loading/unloading information from the stack. The non-sequential increment of the addresses, that is, the jump (absolute or relative) to a new address, is obtained through two looped communication paths, one of which comprises the present address register and the summing unit, and the other path comprises a control memory output register and, in case, the summing unit. All these paths have a common portion accessed through a multiplexer. The essential problem to be solved in such a system is the elimination of interferences among several different savings caused by the particular time at which the interruption occurs. In fact, if the interruption occurs during a conditioned jump microinstruction, two addresses are to be saved. This is allowed in the subject invention by providing that the first microinstruction of the interrupt microprogram must be a conditioned jump microinstruction with save of address. By this, the further advantage is obtained of having a homogenous format to the program microinstructions; the saving function, specified by a predetermined microinstruction bit, is only present in the jump microinstructions where it may be necessary. Such function is not present, in any case, in the sequential microinstructions where it would not be useful and where the utilization of a bit with such a specific use is inconsistent with the need to assign a different meaning to the several microinstruction bits. These and other features of the invention will appear more clearly from the following description of a preferred embodiment of the invention and from the enclosed drawings where:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows how FIGS. 1A and 1B are to be juxtaposed for their reading.
FIGS. 1A and 1B jointly show a microprogrammed control unit comprising a sequencer according to the present invention.
FIG. 2 shows the timing diagrams of some timing signals used in the unit of FIGS. 1A and 1B.
FIGS. 3A through 3E show the format of the microinstructions used in the control unit of FIGS. 1A and 1B.
FIG. 4 shows a slightly modified form of the sequencer of FIG. 1A.
FIG. 5 shows a second modified form of the sequencer of FIG. 1A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1A and 1B jointly show a microprogrammed control unit comprising a sequencer according to the present invention. The microprogrammed control unit of FIGS. 1A and 1B may be associated to central processing units having a different architecture and which are not described herein because they are beyond the scope of the present invention. Particularly, it may be used in the data processing system described in U.S. Pat. No. 4,001,784 to which reference is made as an integral part of the present description in order to have a complete understanding of the whole central processing unit. In such a central processing unit, FIGS. 1A and 1B of the present invention integrally replace the circuits shown in FIGS. 8a and 8b of the mentioned patent.
The control unit substantially comprises (FIG. 1B):
a control memory or ROS 1 where the microprograms are stored;
an output register 2 (ROR) for ROS memory, receiving and storing at each machine cycle a microinstruction read out from ROS memory 1;
an addressing register ROSAR 3 having its outputs connected to the address inputs of ROS memory 1 and receiving and storing at each machine cycle a ROS address;
a microinstruction decoder 4 which receives on its inputs the microinstruction contained in register ROR 2 and decodes it providing on its outputs elementary commands or microcommands. Such decoder may be of the type described in the U.S. Pat. No. 3,812,464, which decodes the microinstructions according to a field of the same, the field having variable length and being named function code. FIG. 1B shows, in output from decoder 4, only the microcommands necessary for the understanding of the invention and precisely S 0 , S 1 , S 2 , S 3 , S 4 , FILE EN, PUSH/POP, RDR, WDR, DR ADDR, EOS, IR;
a timing unit 5 which cyclically generates timing signals for each machine cycle. Such timing signals are forwarded to the several elements forming the central unit for timing them. FIG. 1B shows in output from unit 5 the signals necessary for understanding the invention, and precisely: STRORA, PH2, STCSSA, STINTA, STNSA;
a timing network 6 which receives on its inputs microcommands decoded by decoder 4 and timing signals produced by timer 5. Network 6 performs logical AND operations among timing signals and microcommands, and supplies on its outputs suitable timed microcommands during each machine cycle.
In FIG. 1B only signal STSNA (IR+S 4 ) is shown in output from network 6, which signal is necessary for a full understanding of the invention;
the control unit further comprises an index register IR 7 intended to receive and to store a particular machine status or condition, as for instance the occurrence of an input (CI) or an output (COT) carry due to arithmetical or shift operations, or the occurrence of conditions, detected by comparison and indicated by a positive comparison signal NZ2.
These statuses received from other central unit elements (described, for instance, in the mentioned U.S. Pat. No. 4,001,784) are sent to inputs of register IR7 through a two path multiplexer circuit 8. A bank of registers DR9 is further provided, which may be addressed by microcommands. The content of register IR7 may be saved in such bank and from there the previously saved statuses may be read out and reloaded in the index register IR7. To this purpose, the outputs of index register IR7 are connected through a channel 10 to inputs 11 of register bank 9, and the outputs 12 of register bank 9 are connected, through channel 13, to a set of inputs of multiplexer 8 which may selectively transfer to index register 7 the statuses read out from bank 9 or the statuses which occur during machine cycle. The outputs of index register 17 are further connected, through a channel 14 and a group 15 of enabling AND gates, to decoder 4, to provide it with information which adds to the one obtained from the read out microinstruction.
The control unit sequencer means, that is, the circuit set devoted to the control memory 1 addressing, comprise:
a sequencing unit 16 of the type described in the already mentioned U.S. Pat. No. 3,909,797. Such unit is, for instance, available as an integrated circuit manufactured by the U.S. firm AMD and marketed with code AM2911;
an auxiliary register 17 (ROSPA) intended to contain the address of the microinstruction in the course of execution;
a summing network 18;
a multiplexer circuit 19.
The sequencer unit 16 substantially comprises:
a stack 20;
a microprogram counter register μ PCR 21;
a +1 counter or incrementer 22;
a multiplexer circuit 23;
a set 24 of tristate output control circuits;
a set 25 of AND gates;
an inverter 26 connected to the control input of the tristate set 24.
The sequencing unit 16, in the whole, has a set 27 of address inputs (by connecting in parallel a suitable number of integrated circuits AM 2911, any desired parallelism can be obtained), a set 28 of address outputs and a certain number of control inputs. Two pins S 0 and S 1 are used to control multiplexer 23. Multiplexer 23 is provided with three sets of inputs and transfers the signals present on one of the three input sets to its output depending on the logical combination of the signals present on S 0 , S 1 inputs. An input set 29 of multiplexer 23 is connected to input set 27. A second input set 30 is connected to outputs of register stack 20 and a third input set 31 is connected to the outputs of microprogram counter register μ PCR 21. Outputs of μ PCR 21 are further connected to the inputs of register stack 20. Outputs of multiplexer 23 are connected to inputs of AND gate set 25, the AND gates being enabled by a signal ZERO at logical level 1 applied to a control input 32. The outputs of AND set 25 are connected to the inputs of the tristate output set 24 and to the inputs of incrementer 22. The tristate output set 24 is enabled to the information transfer by a command signal applied to an input pin OE connected to the enabling inputs of tristates 24 through inverter 26. Incrementing counter 22 is controlled by a signal CN applied to input 33.
When CN is at logical level 1 counter 22 increments by one unit the binary information applied to its inputs and transfers it on its outputs; when CN=0 the binary information applied to inputs of counter 22 is transferred unchanged. The loading of register μ PCR 21 and of stack 20 is controlled by a timing signal CK applied to an input 34.
When the CK signal rises from 0 to 1, register μ PCR 21 is loaded and, in case, stack 20 is enabled too. Stack 20 comprises 4 cascade connected registers 20A, 20B, 20C, 20D and its operation is controlled by two signals FILE EN and PUSH/POP applied to two control inputs 35 and 36 respectively. When FILE EN=1, no operation is performed by stack 20. When FILE EN=0, stack 20 operates according to signal PUSH/POP. In case PUSH/POP=1, the information present on the output of μ PCR 21 is stored in register 20A with the rising edge of signal CK (it is therefore available on inputs 30 of multiplexer 23 through channel 37). At the same time, the information previously stored in registers 20A, 20B, and 20C is transferred or pushed into registers 20B, 20C, and 20D respectively.
In case PUSH/POP=0, the information stored in registers 20D, 20C, and 20B is transferred or popped into registers 20C, 20B, and 20A respectively, with the rising edge of signal CK.
The information present, at this point, in register 20A is directly available on inputs 30 of multiplexer 23 through channel 37. Outputs 28 of sequencing unit 16 are connected, through channel 38, to the inputs of the memory addressing register 3 (ROSAR). Such outputs are further connected, through channel 39, to the inputs of present address register 17 whose outputs are connected, through path 40, to a first input set A of summing network 18, which receives, through path 41, on a second input set B a certain number of microinstruction bits read out from ROS memory 1. The outputs of summing network 18 are connected to a first input set of multiplexer 19, which receives on a second input set, through paths 41, 42, a certain number of bits read out from ROS memory 1. A third input set of multiplexer 19 receives a fixed binary addressing code, for instance 000F. The outputs of multiplexer 19 are connected to inputs 27 of sequencing unit 16. The selection of the input set is determined by the logical level of the two signals of control inputs S 2 , S 3 .
The sequencer is completed by some circuits for connection to a logical priority network intended to detect the interruptions coming from several channels connecting peripheral units. The logical priority network may be of the type described and shown in FIG. 7 of the mentioned U.S. Pat. No. 4,001,784. Such priority network emits on one of three output leads 99, 150, 154 an interrupt signal having high, low, intermediate priority respectively. On one of four leads 158, 159, 161, 162, it further emits a signal at logical level 1 which indicates which is the channel sending the interruption. For instance, a channel 1 is associated to lead 158, a channel 2 to lead 159, and so on. One or more peripheral units will be connected to each channel through a peripheral adapter or peripheral control unit.
Turning to FIG. 1B, leads 99, 150, 154 are connected to the inputs of an OR gate 43, each one through AND gates 47, 48, 49 having two, three, four inputs respectively. OR 43 output is connected to an input of a two input AND gate 44; AND gate 44 is controlled by a cyclical timing signal STINTA (INTERRUPTION STROBE) applied to its second input. The output of AND gate 44 is connected, through lead 50, to input OE of sequencing unit 16. When OE is at logical level 1, the outputs 28 of the sequencing unit 16 are locked (in high impedance output status). Output of AND gate 44 is further connected to control input CN of sequencing unit 16 through a NOT 51 and to the control input of a tristate set 46. Tristate set 46 receives in input an interruption vector (that is, the first microinstruction address of the microprogram called for by the interruption) and transfers such vector on channel 38 and on channel 39 when it is enabled by AND gate 44 with output at logical level 1.
The interruption vector is generated by a logical network 45 (VECTOR GENERATOR) which suitably codes the input signals, constituted by the interruption signals at different priority levels (received on leads 99, 150, 154, through AND 47, 48, 49) and by the interrupting channel signals received on leads 1518, 159, 161, 162.
The circuital structure of logical network 45 is beyond the scope of the invention. This network is substantially a coding network which generates an address binary output code on channel 51 depending on the binary code received on its inputs (7 bits, two of which are at logical level 1). In alternative, in order to have an higher flexibility, the interruption vector generator can be constituted by a coding network which generates an addressing binary output code which addresses, in its turn, an auxiliary memory where the interruption addresses are stored.
The vector generator outputs are connected to the inputs of tristate set 46 through channel 51. AND gates 47, 48, 49 together with JK flip-flops 52, 53, 54 and with two AND gates 55, 56 (FIG. 1B) provide suitable timing of interrupt signals and interrupt masking if a higher priority interruption was already in progress. Output of AND gate 47 is connected to J input of flip-flop 52; output of AND gate 48 to J input of flip-flop 53 and output of AND gate 49 to J input of flip-flop 54. The inverted output of flip-flop 53 is connected to an input of AND gates 48, 49. The inverted output of flip-flop 54 is connected to an input of AND gate 49. The inverted output of flip-flop 52 is further connected to an input of AND gates 55, 56 and the inverted output of flip-flop 53 is connected to an input of AND gate 56. A microcommand EOS (end of service) is applied to K input of flip-flop 52 through lead 57 and to an input of AND gates 55, 56 which have their outputs connected to K input of flip-flops 53, 54 respectively. Flip-flops 52, 53, 54 are set/reset according to the logical level on their J, K inputs, by the falling edge of a timing signal PH2 applied to their clock input. The set of such flip-flops determines the interruption level which is in progress.
The time operation of such network will be explained later on. Before explaining the operation of the sequencer object of the present invention, a brief description is made about the system timing and the organization of the microinstructions controlling it with particular reference to the sequencer working.
FIG. 2 shows, in timing diagram, the signals produced by timing unit 5 which are useful for understanding the sequencer working. A machine cycle consists in a time interval from time t 0 to time t 0 1 which is the beginning of the subsequent cycle. A machine cycle start is determined by a timing signal STRORA (diagram a) which rises to logical level 1 at time t 0 and remains at logical level 1 up to time t 5 . The rising edge of STRORA is used as strobe signal for register ROR 2. At a time t 2 a second signal PH2 (diagram b) rises to logical level 1 and remains at such level up to time t 10 . The rising edge of PH2 is used as strobe signal for register stack 9, while the falling edge of PH2 is used as clock signal for flip-flops 52, 53, 54. At a time t 3 a third signal STSNA (diagram c) rises to logical level 1 and remains at such level up to time t 7 . The rising edge of STSNA is used as timing signal applied to network 6. When one of microcommands IR or S4 is present, it produces a timed microcommand STSNA (IR+S 4 ) used as strobe signal for register 7. At an instance t 4 a fourth signal STINTA (diagram d) rises to logical level 1 and remains at such level up to a time t 7 . Such signal is used to enable AND gate 44. At a time t 6 a fifth signal STCSSA (diagram e) rises to logical level 1 and remains at such level up to tie t g . The rising edge of STCSSA is used as strobe signal for register 3, memory 1, register 17 and sequencing unit 16. Times t 0 , t 2 . . . t 11 , orderly follow in the time.
The organization of the microinstructions is now considered, such microinstructions controlling during each machine cycle the operation of the sequencer, the control unit and the whole data processing central system.
FIGS. 3A, 3B, 3C, 3D, and 3E show the format of the several basic types of microinstructions, that is, the meaning assumed by the several bits forming each microinstruction. Essentially the microinstructions are of two types: OPERATIVE microinstructions (FIGS. 3A, 3B) and JUMP microinstructions (FIGS. 3C, 3D, 3E). The OPERATIVE microinstructions may be TRANSFER microinstructions (FIG. 3A TRANSF.) or LOGIC/ARITHMETIC operative microinstructions (FIG. 3B LOGIC/ARITM). A transfer microinstruction comprises several fields of bits having a precise meaning. A first field (bits 0-3), named FC or FUNCTION CODE, characterizes the microinstruction and assigns to the subsequent fields a determined meaning. Decoding network 4 (FIG. 1B) decodes the function code and generates output signals. The output signals from decoding network 4 control the several registers and the several gates constituting the system in order to perform the function defined by the microinstruction bits. A second field (bits 04-07), named BLOCK SEL or block selector, defines which are the system elements involved in the transfer. For instance, the transfer microinstruction can control the information transfer from a register of a bank to a register of another bank, or from the output register of the working memory to an output register of channel interface, etc. (such considerations are referred to the specific architecture described in the already mentioned U.S. Pat. No. 4,001,784). A third field (bits 08-13), named ADDR A, defines the specific address of one of the registers involved in the transfer, for instance, one of the registers of a bank or one of the output registers. A fourth field (bits 14-21), named ADDR B, defines the specific address of the other register involved in the transfer. A fifth field (bit 22), named DIR, defines the transfer direction, that is, if the transfer has to occur from the location defined by ADDR A to the one defined by ADDR B or vice versa. Other fields (bits 23-31) are used for control functions and as parity check bits.
FIG. 3B shows the format of a LOGIC/ARITHMETIC operative microinstruction. Also in this case, there is a field (bits 0-3) with meaning of function code FC, a field (bits 18-20) with meaning of address of the register (SOURCE) containing the operand (the operator may be stored in a fixed register), a field (bits 21-23) which defines the Logic/Arithmetic operation to be executed (OP SEL), a field (bits 24-26) which defines the address of the register where the operation result is to be stored, and a field IR (bit 29) which defines whether the index register is to be updated with the conditions of carry/overflow/etc., which have occurred owing to the operation.
Other fields, not specifically shown, may assume suitable meanings. The operative microinstructions do not contain, contrarily to the jump ones, any useful information defining the subsequent microinstruction address. The subsequent microinstruction will be therefore called for by the sequencer through the increment by one unit of the previous operative microinstruction address.
FIG. 3C shows the format of an absolute jump microinstruction (ABS.JUMP). Such kind of microinstruction specifies the address of the following microinstruction itself. A first field (bits 0-5) constitutes the function code. A second field (bit 06), named SAVE, defines whether the progressive address of the jump microinstruction in progress, incremented by one unit, must be saved into stack 20 in order to be called for later on; if bit 06 is at logical level 1, the saving operation occurs. A third field (bits 07-22), named ADDR, constitutes the absolute address of the subsequent microinstruction. Other fields, not specifically shown, may assume suitable meanings.
FIG. 3D shows the format of a relative conditioned jump microinstruction (REL. COND. JUMP). Such kind of microinstruction, having a generical address N, defines that the subsequent microinstruction must be the one having address N+1 if a condition specified by the same microinstruction is not verified, and must be the one having address N+K if the condition specified by the same microinstruction is verified. The displacement K is provided by the same microinstruction. Also in this case, a first field (bit 0-5) defines the function code. A second field (bit 06), named SAVE, defines whether the progressive address of the jump microinstruction in progress, incremented by one unit, must be saved into stack 20 in order to be recalled later on. A third field (bit 07), named C DR, defines whether the condition to be verified is contained in a DIRECT REGISTER. A fourth field (bits 08-16) defines which is the condition COND to be verified. A fifth field (bits 17-29) defines the displacement K.
At last FIG. 3E shows the format of a relative unconditioned jump microinstruction (REL. UNC. JUMP), with possible operations of saving and of return from subroutine and with possible priority change. Such microinstruction is typical for the start of a subroutine or of an interrupting microprogram and for the return from a subroutine or from an interrupting microprogram. Also in this case, a first field (bits 0-05) defines a function code and a second field (bit 06), named SAVE, indicates if the progressive address of the jump microinstruction in progress, or more generally, the address present in register ROSPA, incremented or not by one unit, must be saved into stack 20 in order to be recalled later on. A third field (bit 07), named RD DR, defines if the content of a DIRECT REGISTER must be read out and transferred into register IR 7. A fourth field (bit 08), named WR DR, defines if the content of register IR 7 must be saved by writing it in a DIRECT REGISTER. A fifth field (bit 09), named RET, defines if the microinstruction is a microinstruction of return from a subroutine or from an interrupting microprogram; in this last case a pop operation of stack 20 is commanded and the subsequent microinstruction address is read out from stack 20. A sixth field (bits 10-13), named DR ADDR, defines which DIRECT REGISTER of stack 9 is interested in the transfer (read or write). A seventh field (bit 14), named PC (PRIORITY CHANGE), defines if a priority change must occur, for instance, because a microprogram of interruption treatment ends. An eighth field (bit 17-29) gives the jump displacement K. Once described, the format of the microinstructions used to control the central system and the sequencer object of the invention, as well as the essential timings of a machine cycle, the sequencer working may be examined in the different possible cases.
1 - Initialization
To initialize the system it is enough to force by a start push button (not shown), which activates at the same time a machine cycle, a logical level 0 on input 32 which locks AND gates 25. An assumption is made that no external interruption be present, a start address 0 is forced on channels 38 and 39 and is applied to inputs of incrementer 22. Such address is loaded into registers 17 (ROSPA) and 3 (ROSAR) by the rising edge of signal STCSSA, while address +1 is loaded into counter μ PCR 21.
A read operation of ROS memory 1 starts, at the end of which the microinstruction of address 0 is available on the output of such memory. At the subsequent cycle start (time t 0 ) the read out microinstruction is loaded into register ROR 2 by the rising edge of timing signal STRORA, so that the microinstruction is available on inputs of decoder 4 and a set of microcommands is produced on the outputs of decoder 4. Such microcommands allow the microinstruction execution during the cycle. Supposing that the read out microinstruction is an operative microinstruction, it causes an address sequential updating.
2 - Address sequential updating:
Microcommands S 0 and S 1 at logical level 0 are two of the microcommands generated by decoder 4 and they are available from time t 0 . Such microcommands select input set 31 of multiplexer 23, so that the new address "1", present in register μ PCR 21, is transferred on channels 38 and 39 and applied to inputs of incrementer 22. At instant t 6 the new address "1" is loaded into registers 17 and 3 by the rising edge of signal STCSSA, and an address incremented by one unit, that is "2", is loaded into register μ PCR 21.
Generally, if at instant t 0 of any cycle, an operative microinstruction of address N is loaded into register ROR 2, this means that during the previous cycle address N was loaded into registers ROSPA 17 and ROSAR 3 and that address N+1 was loaded into register μ PCR 21, all these loadings occurring at a time t 6 by rising edge of timing signal STCSSA.
During the cycle within which the microinstruction of address N is executed, the new address N+1 is transferred by the rising edge of STCSSA from μ PCR 21 to channels 38, 39 through multiplexer 23, AND gates 25, tristate circuits 24, and then loaded into registers ROSPA and ROSAR.
At the same time the content of μ PCR 21 is incremented to N+2.
3 - Forcing to microprogram routine or error treatment.
It is to be noted that if the operative microinstruction in progress is of the logic/arithmetic kind, field IR (bit 29) may define, if at logical level 1, that register IR 7 must be loaded with the conditions verified during the execution of such microinstruction. Such conditions, coming from a condition check network, not shown, are transferred through multiplexer 8 (enabled by a microcommand S 4 ) to inputs of register 7 and loaded into it by the rising edge of a signal STSNA.IR which is obtained as a logical AND of microcommand IR with timing signal STSNA. Register IR7 is therefore loaded at time t 3 and its outputs are connected, through AND gates 15 enabled by STSNA.IR, to channel 14 which supplies decoding network 4. Some microcommands generated by such network are therefore modified. Particularly, if among the conditions received by register IR 7 an ERROR condition is present, microcommands S 0 S 1 assume a logical condition which selects input set 29 of multiplexer 23 and microcommands S 2 S 3 assume a logical level which selects inputs 000F of multiplexer 19. So, starting from time t 3 , when STSNA signal rises (or better with a certain delay due to the signal proposition time, but however before time t 6 ) an address 000F is forced, through multiplexer 19, inputs 27 and 29, multiplexer 19, inputs 27 and 29, multiplexer 23, gates 25, tristates 24, on channels 38 and 39. A start address 000F of an error treatment routine is therefore loaded into registers 17 (ROSPA) and 3 (ROSAR) by timing signal STCSSA. At the same time the address 000F+1 is loaded into register μ PCR 21, while the previous address contained into μ PCR 21 is lost. In fact, when an error occurs, it is not useful to save information in progress (microprogram addresses included) in order to resume operations which have not been correctly executed.
4 - Absolute jump with address saving.
Assumption is made that, during a general machine cycle n-1, an absolute jump microinstruction of address N is addressed. At time t 6 of cycle n-1 registers ROSPA 17 and ROSAR 3 are loaded with address N and register μ PCR 21 is loaded with address N+1. At time t 0 of cycle n, the microinstruction of address N is available in register ROR2 and is decoded.
Field 07-22 defines a new address NA to be used to address the subsequent microinstruction: such bit field is transferred through channels 41, 42 to an input set of multiplexer 19. The microinstruction decoding produces a group of microcommands S 2 , S 3 at logical level such as to select the input set of multiplexer 19 connected to channel 42, as well as a set of microcommands S 0 , S 1 which select input set 29 of multiplexer 23. Therefore, new address NA is transferred on channels 38, 39 and to inputs of incrementer 22. Besides, if bit 06 (SAVE field) is at logical level 1, two microcommands FILE EN at logical level 0 and PUSH/POP at logical level 1 are generated; such microcommands are applied to inputs 35, 36 of the sequencing unit 16 respectively. At time t 6 of cycle n, new address NA is loaded into registers ROSPA 16 and ROSAR 3, while address N+1 contained in μ PCR 21 is loaded into register 20A of stack 20. At the time, address NA+1, present on outputs of network 22, is loaded into register μ PCR 21. The new microinstruction, which will be recalled, will therefore be the one of address NA, while the sequential address N+1 is saved into stack 20 and will be recalled later on. If the microinstruction of address N was a jump microinstruction without address saving (that is, bit 06 SAVE was at logical level 0), the saving operation would not have occurred.
5 - Relative conditioned jump.
Assumption is made that, during a general machine cycle n-1, a relative conditioned jump microinstruction of address N is addressed. At time t 6 of cycle n-1, an address N is loaded into registers ROSPA 17 and ROSAR 3 and an address N+1 is loaded into register μ PCR 21. At time t 0 of cycle n, the microinstruction of address N is available into register ROR 2 and is decoded. Field 17-29 defines a jump displacement K to be used to address the subsequent microinstruction if a determined condition is verified. Such bit field is transferred, through channel 41, to input set B of summing network 18 which receives on its input set A the address N coming from ROSPA through channel 40.
The microinstruction decoding produces a group of microcommands: microinstruction bit 07 defines whether the condition to be examined is contained in a register DR of bank 9, whose address is expressed by the field of bits 10-13. In the affirmative case, addressing microcommands of bank 9 and a read microcommand RDR are generated by network 4. Timing signal PH2 therefore controls the reading of the selected register. At time t 2 , the content of the selected register is available on output set 12. The selected register content defines the condition to be examined and is transferred through multiplexer 8, controlled by microcommand S4 at suitable logical level, to inputs of register IR 7. At time t 3 , by the rising edge of STSNA, the content read out from the selected register is loaded into register IR 7 and transferred then through AND gate 15 and channel 14, to decoding network 4.
Such network selects in the contained information the condition to be verified and, if this last one is verified, it generates a set of microcommands S 2 , S 3 at a logical level such as to select the input set of multiplexer 19 which is connected to the output set of summing network 19, and a set of microcommands S 0 S 1 which select input set 29. Besides, if bit 06 is at logical level 1 (that is, the command of saving into stack is present), microcommands FILE EN at logical level 0 and PUSH/POP at logical level 1 are also generated. So, at time t 6 , address N+K is loaded into ROSPA 17 and ROSAR 3, while address N+1 contained in μ PCR 21 is transferred to register 20A of stack 20 and address N+K+1 is loaded into μ PCR 21. If the condition had not been verified, no saving would have occurred and the address loaded into ROSPA 17 and ROSAR 3 would be N+1, while the address contained in μ PCR 21 would be N+ 2.
6--External interruption.
Assumption is made that an interruption request is presented by a peripheral unit of the system. Such completely asynchronous event is considered at a suitable time of a machine cycle; it is recognized only if there are not interruption requests of higher priority or interruption requests in progress having the same priority level and is presented to the central unit in order to develop an interruption execution microprogram.
These operations are performed by an interface priority network, not shown because it is beyond the scope of the invention. An embodiment of such network is described in the already mentioned U.S. Pat. No. 4,001,784.
For the invention purposes it suffices to point out that such network provides leads 99, 154, 150, with signals indicating an interruption having high, means, low priority and leads 158, 159, 161, 162 with signals indicating an interrupting channel. The number of such leads is variable and it depends on the number of priority levels that the system is able to consider and on the number of interface channels.
FIG. 1B is considered and assumption is made that an intermediate priority interruption occurs on lead 154 during the initial phase of a machine cycle and that, at the same time, a signal of interrupting channel is applied to lead 158. It is further to be supposed that no treatment of high or intermediate priority interruption is in progress, that is, flip-flops 52 and 53 are reset. The interruption is therefore transferred through AND 48, is applied to vector generator 45, and through OR 43, is applied to an input of AND gate 44. At time t 4 , the interruption is transferred to lead 50 by the rising edge of STINTA and it enables tristate circuits 46, while NOT 51 applies a logical level 0 to input CN. Therefore, an interrupting microprogram address MI, coming from network 45 as interrupting vector and present on channel 51, is applied to channels 38 and 39. The interruption signal is present on lead 50 for a suitable portion of the cycle, that is, from time t 4 (signal STINTA rising to 1) up to time t 7 , when signal STINTA falls to logical level 0. When the interruption is received, the sequencer is in a state determined by the microinstruction in progress. Assumption is made that an operative microinstruction of address N is in progress. It is therefore clear that address N is contained in registers ROSAR 3 and ROSPA 17 and an address N+1 is contained in register μ PCR 21. The several commands S 0 , S 1 , S 2 , S 3 enable multiplexers 19 and 23 to transfer address N+1 to output set 28 of sequencing unit 16 to inputs of incrementer 22. But, at time t 4 , the output tristate gates 24 are locked by the interruption and a signal CN=0 is applied to input 33. So, at instant t 6 , address N+1 is not loaded into registers ROSPA and ROSAR by the rising edge of STCSSA. Instead of it, address MI of interrupting microprogram is loaded. At the same time address N+2 is not loaded into register μ PCR 21, but, instead of it, N+1 is loaded again (because CN=0). Microinstruction MI is therefore addressed and it is executed during the subsequent cycle.
According to an aspect of the invention, such microinstruction is a jump microinstruction and not an operative microinstruction and it allows the saving of the machine states existing before the interruption. Such microinstruction has the format shown in FIG. 3E. A first field (bits 0-5) constitutes the function code. A second field (bit 06), named SAVE, in this case at logical level 1, defines that the pre-existent microprogram address must be saved. A third field (bit 07), named RDR, is not used in this case and is at logical level 0. A fourth field (bit 08), named WDR, is at logical level 1 and determines that the information contained in register IR 7 must be saved into a DIRECT REGISTER. A fifth field (bit 09), named RET, is in this case at logical level 0 and is not used. A sixth field (bits 10-13), named DR ADDR, determines the DIRECT REGISTER address to be used for the writing operation specified by bit 08. A seventh field (bit 14), named PC, is in this case at logical level 0 and is not used. An eighth field (bits 17-29), named K, defines the jump displacement K to be used to establish the subsequent microinstruction address. Therefore, in case of interruption, the called microinstruction of address MI (specified by the interruption vector) contains the following useful information:
A. SAVE=1 to save the pre-existent address.
B. =WDR 1 to save the content of register IR 7 into a DIRECT REGISTER.
C. DR ADDR:DIRECT REGISTER address.
D. K:jump displacement necessary to generate the subsequent address. Such quantity may suitably be equal to 1.
All this information is available at time t 0 , that is at the machine cycle start. DR ADDR information allows the selection of a register of bank 9. Information WDR=1 together with signal PH2 allows the controlling of a writing operation at instant t 4 : the content of register IR 7 is loaded into the selected DR register through channel 10 and inputs 11. The function code specifies that the microinstruction is a relative unconditioned jump microinstruction and generates, when it is decoded, signals S 2 , S 3 such as to select the input set of multiplexer 19 which is connected to the output set of summing network 18. It also generates signals S 0 , S 1 such as to select input set 29 of multiplexer 23. So, address MI present in ROSPA is added to jump displacement K (which is assumed =1), is transferred on channels 38, 39 and is applied to inputs of network 22.
Command SAVE=1, suitably decoded, generates a signal FILE EN at logical level 0 and a command PUSH/POP at logical level 1. So, by timing signal STCSSA, address N+1 present in μ PCR 21 is saved or loaded into stack register 20A and address MI+1 is loaded into ROSPA 17 and ROSAR 3.
At the same time, a new address MI+2, which can be used for the following sequential addressing of the microprogram, is loaded into μ PCR 21. In case the interruption occurs during a jump microinstruction, the several addresses can be easily saved by using the several available paths. If a jump microinstruction of address N is in progress, register μ PCR 21 contains address N+1. Such address is saved into the stack by signal STCSSA (if SAVE=1) and, at the same time, μ PCR 21 is loaded with the jump address (absolute or relative) obtained through multiplexers 19, 23, AND gate 25 and network 22 (which does not increment such jump address because an interruption has been previously recognized by signal STINTA). Always by signal STINTA, tristate circuits 24 have been locked and tristates 46 enabled, so that by STCSSA, the interrupt vector, instead of the jump address, is loaded into ROSPA and ROSAR. During the execution of the interrupt microinstruction, also the jump address contained in μ PCR 21 is then saved into stack 20. Evidently this is possible only because the interrupting microinstruction is a jump microinstruction (with saving) which does not use, for the address increment, network 22 and register μ PCR 21 as temporary store, but it uses a path different from the first one. Such different path has only a section in common with the first path and is provided with summing network 18 and with temporary storing register of the addresses (ROSPA). So, during the second phase of the cycle within which an interruption occurs, and during the first phase of the executing cycle of the first microinstruction, register μ PCR 21 can be used as temporary register of the jump address which can therefore be saved. The unconditioned relative jump microinstruction, having the format shown in FIG. 3E, is also used as return microinstruction both from interrupting microprogram and from subroutine.
7--Return from subroutine.
In such case, the last microinstruction of the microprogram is of the type shown in FIG. 4E. Field 09 (RET) is at logical level 1 and commands, when decoded, a pop operation of stack 20: the address of the following microinstruction is read out from stack 20.
8--Return from interrupting microprogram.
Every time an interruption at a certain priority level is recognized, that is, it causes a jump to an interruption treatment microprogram, a flip-flop indicating the interruption priority level is set. The flip-flops indicating the several priority levels are flip-flops 52, 53, 54.
FIG. 1B shows that a high priority interruption INT HP is transferred through AND gate 47 only if flip-flop 52 was reset. During the same machine cycle, interruption INT HP addresses the interruption treatment microprogram by means of signals STINTA (which enables AND gate 44) and by signal STCSSA. Always during the same machine cycle, flip-flop 52 is set by the falling edge of PH2, because its J input is at logical level 1. The set of flip-flop 52 locks AND gate 47 and henceforth interruption INT HP may be removed from lead 99. No other interruption occurring on lead 99 is recognized, until flip-flop 52 is set. The set of flip-flop 52 also locks gates 48 and 49 so that the interruptions having lower priority level cannot be recognized too. Likewise an intermediate priority interruption, if it is recognized, sets flip-flop 53, which inhibits, until it is set, that other subsequent interruptions having intermediate or low priority be recognized. Likewise, a low priority interruption INT BP, if recognized, sets flip-flop 54, which inhibits, until set, that other subsequent low priority interruptions be recognized. The function of the return microinstruction from interrupting microprogram is in this case double. On one side such return microinstruction commands, by field 09 (RET) at logical level 1, a pop operation of the stack and the recall from stack 20 of the lower priority microprogram address previously interrupted. On the other side it commands the transition to a lower priority level by field 14 (PC) at logical level 1. Field 14, when it is decoded, generates a microcommand EOS which is applied to K input of flip-flop 52 through lead 57, and to K input of flip-flops 53, 54 through AND gates 55 and 56 respectively. As AND gate 55 receives to its input the signal present on Q output of flip-flop 52 and AND gate 56 receives to its inputs the signals present on output Q of flip-flops 52 and 53, it is clear that EOS applies a signal at logical level 1 to input K of flip-flops 53, 54 only if flip-flop 52 is reset, as well as that EOS applies a signal at logical level 1 of input K of flip-flop 54 only if flip-flops 52, 53 reset.
Therefore, when during the execution of the microinstruction of return from interrupting microprogram timing signal PH2 falls to logical level 0, that flip-flop is reset among flip-flops 52, 53, 54 which were set.
In conclusion, the sequencer object of the invention is able to generate microprogram addresses with the possibility of inserting subroutines at the same priority level and saving microprogram addresses, as well as with the possibility of interrupting microprograms to jump to interrupting microprograms, and saving addresses and, finally, of returning from such subroutines or interrupting microprogram. This is allowed because two address generation loops having a common section and two address latch registers are provided, as well as a stack connected to one of such loops. A first loop is formed by multiplexer 23, by AND gate 25, by incrementer 22, by register μ PCR 21 and by the connection between output set of μ PCR 21 and input set 31 of multiplexer 23.
A second loop is formed by multiplexer 23, by gate sets 25 and 24, by channel 39, by register 17, by channel 40, by summing network 18, by multiplexer 19 and by the connection between the output of multiplexer 19 and input set 29 of multiplexer 23. On the first loop the stack 20 of address saving is inserted. A preferred embodiment of the invention has been described, but it is clear that several modifications can be made without departing from the scope of the invention. For instance, the use of two multiplexers 19 and 23 connected in cascade is arbitrary and is due to the advantage of using a component (sequencing unit 16) available on the market. Actually, two multiplexers 19 and 23 may be included in one multiplexer 23A, as shown in FIG. 4.
In FIG. 4 a modified embodiment of the sequencer of FIG 1A is shown. The elements corresponding to those of FIG. 1A are identified by the same reference numbers. The two address generation loops, essential for the sequencer working, are evidenced by a double line.
FIG. 5 shows a second modified embodiment of the sequencer of FIG. 1A; such modified embodiment uses two multiplexers and differs from FIG. 1A only because multiplexer 19 is downstream of multiplexer 23. Also in this figure, the elements corresponding to those of FIG. 1A are identified by the same reference numbers and the two address generation loops are evidenced by a double line. Other modifications may be made by the people skilled in the art.
For the use which is made herewith, it is specified that by "loop" or "looped communication path" it is meant a set of logical elements cascade connected with the output of one element connected to the input of the following one and with the output of the last cascade element connected to the input of the first element so as to form a closed path or loop where logical information can be recirculated.
The information flow direction in the loop establishes an upstream or downstream relation among elements if more than two elements are in the loop.
An element is upstream of another when its outputs are connected to the inputs of the other element. | Sequencer means for a microprogrammed control unit which develops consecutive addresses of microprograms, branches to subroutines with address saving and possible return to microprogram, as well as interrupting microprogram forcings with address saving of the interrupted microprograms.
In order to allow the double saving of microprogram and subroutine addresses in case of concurrent interruptions and branches, the sequencer means is provided with two address generation loops each including a register. The two loops have a common portion to which they accede through a multiplexer. The first loop is further coupled to a saving register stack.
While the first loop executes the saving of a microprogram address and the latching or a branch address received from the second loop, the second loop executes a first updating and related latching or interrupting microprogram address. During the following cycle, by command of the first microinstruction of the interrupting microprogram, the second loop performs a first updating and related latch of the interrupting microprogram address and the first loop saves into the register stack the branch address and performs a second updating and related latching of the interrupting microprogram address. | 6 |
FIELD OF THE INVENTION
[0001] The invention relates to a new and improved apparatus and method for cleaning and lubricating conveyors using a microprocessor controlled control system. The control system senses the activity of the conveyor and the presence of items on the conveyor, and in return lubricates and washes the conveyor as needed. This automated system also reduces the amount of cleaning labor needed, as well as reduces the amount of wasted cleaning and lubricating supplies.
BACKGROUND OF THE INVENTION
[0002] Conveyors commonly used in the food and packaging industries (in particular soft drink manufacturing facilities, breweries, fruit juice manufacturing facilities, dairies, etc.) generally require periodic cleaning in order to maintain the conveyor in a sanitary condition. This cleanliness requirement in turn requires the application of various cleaning ingredients such as detergents, sanitizers, bactericides, slimicides, etc. A simple, yet very time and labor intensive practice is to apply these cleaning ingredients to the conveyor system manually, either by high pressure hot water, steam, or other methods. Additionally, there is a tendency in manual cleaning to over-apply and waste the cleaning products. This manual practice is both expensive, cumbersome and dangerous and may not provide an adequately clean conveyor belt. The art recognizes a need for improved methods and apparatus. U.S. Pat. No. 5,372,243 provides an alternative to the above described cleaning method. King teaches a pneumatically controlled cleaning and rinsing system for conveyors. The valves for providing cleaning and rinsing ingredients are pneumatically actuated, as are the timers and sequencer valves. Pneumatically controlled and actuated equipment is stressed because of the desire to eliminate corrosion of electrical equipment and components in wet environments.
[0003] Others have provided alternate conveyor cleaning and/or lubricating systems to replace systems that include electrical equipment. U.S. Pat. No. 5,129,481 describes an apparatus and method for lubricating conveyors and belts used in the food industry comprising a device including valves which are alternately opened and closed by an actuating device driven from the conveyor movement. The valves supply a lubricant which is fed to output nozzles for spraying onto the conveyors for lubricating purposes, and the valves will only feed lubricant when the conveyor is moving. Alternately, U.S. Pat. No. 5,289,899 teaches an air-driven delay valve or relay, which is driven from the conveyor system, and which connects to a counter which controls the valve that passes lubricant in a pulsating or intermittent fashion.
[0004] However, pneumatically controlled systems, such as those described above, can be inaccurate, for example, in their time measurement and fluid dispensing, leading to ineffective cleaning and/or lubricating of the conveyor and wasted supplies. A substantial need exists for a cleaning and lubricating system for conveyors that is simple, accurate, versatile, reliable, and is easy to maintain.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a new and improved apparatus and method for cleaning and lubricating conveyor systems using a microprocessor controlled control system. The control system senses movement of the conveyor belt and the presence of any items, such as cans, bottles, or food products, on the conveyor belt, and in return either cleans or lubricates the conveyor as needed. This automated system reduces the amount of labor needed to perform these critical tasks, as well as reduces the amount of wasted cleaning and lubricating supplies.
[0006] In particular, the present invention relates to a conveyor system that includes the combination of a conveyor system, a washing system, and a lubrication system. The conveyor system is for transporting an object, with the conveyor system including a conveyor belt having a front side and a back side, and a drive mechanism for providing movement to the belt. The washing system is for rinsing and washing the conveyor belt and includes a water source, a detergent source, a mixing chamber to mix the water and the detergent to form a cleaning solution, and an applicator for application of the cleaning solution onto the belt. In some embodiments, the applicator is a spray nozzle. The application of the cleaning solution onto the belt is controlled by a control system, which comprises a microprocessor adapted to provide a signal to open the applicator to provide rinse or cleaning solution onto the belt. The lubrication system is for lubricating the conveyor belt to improve belt tracking and to extend the useable life of the belt. The lubrication system includes a lubricant source and an applicator for application of the lubricant onto the belt. In some embodiments, the applicator is a spray nozzle. The application of the lubricant onto the belt is controlled by a lubricant control system that includes a first sensing system to sense movement of the belt, a second sensing system to sense presence of items on the belt, and a control system comprising a microprocessor that receives signals from the sensing systems and sends signals to open the applicator to provide lubricant onto the belt on a predetermined, timed basis.
[0007] The amount of lubricant applied to the belt is dependent on the signals from the first and second sensing systems. In particular, if the first sensing system confirms movement of the belt and the second sensing system confirms an object, the microprocessor provides a signal to provide lubricant so that a first amount of lubricant is fed from the lubricant source and is applied onto the conveyor. If the first sensing system confirms movement of the belt but the second sensing system does not confirm the presence of an object, the microprocessor provides a signal to provide lubricant so that a second amount of lubricant is fed from the lubricant source and is applied to the conveyor, the second amount of lubricant being less than the first amount. If the first sensing system does not confirm movement, whether or not items are present on the belt, the microprocessor does not provide a signal to apply lubricant.
[0008] In a further aspect of the invention, the washing system comprises a microprocessor to provide a signal to apply a rinse or cleaning solution to the conveyor belt for a predetermined time interval. Typically, this washing process occurs after any production run on the conveyor system is complete. The washing process generally includes a first rinse step, a cleaning step, and a second rinse step.
[0009] The invention will be further described in relation to the included drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a schematic perspective view showing an apparatus of this invention, including a conveyor system;
[0011] [0011]FIG. 2 is a simplified schematic diagram in top view of a conveyor system having multiple zones; and
[0012] [0012]FIG. 3 is a block diagram illustrating the logic used by the apparatus of this invention to provide the method for the lubrication and cleaning of the conveyor system.
DETAILED DESCRIPTION
[0013] The invention relates to a new and improved apparatus and method for cleaning and lubricating conveyors using a microprocessor controlled control system. The control system senses the activity of the conveyor and the presence of items on the conveyor, and in return either cleans or lubricates the conveyor as needed. If the control system only senses movement of the conveyor but no item on the conveyor, only a small amount of lubricant is applied to the conveyor sufficient to keep the conveyor belt properly lubricated.
[0014] Referring now to the Figures, wherein like elements are represented by like numerals throughout the various views, FIG. 1 shows a general arrangement of a conveyor maintenance system 100 that has a lubrication system 200 and a washing system 300 . The apparatus 100 is used for lubricating and washing a conveyor system 110 , although not necessarily simultaneously.
[0015] Conveyor system 110 includes a conveyor belt 120 having a front side 122 and a back side 124 , and a structure 115 to support belt 120 . Front side 122 of belt 120 is the side on which items, such as bottles or cans 50 , are carried. Back side 124 is the inner side when belt 120 is formed as a loop (as shown in FIG. 1), and back side 124 typically contacts a drive mechanism (not shown). Conveyor systems, such as those designated as conveyor system 110 , are well known.
[0016] Washing system 300 has a water source 302 , a detergent source 310 , and a device in which the water and the detergent are mixed. In FIG. 1, such a mixing device is shown as mixing chamber 320 . Water source 302 is typically a potable water source and is generally supplied at about 5 to 20 gallons per minute at a pressure of about 60 to 125 psi, although other volumetric rates and pressures could be used. Detergent source 310 can be a drum 312 , such as a 55 gallon drum, or a larger storage tank. The detergent may be any solution, mixture, component or the like used for cleaning, disinfecting, degreasing, etc. A low level alarm 316 may be used within detergent source 310 to warn of low detergent supply. A controller 305 is used to control valves 304 , 314 which allow feed from water source 302 and detergent source 310 , respectively, to flow to mixing chamber 320 . Once the water and detergent are mixed in a mixing device, for example, mixing chamber 320 , the cleaning mixture or solution is applied to the conveyor belt. In FIG. 1, the solution is supplied via delivery pipe 330 to a detergent applicator, shown as spray nozzle 350 (shown in phantom in FIG. 1). Spray nozzle 350 applies cleaning solution to back side 124 of conveyor belt 120 . Optionally, the cleaning solution could be applied to front side 122 of conveyor belt 120 or other areas of conveyor system 110 , such as structure 115 .
[0017] In some steps during the washing procedure, it may be desired to provide a water-only rinse of the conveyor system 110 ; that is, no detergent is used. The process of washing is considered to comprise rinsing. Rinsing is performed in the same manner as washing, except that typically no detergent is added to provide the solution. There may, however, be additives provide to the water source to produce a rinse solution. Often, a three-step process is used: a first rinse step, a washing or cleaning step, and a second rinse step.
[0018] The washing process, which includes the steps of applying rinse and/or cleaning solution, may be applied to conveyor belt 120 at predetermined intervals, for example, a one to three minute rinse after every hour of operation. Rinse and/or cleaning solution may also, or alternately, be applied at the end of the production run that uses conveyor system 110 , for example, at the end of the work day or shift. The conveyor belt 120 may continue to run (i.e., move) during the cleaning operation or may be stopped.
[0019] Generally, no sensors are needed in washing system 300 if it is desired to rinse and/or washing conveyor belt 120 after its use. The washing may be activated by, for example, a manual switch after the production run has been completed.
[0020] Lubrication system 200 has a lubricant source 210 and a lubricant applicator, such as spray nozzle 250 , to apply lubricant to front side 122 of conveyor belt 120 . Optionally, the lubricant could be applied to back side 124 of conveyor belt 120 . In accordance with the present invention, the amount of lubricant applied to belt 120 is dependent on both the movement of conveyor belt 120 and the presence of items, such as cans 50 , on belt 120 . If belt 120 is in motion and items are present on the belt, a first amount of lubricant is applied to front side 122 of belt 120 . If belt 120 is in motion and no items are present, a second amount of lubricant is applied, with the second amount of lubricant being less that the first amount. If no movement of belt 120 is sensed, whether or not any items are present on belt 120 , no lubricant is applied. This series of inquiries and resulting actions is illustrated in FIG. 3, which is a block diagram of the logic used to determine the application of the lubricant.
[0021] Movement of belt 120 is sensed by a sensor 220 , which in FIG. 1 is positioned to monitor back side 124 of belt 120 . Presence of items, such as cans 50 , is sensed by sensor 225 . FIG. 1 shows two sensors 225 , 225 ′ on opposites sides of belt 120 and mounted on structure 115 . Although only one sensor 225 for monitoring the belt and two sensors 225 , 225 ′ for monitoring presence of items are shown, any number of sensors can be used. Sensors 220 , 225 , 225 ′ may be any sensors capable of sensing movement and/or presence of items; usable sensors include well known devices such as motion or vibration detectors, or laser, IR or other sensors. In another embodiment, the sensor may be directly wired or otherwise connected to the conveyor system's motor.
[0022] Sensors 220 , 225 , 225 ′ are connected to a control system 205 which includes a microprocessor (not shown) therein. Signals from sensors 220 , 225 , 225 ′ are processed by the microprocessor, which then sends a signal to valve 204 which controls supply of lubricant from source 210 to nozzle 250 .
[0023] The microprocessor usable in the control system 205 of the present invention may be a programmable general purpose microprocessor, also known as a “PLC” or a programmable logic controller. ‘Ladder logic’ is typically the format used when programming this microprocessor. The microprocessor is incorporated into the control system 205 and may be attached to equipment such as a monitor, touch screen, keyboard, or a mouse. The microprocessor is then also connected to the sensors and valves.
[0024] If sensor 220 provides a negative signal to control system 205 indicating that belt 120 is not moving, control system 205 provides a signal to close valve 204 so that no lubricant is applied to belt 120 . If sensor 220 provides a positive signal indicating that belt 120 is in motion, and sensor 225 provides a positive signal indicating that items such as cans 50 are present on belt 120 , control system 205 provides a signal to open valve 204 so that a first amount of lubricant flows to nozzle 250 and is applied to belt 120 . If sensor 220 provides a positive signal indicating that belt 120 is moving, but sensor 225 provides a negative signal indicating that no items are present on belt 120 , control system 205 provides a signal to open valve 204 partially so that a second amount of lubricant flows to nozzle 250 and is applied to belt 120 . The second amount of lubricant allowed through valve 204 and applied by nozzle 250 is less that the first amount, because no lubrication is need between items and the belt if no items are present. The lubrication desired, when no items are present, is a minimal amount, simply to reduce friction and maintain flexibility of the belt.
[0025] Lubricant source 210 can be any container such as a drum, a large storage tank, or can be supplied by a delivery pipe from a remote location. Valve 204 is preferably a pneumatic (air actuated) valve and is controlled by signals from control system 205 . An air injection tee 214 may be included in lubricant system 200 to provide a stream of air to be mixed with the lubricant before it is applied to belt 120 .
[0026] Referring now to FIG. 2, a conveyor system 500 is typically divided into multiple zones, generally at least two zones, often more than two zones. FIG. 2 shows conveyor system 500 with four zones. A “zone” is a region or length of conveyor and each zone typically has its own conveyor belt, support framework, conveyor track, and drive mechanism for the conveyor belt. Often, a zone may have multiple conveyor belts that may or may not have their own drive mechanism.
[0027] [0027]FIG. 2 is a top simplified schematic diagram of conveyor system 500 divided into four zones. Conveyor system 500 includes a filler station 520 where a container, such as a can or bottle, is filled. Conveyor belt 510 moves the container from one station, such as filler station 520 , to the next station. From filler 520 , the container progresses along conveyor belt 510 to seamer station 530 where the container is sealed, e.g., capped. From seamer 530 , the container progresses through a warmer station 540 . After warmer 540 , the container progresses to accumulation area 550 , where multiple containers are stored until they are ready to be sent to caser station 560 . At caser 560 , the containers are packaged for delivery and distribution, for example, cans may be packaged in plastic 6-pack rings, or in paperboard boxes for 12 and 24 packs.
[0028] Conveyor system 500 is divided into four zones I, II, III, and IV, which extend from seamer 530 to caser 560 . Zone I extends from after seamer 530 to warmer 540 , but could optionally start at filler 520 . Zone II extends from after warmer 540 to accumulation area 550 . After accumulation area 550 , conveyor system 500 is divided into two zones, III and IV, which extend to caser station 560 . In accordance with the present invention, each zone may include a system for controlling the lubricant and a system for controlling the rinse and cleaning solutions, the systems may, however, be shared with one or multiple additional zones. In a preferred embodiment, a single control system is capable of controlling all lubricant systems, without the need for an individual control system for each lubrication system.
[0029] It should be noted that although FIG. 2 is schematically drawn showing a single conveyor belt 510 extending the length of conveyor system 500 , conveyor belt 510 actually may include multiple belts. Typically, each bend or turn in the system requires a new belt. For example, conveyor belt 510 a extends from filler station 520 to seamer station 530 . From seamer 530 , two belts 510 b , 510 c extend to warmer 540 . Both belts 510 b , 510 c are within zone I. From warmer 540 , belts 510 d , 510 e , 510 f and 510 g in zone II extend to accumulation area 550 . Belt 510 h in zone III and belt 510 I in zone IV extend to caser station 560 . Each belt 510 a , 510 b , etc., may have its own drive mechanism (not shown), or multiple belts may share a drive mechanism.
[0030] A single control system with a microprocessor can be used to control all lubricant systems that apply lubricant to belts 510 a , 510 b , etc. Similarly, a single control system with a microprocessor can be used to control all washing systems.
[0031] The above-captioned drawings, explanation and specification describe the elements of the conveyor system lubrication and washing system and its method of use. While a variety of embodiments can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A method for automatically cleaning and lubricating conveyor belt systems is disclosed. A microprocessor controlled control unit senses the movement of the conveyor belt and the presence of items, for example bottles, on the conveyor. The control unit initiates the application of lubricant, detergent and rinse water onto the conveyor according to the speed of the conveyor, the presence of items and the time passed since the previous application. If the conveyor is stationary, that is, is not in motion, no lubricant or cleaning solution is applied. If the conveyor is moving but no items are on the belt, a reduced amount of lubricant is dispensed onto the conveyor system. The conveyor cleaning and lubricating process may be carried out during normal production operations. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to information printers of the dot-matrix type and, more particularly, to novel split-frame stackable blades for use in the printhead thereof.
Known embodiments of printer blades for use in dot-matrix printers may be as described and claimed in U.S. Pat. No. 4,129,390, issued Dec. 12, 1978 to the assignee of the present invention and incorporated herein by reference. The printer blades described therein have a mount portion attached to an oval-shaped rim by a pair of resilient arms; a coil of conductive ribbon is wound about a substantially oval central member and is insulatively maintained within the oval rim. A printing tip, extending away from the coil-bearing rim, is caused to move and to impact an ink-retaining ribbon and ink-retaining media, when current flowing through the coil interacts with a transverse magnetic field. The interaction moves the integral combination of coil-rim-printing tip and results in deflection of the resilient arms with respect to the stationary mounting portion. This configuration, while having many desirable features, does experience connection failure at (a) the connective lead attachment at the inner, coil-bearing rim, at which point one end of the coil is attached, and (b) the coil connection to the outer rim, which is itself integrally joined to the resilient arms-mounting portion of the blade. A more reliable printing blade for use in a matrix-type printer head, is desirable.
BRIEF SUMMARY OF THE INVENTION
In accordance with the invention, a printhead for a dot-matrix printer comprises a plurality of stacked printing blades. Each blade has a stationary mounting portion attached to a common housing member of the printhead and also has a printing tip. The printing tips of all of the plurality of blades are arranged along a common line extending outwardly from the printhead for selectively and individually impacting a printing medium. Each print blade is formed of a single piece of resilient, conductive material and has a generally oval-shaped rim portion spaced from the mounting portion and supported by a pair of generally parallel resilient arms integrally joined between opposite locations on the rim and on the opposite ends of the mounting tab. A coil wound of flat conductor is positioned within the central opening of the rim; the outer end of the coil is joined to a first portion of the rim, to one side of an imaginary line passing through the center of rim and parallel to the arms, while a thin piece of conductive foil insulatively overlies the coil to connect the inner end of the coil to a second portion of the rim lying on the opposite side of the line. The coil is cemented in place within the rim and a thin insulating film is cemented across one surface of the coil-rim combination. Opposite sections of the rim, along the imaginary line, and the mounting portion are then split, to provide a pair of conductive blade portions, each acting as a conductive member connecting one end of the coil through an associated resilient arm to an associated part of the split mounting portion.
In one preferred embodiment, the plurality of blades are stacked in side-by-side relationship, with insulative material placed between each pair of aligned mounting portions. Insulated members are utilized to fix the mounting portions to a frame member of the printing head. A common aligned tab on one part of each mounting portion provides for a first connection to each of the coils, while a set of indexed tabs positioned at a different point upon the remaining part of each mounting portion of each of the plurality of blades, provides separate connection points for the remaining end of the coil of each of the plurality of printing blades. A flow of current through the coil of a particular blade interacts with a magnetic field formed transverse to the coil plane of all of the stacked blades, to cause movement of the printing tip of the energized blade in a direction substantially parallel to the mounting portion, for impacting upon reception media for subsequent formation of characters, symbols and other indicia in dot-matrix fashion.
Accordingly, it is an object of the present invention to provide novel split printing blades and methods of fabrication therefor, for use in a matrix printer head, wherein the printing blades provide highly reliable electrical connections to the coils of the blades.
This and other objects of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a plan view of a prior art printer blade;
FIG. 1b is a prospective view of a prior art printer head, utilizing the printing blades of FIG. 1a;
FIG. 2 is a plan view of a unitary printing blade member; and
FIGS. 3a and 3b are respectively a plan view and an end view of a printhead utilizing a plurality of printing blades fabricated from the printing blade member of FIG. 2, in accordance with the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIGS. 1a and 1b, a prior art printhead 10, as described and claimed in the above-mentioned U.S. Pat. No. 4,129,390, utilizes a plurality, illustratively seven in number, of printing blades 11. Each printing blade includes a printing tip 12 having translational motion when the printing tip is caused to move with respect to a mounting portion 14. The mounting portion 14 is relatively thick and has a plurality of apertures 15 each receiving a fixed pin 17 therethrough to facilitate stacking a plurality of blades 11 with their thickened mounting portions 14 in abutment with each other.
Each printing blade is formed of a unitary frame including a central oval-shaped rim 20, of relatively lesser thickness than mount portion 14, and having an aperture 22 formed therethrough of similar oval-shaped, but of slightly smaller, dimensions in the non-magnetic, conductive blade member frame. A pair of substantially linearly elongated and substantially parallel resilient spring arms 24 and 25 respectively, couple opposite ends of mount portion 14 to one of outward extensions 20a and 20b formed on rim 20. Outward extension 20b is further extended to form a beam 26, below resilient arm 25, to position printing tip 12 at a selected distance therefrom. The printing tip is intentionally thickened to the same thickness as that of mount portion 14 to provide a substantially square printing surface 12a.
A hub member 28 has an oval shape and has a central oval aperture 28a bridged by a thin tab 29 at one of a plurality of positions, shown in broken line by alternate tab positions 29a, 29b, etc. Non-interfering connection to each of the plurality of stacked blades is provided means of flexible leads 30, with each lead having a first end 30a connected, as by welding and the like processes, to one of tabs 29. Each lead 30 has a remaining end coupled to an insulated terminal 32 upon a cover 34 of the printhead housing 36. A single-layer coil 40, of wire with substantially rectangular cross-section, is wound about the periphery of central hub 28. A first end 40a of the coil is joined to the hub and the remaining coil end 40b is joined to rim 20. Thus, current may flow from a source (not shown) connected to one of terminals 32, through the associated flexible lead 30, to hub 28 and thence into coil 40 at first end 40a. The coil current exits at coil end 40b and flows through rim 20 and resilient arms 25 to mounting portion 14, forming a common connection for all stacked printing blades in a print head. The flow of currents through the coil interacts with magnetic field B 1 and B 2 , flowing in opposite directions through opposite portions of the coil, as provided by a set of magnets 45 external to the stack of printer blades, but within printhead 10. Thus, when current flows through coil 40, force is generated within the coil, causing the printing tip to move outward from housing 36, to impact printing media; upon cessation of coil flow, the energy stored in resilient arms 24 and 25 returns the printing blade to its original position. A stop member 48 is utilized to absorb the return energy of the printing blade and position the blade for the next current-pulse-altered printing movement.
The connection, at point 30a, of one end of each lead 30 to the associated cross-tab 29, is prone to breakage, and renders the printhead unusable until delicate and time-consuming repair has been made. It is thus desirable to provide printing blades having improved coil connection means for use in a dot-matrix printer head of this type.
Referring now to FIGS. 2 and 2a, an improved printing blade 60 is fabricated by chemically etching a single sheet of a non-magnetic conductive material, such as beryllium copper and the like, to include a generally oval-shaped rim 62 having a generally oval-shaped aperture 63 formed centrally therein and having a pair of outward extensions 62a and 62b formed outwardly upon the respective parallel longer sides of rim 62. A pair of formation 65a and 65b are formed substantially opposite each other, along an imaginary line 65 cutting through aperture 63 and the shorter sides of oval-rim 62; each formation includes a slot 66a and 66b, respectively, cutting partially, but not completely, through the thickness of rim 62. A pair of linearly elongated and substantially parallel resilient spring arms 67 and 68, respectively, extend substantially parallel to the longer sides of oval rim 62, respectively from rim extensions 62a and 62b. A mounting member 70 is formed substantially transverse to, and between, the ends of resilient arms 67 and 68 furthest from rim extension 62a and 62b. Mounting member 70 is somewhat rectangular in shape and includes a pair of apertures 72a and 72b, for passing insulated-shank fastening means, to facilitate mounting a stack of a plurality of printing blades in a printer head housing, as more fully explained hereinbelow. A channel 74 is formed, during initial etching of the printer blade blank, to connect the interior mounting member edge 70a to the open area of one of the fastening means apertures, e.g. aperture 72b. An additional channel portion 76 may advantageously be formed from the open aperture interior of the same aperture (aperture 72b) and extends partially, but not completely, through the remaining width of mounting member 70 toward the remaining, outward edge 70b thereof. A plurality of indentations 78 are formed into outer mounting member edge 70b to define a series of substantially equally spaced tabs 80a-80i, each having a small aperture 82 formed therein for receiving a current-carrying lead (not shown). The number of formations 80 is equal to one more than the number N of blades to be utilized in a given printer head configuration. Advantageously, channel portion 76 is so positioned as to extend from one of the fastening means apertures (e.g. aperture 72b) toward the indentation 78 between the first and second tabs 80a and 80b for a purpose hereinbelow explained.
One of outward rim extensions 62a and 62b, e.g. extension 62a, is provided with a flat portion 85, against which the stop member 48 (FIGS. 3a and 3b) may bear, while the other outward extension, e.g. extention 62b, continues outwardly of rim 62 to form a beam 87 carrying a printing tip 89 at the end thereof furthest from the rim. Printing tip 89 has a flat surface 90 for impacting against printing media, such as an ink ribbon and paper sheet (both not shown for reasons of simplicity).
After printing blade blank 60 is etched to a shape in accordance with the above description, a flat coil 95 of conductive wire, wound to have a central aperture 96a and having the turns thereof insulated from each other, is positioned within aperture 63 formed in oval rim 62. Coil 95 is so formed that a first end 95a thereof is positioned along the periphery of interior coil aperture 96, substantially at one of the ends thereof having a smaller dimension. The remaining coil end 95b is positioned at the exterior periphery of coil 95. Advantageously, a portion 62c of the oval rim is slightly distorted outwardly, from an oval shape, to provide an area, adjacent to the location at which exterior coil lead 95b will be placed when the coil is positioned within blade aperture 63, to facilitate attachment of outer coil lead end 95b to rim portion 62c, as by welding, soldering and the like processes. Coil 95 is of thickness substantially equal to the thickness T (see FIG. 2a) of the blade member frame 60 and, when coil 95 is positioned within aperture 63 and cemented therein, the coil-bearing blade member has substantially the blade thickness T. A thin insulating film 98 is fastened in place across one surface of the coil 95 and blade rim 62 to provide insulation between adjacent printing blades in a stack of a plurality of such blades. The area of film 98 is of substantially oval shape, and of greater extent than the oval-shaped coil 95, but of slightly lesser extent than the outer periphery of rim 62 (see film 98 shown in broken line in FIG. 2).
After cementing coil 95 in place and applying insulating film 98, a thin conductive foil strip 100 (FIG. 3a) is positioned between that end of coil aperture 96 at which coil end 95a is located and a portion 62d of the rim located upon the opposite side of imaginary line 65 from rim portion 62c at which the exterior coil lead 95b is connected. One end of foil strip 100 is electrically connected, as by welding, soldering and the like, at rim portion 62d, while the remaining end of foil strip 100 is electrically connected to interior coil lead 95a. Thus, the opposite ends of coil 95 are respectively in electrical connection to rim portions 62d and 62c, respectively. Advantageously, foil strip 100 is also cemented to coil 95 for greater mechanical stability.
After the cement, utilized to hold coil 95 within aperture 63 and then hold film 98 to the surface of blank 60, has hardened to rigidly hold the blade rim and coil in planar relationship, the blade rim and mounting portions are split by the formation of additional channels 105a and 105b respectively in rim portions 65a and 65b, and by channel 105c in mounting member 70. Thus, rim channels 66a and 66b are extended completely through the rim portion by respective channels 105a and 105b, and mounting member 70 is split into a first mounting part 70c, having tab 80a thereon, and a second mounting part 70d, having the remaining mounting tabs 80b-80i thereon, by channel 105c continuing the break formed by channels 74 and 76 and by aperture 72b. All but one of the remaining N tabs 80b-80i on mounting part 70d are now removed; the particular tab remaining is associated with the position of a printer blade in a stack of a plurality thereof. Thus, in FIG. 3b, the eight stacked blades shown have, from left to right as illustrated, sequentially staggered tab positions 80b, 80c, 80d, 80e, 80f, 80g, 80h and 80i provided at the end of the sequentially arranged blades, whereby connection can be made in non-interfering and unique manner.
It will be seen that current (from a current driving source not shown) will flow into a particular blade at one of the blade-position-associated tabs 80b-80i thereof, and will flow through mounting part 70d, upper resilient arm 67 and rim portion 62c to outer coil end 95b. The current flows through coil 95 and exits therefrom at interior coil end 95a, flowing through foil strip 100 to rim portion 62d, thence through lower resilient arm 68 to mounting part 70c and common contact tab 80a.
The current thus flowing in coil 95 interacts with magnetic fields B 1 and B 2 provided by magnets 45, to generate a force F causing extension of printing tip 89 beyond the face of printing tip housing portion 36a, while temporarily twisting arms 67 and 68 to store force therein. Upon cessation of the current, the force stored in resilient arm 67 and 68 acts to return the blade towards its rest position, and against stop 48.
The hollow rectangular housing 36 has a shelf-like formation 36b at one end of the central cavity thereof, for receiving the two parts of the mounting portion of each blade in a stack of a plurality of aligned blades. A thin sheet 110 of insulated material is placed between the aligned mounting portions 70 of each pair of adjacent blades in the stack and between the mounting portion 70 of bottom-most blade in the stack and the housing shelf-like formation 36b on which the stack mounts. Each sheet 110 has apertures formed therethrough in alignment with the apertures 72a and 72b in the aligned mounting portions. Fastening means, such as screws 115, having insulated shanks, are passed through the aligned mounting apertures 72a and 72b of the stack of blades and fastened into printer head housing shelf 36b to fasten the blade stack within the housing. Additional details concerning the housing and printer head may be found in the above-incorporated U.S. Pat. No. 4,129,390.
One presently preferred embodiment of my novel improved printer blade, having split rim and mounting member, has been described herein. Many variations and modifications, in accordance with the principles of the present invention, will now occur to those skilled in the art. It is my intent, therefore, to be limited only by the scope of the appending claims and not by the specific detail shown herein. | Flat, stackable printing blades for use in an impact printer head of the dot-matrix type, each blade including a conductive coil fastened within a central aperture of a conductive frame having a pair of arms resiliently connecting the coil frame to a stationary mounting portion. The mounting portion and the coil-retaining frame are split, with one of a pair of coil leads attached to each of the pair of electrically-isolated blade members thus formed, for facilitating a flow of current from one portion of the mounting tab, through one resilient arm and the coil, and thence through the remaining resilient arm to the remaining portion of the mounting tab. A stack of blades, having printing tips extending from the frame in a common direction, is arrayed to form a dot-matrix-type printhead. | 1 |
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyrights whatsoever.
FIELD OF THE INVENTION
[0002] The present invention relates to shoes and, more particularly, to high heel shoes.
BACKGROUND OF THE INVENTION
[0003] Conventionally, high heel shoes are constructed such that the user's weight is shifted primarily onto the ball of the foot and the toes. This can cause a large amount of pressure to be placed on a small area of the foot, rather than distributed more evenly throughout the entire foot and heel. As a result, the user's weight is shifted unnaturally forward, which can cause the user to compromise her posture. This change in posture can create pressure in the lower back, tension and curvature in the shoulders, joint pain, muscle tightness and general discomfort. Additionally, excess weight in the toes and ball of the foot can cause foot cramping, arch compression, and pronation, as well as bunions and Morton's neuromas. In addition to causing discomfort to the user, conventional high heels can cause injury, either permanent or temporary, particularly after repeated or prolonged use.
[0004] Many shoe companies create high heels with features intended to reduce foot pain, such as lower heels, more padding, and wider areas in the toes and ball of foot. However, while these features may reduce pain, they do not fundamentally impact the posture of the wearer.
[0005] The present invention enables the user to retain a more natural posture and weight distribution, thereby reducing, eliminating, or counteracting the typical ill effects of wearing high heels. These and other features of the invention will be fully understood from the following description.
SUMMARY
[0006] Accordingly, provided is a high heel shoe having an insole, an outsole, and a shank embedded between the insole and outsole, the shank comprising a heel portion with a depression to accommodate a user's heel, and a lateral ridge element in front of the heel portion that exerts pressure against the forward movement of a user's heel when worn. The shank further comprises a front portion sloping downward from the lateral ridge along the arch of the insole, which optionally is padded.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Embodiments are illustrated in the figures of the accompanying drawings, which are meant to be exemplary and not limiting, and in which like references are intended to refer to like or corresponding things.
[0008] FIG. 1 is a partial cross section perspective view of an embodiment of a high heel shoe according to the present invention.
[0009] FIG. 2 is a perspective view of the top of a shank component of an embodiment of a high heel shoe according to the present invention.
[0010] FIG. 3 is a perspective view of the bottom of a shank component of an embodiment of a high heel shoe according to the present invention.
[0011] FIG. 4 is a side cross-section of an embodiment of a high heel shoe according to the present invention, with a user's foot shown in dashed lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] Referring to the drawings, FIG. 1 shows an embodiment of a high heel shoe 10 having an upper 12 , an outsole 14 , an insole 16 , a high heel 18 , and a shank 20 , depicted in dotted lines. The shank 20 is embedded between the insole 16 and the outsole 14 . The shank 20 extends generally along a longitudinal direction through the shoe 10 from the heel area to approximately the beginning of the ball of the foot.
[0013] As shown in FIG. 2 , the shank 20 has a heel portion 22 and a front portion 26 . Immediately in front of the heel portion 22 is a lateral ridge 24 , which extends across the shank 20 in an area that would be just in front of a user's heel. A depression 28 is disposed generally centrally within the heel portion 22 of the shank 20 . The depression 28 is configured to receive the user's heel. The depression 28 and the lateral ridge 24 prevent the user's foot from sliding forward in the shoe 10 . The front portion 26 of the shank 20 descends from the lateral ridge 24 toward the front of the shoe 10 . The embodiment seen in FIG. 2 is shown with an attachment mechanism 30 to secure the shank 20 to the sole structure of the shoe. The attachment shown is a set of holes disposed near the front end of the shank 20 adapted to receive studs or screws. However, in other embodiments the shank can be secured within the shoe by any means known in the art, and at any location along the shank 20 .
[0014] FIG. 3 shows the bottom view of the shank 20 of FIG. 2 , from a high heel shoe embodiment according to the present invention. The shank 20 embodiment shown in FIGS. 2 and 3 has a generally uniform width along the entirety of the component. In other embodiments, the shank 20 can vary in width, for example, having a narrowing in part or all of the front portion 26 . The shank can be composed of metal, plastic, or any rigid material or combination of materials as known in the art.
[0015] FIG. 4 shows a side cross-section of an embodiment of a high heel shoe according to the present invention. A user's foot is shown in dashed lines to illustrate how the foot sits within the shoe 10 . The depression 28 receives the user's heel, and the lateral ridge 24 is located just in front of the user's heel and helps prevent the heel from sliding forward. By holding the user's heel in place, the heel does not drop toward the ball of the foot, compressing the foot and causing cramping. Rather, the foot is permitted to stretch out comfortably within the shoe, without unnecessary stress on the toes and ball of foot.
[0016] The depression 28 allows the user to settle more weight into the heel than in a conventional high heel shoe. In a conventional shoe, the user's weight is shifted forward, and the leg extends upward from the shoe at a forward tilted angle. In contrast, by settling the heel into the depression 28 , the user can stand comfortably upright, with the ankle and calf extending generally straight up from the shoe, as depicted in FIG. 4 . This encourages a more natural posture in the user.
[0017] By allowing the user to stand more upright, the high heel of the present invention helps to improve the user's posture, correct lower back problems, and can be worn for extended periods of time without pain and longer term injury to the feet or body. The user can comfortably stand taller and walk straighter than in conventional high heels.
[0018] In the embodiment shown in FIG. 4 , padding 32 is disposed along the midsole of the shoe, generally where a user's foot arch would fall. The padding 32 allows the user's mid-foot to maintain contact with the shoe and provides support to the user's arch. This allows more complete weight distribution along the entirety of the foot, rather than only at the front foot and heel, which can cause strain and painful pressure to the foot. The padding 32 can be of any appropriate resilient cushioning material, such as foam or memory foam.
[0019] It should be understood that the dimensions of the different components may vary. However, it has been found that an embodiment of the high heel shoe functions as described where the components have dimensions as follows, where all measurements are in centimeters: (a) high heel—the height from the center of the ground to the center rear of the high heel at the highest point is approximately 10 cm; (b) heel portion of the shank—the longitudinal length is approximately 4.5 cm, with a lateral width of approximately 4 cm; (c) depression—at the lowest point, the depression is approximately 1 cm below the heel portion of the shank; (d) lateral ridge—at its highest point the lateral ridge is approximately 0.5 cm above the heel portion of the shank and extends across the lateral width of the shank, the width of the lateral ridge is approximately 1.2 cm; (e) front portion of the shank—the longitudinal length extends approximately 9 cm from the lateral ridge, and the lateral width is approximately 4 cm, slightly narrowing to approximately 3.5 cm generally in the center where a user's foot arch would fall.
[0020] Also shown in the embodiment of FIG. 4 is a platform 34 which raises the height of the front of the shoe, decreasing the angle of the midsole of the shoe while maintaining heel height. It should be appreciated that other embodiments of the present invention do not contain a platform 34 feature. Moreover, it should be appreciated that although the embodiments shown in the figures are in the form of high heel pump style shoes, all styles and heights of high heel shoes are intended to fall within the scope of the present invention, including, for example, high heel boots and sandals.
[0021] It should be understood that the dimensions of the high heel shoe, shank and all components will vary depending on the foot and shoe size of the user, the style of shoe, and the height of the heel. For example, in larger shoe sizes, the length of the shank will be adjusted correspondingly to be longer and/or wider as necessary.
[0022] Some embodiments of the present invention comprise additional features such as additional insole cushion layers, or other features as known in the art. The shoe may be made of any suitable materials, such as leather, fabric, plastic, cork, felt, and/or rubber, without departing from the underlying idea or principles of the invention within the scope of the appended claims. | A high heel shoe has an insole, an outsole, and a shank embedded between the insole and outsole, the shank comprising a heel portion with a depression to accommodate a user's heel, and a lateral ridge element in front of the heel portion that exerts pressure against the forward movement of a user's heel when worn. The shank further comprises a front portion sloping downward from the lateral ridge along the arch of the insole, which optionally is padded. | 0 |
This invention is directed to rolled aluminium sheet having a surface that is rough, and to a method of making the sheet. Although other uses are envisaged, the main application of this rough-surface aluminium sheet is expected to be as lithographic plate supports.
Most lithographic printing is from aluminium plates. These are typically 0.15 to 0.51 mm thick, depending on the size and type of press, although thinner sheets laminated to supports are also used. Aluminium sheet for lithographic plates is generally produced by rolling. This results in a metallurgical structure which is elongated in the rolling direction. The surface of the rolled sheet has marks (roll lines) extending longitudinally, which are not desired in the final grained product, and careful preparation of the rolls is necessary to minimise this effect.
To make an aluminium sheet suitable for use as a lithographic plate support, the surface needs to be roughened or grained. Standard techniques for this include: mechanical graining by the use of balls or abrasives or wire brushing; electrochemical graining, by the application of an AC current in an acidic electrolyte; and chemical graining, by simple immersion in an etch. Roughening is carried out in order to enhance the adhesion of an organic coating on the support, and to improve the water retention properties of the uncoated support surface. Application to the support of a photosensitive layer, followed by irradiation and development, generally result in a lithographic plate having ink-receptive image areas which carry an organic coating, and water-retaining non-image areas, the latter generally being the uncovered support surface. For this purpose the aluminium sheet needs to be roughened on a scale of approximately 1 to 15 μm.
The cost of the graining or roughening step is an important part of the economics of lithographic plate support manufacture. One advantage of the method of the present invention is that it makes possible a reduction in the time and energy used for graining.
In a different field, aluminium foil e.g. for domestic purposes is generally made by pack rolling. By this technique, a pack of two or more ribbons of aluminium is passed between the rolls, and the rolled sheets thereafter separated. The aluminium ribbons need to carry sufficient lubricant to prevent welding of adjacent sheets in the nip of the rolls, but this is often present without the need for deliberate additions. When two ribbons are pack rolled, each of the resulting sheets has a bright surface, which was in contact with the roll; and a matt surface which was in contact with the other sheet. When a pack of more than two aluminium ribbons is pack rolled, all sheets except the two outermost ones have two matt surfaces.
Pack rolling has, as noted, been widely used for many years in the production of aluminium foil for the retail market. We are aware of two published proposals to use pack rolled aluminium sheet as a lithographic plate support. The first is in British patent specification 2,001,559 published in February 1979. The second is in Japanese patent application 57203593 published in December 1982. But in our hands, pack rolled aluminium sheet is not satisfactory as a lithographic plate support, because the organic material which is applied to form a lipophilic image area does not bond well and rapidly flakes off. To the best of applicants' knowledge, pack rolled aluminium sheet has never achieved commercial success as lithographic plate support; and certainly not for long print runs.
EP-A-115 678 describes a technique for preparing Al sheet for use as a lithographic plate support by repeated pack rolling.
This invention is based on an initial discovery that subjecting the matt surface of pack rolled aluminium sheet to a roughening or graining process dramatically improves the properties of the sheet as lithographic plate support. Only a minor roughening or graining treatment is necessary to achieve this effect. The inventors have analysed the topography of their roughened surfaces, and have defined novel criteria for high performance.
In one aspect, this invention provides rolled aluminium sheet having a surface that is uniformly rough by virtue of: a rippled topography comprising ridges and troughs extending transverse to the rolling direction; and a pitted structure.
The surface of the rolled aluminium sheet is uniformly rough because each of the rippled topography and the pitted structure extends over the whole surface, rather than being confined to particular regions. The generally coarser rippled topography and the generally finer pitted structure are superimposed on one another.
In another aspect the invention provides a method of making a sheet having a roughened surface, starting from two or more ribbons of aluminium, by the steps of:
a) Pack rolling the ribbons to provide a pack of two or more sheets and separating the pack into individual sheets each having a matt surface that faced another sheet of the pack during rolling, and
b) Graining the said matt surface of the sheet.
This aluminium sheet is expected to be useful as lithographic plate support. For that use, it is preferred that the roughness of the rippled topography be sufficient to make the surface water-retentive, and the roughness of the pitted structure be sufficient to permit a layer of an organic material to become firmly bonded to the surface.
As noted above, it has long been well known that the lithographic plate grain provides protrusions for anchorage of an organic coating, to provide a lipophilic surface receptive to ink, and recesses which help the surface carry moisture. Applicants currently believe that the nature/extent/scale of the roughness required is different for each of these two different effects. Thus the rather coarse rippled topography that results from pack rolling provides a good moisture-receptive surface, but is not good as the basis for a firmly bonded organic layer. Conventional roughening on a finer scale is necessary to provide a good key for the firm adhesion of an applied organic layer. Lithographic plate supports having rough surfaces which meet both these criteria, may be novel materials in their own right, and can be manufactured in an economical way.
Pack rolling, as typically used in final passes for thin gauge aluminium foil production, provides an outer bright finish and an inner surface that has a matt appearance. When examined microscopically, it can be seen that the matt finish is not uniform but comprises surprisingly deep transverse linear features. The finish has the appearance of a rippled topography comprising ridges and troughs, whose major axis is transverse to the rolling direction. The aspect ratio of these features (i.e. the ratio of their length in a direction transverse to the rolling direction to their width in the rolling direction) may be at least 1.3, and typically in the range 1.5-4, although aspect ratios of 5 and greater are perfectly possible and within the scope of the invention. The average spacing between adjacent ridges (measured in the rolling direction) is typically in the range of 5-200 μm. The average roughness is typically of the same order as that of conventional commercial lithographic plate supports.
In rolled aluminium sheet, the metallurgical structure and the surface topography on the rolled side are strongly aligned in the rolling direction. The rippled topography on pack rolled sheet has been described by R. Akeret (Aluminium, Vol 68, 1992, 319-321), and by P. F. Thompson (J. Australian Inst. Metals, 15, 1970, 34-46). The scale and nature of the ripples can be modified by the choice of starting material. A fine rippled topography is produced on cold worked sheet and a coarser rippled topography on recrystallised sheet. The dimensions of the rippled topography also appear to depend to some extent on the rolling conditions employed, reduction during the final pass between the rolls, thickness of the rolled sheet, amount of lubricant on the matt surfaces of the sheets, etc. But it has not been found necessary to use unusual pack rolling conditions. The rippled topography that results from pack rolling is generally conducive to water retention, but not (at least not without further treatment) conducive to providing a key for firm bonding of applied organic coatings.
Superimposed on this rippled topography is a pitted structure comprising pits preferably having an average diameter of 1-20 μm. The technique used to achieve this pitted structure is not material to the invention. Suitable are the standard commercial roughening and graining techniques, including mechanical roughening, spark erosion, chemical graining, and particularly electrochemical graining. Chemical and electrochemical graining techniques typically give rise to pits having an aspect ratio (ratio of long axis to short axis of pits in the plane of the sheet) of less than 1.5 e.g. about 1.0. The extent of pitting needed to provide a key for firmly bonding an organic coating is quite slight. As shown in the examples below, an electrograining treatment involving a power input of 0.25 of that required commercially, provides excellent results, and it is expected that much milder graining than this will provide noticeable advantage. Preferably the extent of graining is from 1% to 80% of that performed on commercial single rolled aluminium sheet. But even when the extent of graining is 100% of that performed on commercial single rolled aluminium sheet, the resulting lithographic plate support is expected to be of excellent quality and is included within the scope of the invention.
The term aluminium is herein used to cover the pure metal and alloys in which aluminium is the major component. Preferred alloys for use in the present invention are those in the 1000, 3000, 5000 and 6000 series of the Aluminum Association Register, and also AlFeMn alloys in the 8000 series. The invention has the advantage that, because the pitting structure is not so critical, a wider range of alloys can be used.
The invention provides various advantages, both for the aluminium producer who rolls the aluminium sheet, and for the plate maker who converts the sheet into lithographic plate supports and then to lithographic plates. The latter can reduce the graining time normally necessary to a) produce the coarse pitted features required, and, b) cover up the roll lines as there is less directionality, thus reducing time and energy and eliminating the high degree of attack required on conventional substrates. The aluminium producer has the advantage of passing two aluminium ribbons through the mill for the final pass, thus increasing productivity. Also, when pack rolling to produce a matt surface, the roll surface topography is not of prime importance and so the special roll finishes currently used for final rolling lithographic sheet are not needed. Hence, much less fine grinding is required, representing considerable savings in roll production time.
In addition, it is important that lithographic sheet have a low surface electrical resistance which is amenable to electrograining and anodising, and in turn this means that the surface should be free of surface disruptions generated by interaction of the surface with the rolls. The matt surface of pack rolled sheet is expected to have a much reduced disturbed layer, thus minimising this problem.
Furthermore, current lithographic sheet has to be produced two-sided so that customers can use either side. This originates from the little used practice of graining on both sides. Producing a single-sided product that is recognised by plate makers as having to be in this form of necessity, means that the side destined to become the matt side can be treated more carefully during manufacture, i.e. can be kept upwards during rolling thus reducing handling damage from tables and guide rolls.
Different alloys can be employed if surface graining treatments only need to be light, or foil can be laminated to strip substrates (plastic or metal), thus separating the demands of mechanical properties and surface requirements.
The roughened surface of aluminium sheet for use as lithographic plate support generally carries an aluminium oxide film. This may be produced by anodising.
In addition to lithographic plate support, aluminium sheet according to this invention has various other uses:
Capacitor foil.
An improved surface finish for adhesion of organic coatings.
Roller coated pretreatments tend to coat in a manner dictated by the topography. Conventional material with highly directional features allows the pretreatment to run into the troughs with less pretreatment covering the peaks. The less directional surface topography of sheets according to this invention, tends to hold the liquid in discrete wells and helps spread the liquid transversely to produce a more homogeneous covering not unlike a gravure roll.
Matt products, i.e. clear lacquered or gold covered architectural coil.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is directed to the accompanying drawings, each of which is a photomicrograph at a magnification of about 640× so that the white bar is 50 μm in length:
FIG. 1 shows the surface of the bright side of hard 1200 foil as rolled. The rolling direction is from 12.30 to 6.30, (when viewed as the hour hand on a clock face) and the same is true of FIGS. 2, 3 and 4.
FIG. 2 is a corresponding picture of the matt side of the rolled sheet. The rippled topography, extending transverse to the rolling direction, can be clearly seen.
FIG. 3 is a photomicrograph of the bright side of the sheet, corresponding to FIG. 1, after it has been subjected to electrograining for 20 seconds at 14 V in 1.0% nitric acid with an electrode spacing of 1.5 cm.
FIG. 4 is a corresponding picture of the matt side of the aluminium sheet, corresponding to FIG. 2, after having been subjected to electrograining under the same conditions as FIG. 3.
FIG. 5 is a photomicrograph (magnification ×150) of the surface of Sample A (Table 2, Example 3) in which a rippled topography and a superimposed pitted structure are clearly visible.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLE 1
Profilometry measurements were made on samples of 1050A (9963) litho sheet 0.295 mm thick, both in the as-rolled condition, and after electrograining under simulated commercial conditions (30 seconds at 14 V in 1.0% nitric acid at an electrode spacing of 1.5 cm). Corresponding profilometry measurements were also made on 20 μm commercial 1200 foil, both as pack rolled with measurements being made on the bright and the matt surfaces, and after electrograining both surfaces under the above conditions.
Results are set out in the following Table 1, and are expressed in terms of R a and R z (DIN 4768) measured using a non-contact profilometer.
TABLE 1______________________________________ R.sub.a R.sub.zMATERIAL (μm) (μm)______________________________________1050A (9963) 0.44 4.14As Rolled1050A (9963) 1.2 10.0Grained 30s1200 (20 pm, Hard, Bright) 0.35 3.17As Rolled1200 (20 pm, Hard, Matt) 1.09 9.92As Rolled1200 (20 pm, Hard, Bright) 1.06 9.12Grained 30s1200 (20 pm, Hard, Matt) 1.14 9.50Grained 30s______________________________________
The roughness of the matt side of the pack rolled 1200 sample, both as rolled and after graining, was similar to that of the grained 1050A litho sheet sample.
EXAMPLE 2
FIGS. 1 and 2 of the accompanying drawings are photomicrographs of the bright and matt sides of the 1200 sample whose roughness parameters are quoted in rows 3 and 4 of the above table.
On subjecting this hard foil sample to a standard nitric acid electrograining treatment lasting 30 seconds, surfaces typical of those obtained commercially were produced. By contrast, when annealed foil rather than hard foil was used, the graining response was not as uniform and larger plateaus were encountered with rougher pitting.
When the electrograining treatment time was reduced from 30 seconds to 20 seconds, it was found that the surface produced on the bright rolled side had more plateau areas and the rolling direction could be readily discerned by the unaided eye, while the matt side was satisfactory. FIGS. 3 and 4 are photomicrographs of these two surfaces. Thus a light electrograining treatment on the matt pack-rolled side of the sheet produced a litho sheet support that looked as though it would have had useful properties.
EXAMPLE 3
Ribbons of AA1050A aluminium sheet 0.65 mm thick, in an annealed condition achieved by a recovery anneal at 400° C. for 5 minutes, were pack rolled to give rise to sheets approximately 0.425 to 0.485 mm thick. The front matt surface of some of the samples was electrograined at 70 Amps for 5 seconds in 1.5% hydrochloric acid. This treatment results in a charge input about 25% of that required for commercial electrograining of conventional rolled sheet. The various samples were anodised to generate an anodic oxide film on the roughened surface at a rate of 2.4 g/m 2 . Profilometry measurements were made using a mechanical stylus. It is accepted that a mechanical stylus gives roughness figures about half those obtained using a non-contact profilometer; commercial litho sheet support has an R a roughness typically in the range 0.4-0.5 μm and an R z roughness typically in the range of 3-6 μm.
The electrograined and anodised samples were used as supports for the preparation of lithographic plates which were employed in print runs. Results are set out in the following Table 2.
TABLE 2______________________________________Sample A B C D______________________________________Thickness (μm) 0.476 0.430 0.425 0.475Electrograining 70 A -- -- 70 A 5 sec 5 secSurface RoughnessR.sub.a (μm) 0.74 0.78 0.80 0.78R.sub.z (μm) 6.26 6.45 7.65 6.25Run clear 25 35 40 25Impressions (×1000) 130 1 1.5 120______________________________________
Samples A and D were subjected to electrograining; samples B and C were not. This electrograining had little effect on the surface roughness figures, although R z was slightly increased. The run clear figure is the number of impressions that need to be run off the lithographic plate before a good clear image is obtained. The non-grained samples B and C needed a little longer to run clear than the grained samples A and D.
The final row of the table records the number of impressions obtained off the lithographic plate before failure; the figures are expressed in thousands.
The non-electrograined samples B and C failed after a few thousand impressions because the organic coating flaked off the support. This was presumed to be because the organic coating was not firmly bonded to the support. By contrast, the electrograined A and D gave print runs continuing to 120,000 or more impressions, equivalent to high performance commercial plates. It will be recalled that the samples A and D have advantages over commercial lithographic plates:
The samples were produced by pack rolling, two at a time, rather than by single rolling; and
The samples received only a short electrograining treatment amounting to 25% of that required for the commercial litho plates.
FIG. 5 is a micrograph of the surface of Sample A. A rippled topography extending generally horizontally, and a pitted structure, are clearly visible.
EXAMPLE 4
In order to further characterise a matt pack rolled lithographic surface, gloss and R a roughness measurements were made on a specimen of 0.3 mm gauge commercially rolled lithographic sheet, a commercially nitric acid electrograined lithographic plate also of 0.3 mm gauge and a sample of matt pack rolled sheet of gauge 0.5 mm. Gloss measurements were made at 20° to the surface normal either in the rolling direction or the transverse direction. (This angle was chosen as it represents a typical viewing angle when inspecting surfaces). The standard commercial as-rolled specimen had a gloss measurement of 121 gloss units in the rolling direction but only 62 gloss units in the transverse direction. It had a roughness, R a , of 0.4 μm measured with a non-contact profilometer. These values indicate that this specimen had a highly reflective smooth and anisotropic surface. In contrast, the commercial electrograined sample had gloss values of 1.7 and 1.6 gloss units in the rolling and transverse directions respectively, which indicated a far more uniform, matt surface. This sample had a roughness of 1.14 μm. The matt pack rolled specimen had gloss values of 14 gloss units in both the rolling and transverse directions and a roughness of 1.24 μm. This showed that the matt pack rolled surface had a high degree of uniformity, that the coarse topography was already of the correct order for a lithographic substrate and that relatively little further fine roughening would be required to produce a surface having similar characteristics to a conventionally produced and high grade commercial plate. | Aluminium sheet suitable for use as a lithographic plate support has a surface that is uniformly rough by virtue of a rippled topography having an aspect ratio of at least 1.3 on a ale of 5-200 μm and a superimposed pitted surface on a scale of 1-20 μm. | 8 |
CROSS-REFERENCE TO RELATED CASES
This application is related to the commonly assigned, co-pending United States application Ser. No. 8543, filed Feb. 1, 1979 of Hans Zollinger, entitled: "Withdrawing Carrier For Looms With Removal Of The Filling Thread From Stationary Bobbins", and also to the commonly assigned co-pending U.S. application Ser. No. 06/179,105, filed Aug. 18, 1980, of Lothar Kohler, entitled "Threaded Light Metal Gripper With Reinforcement Rib".
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of a gripper head for looms working with removal of the filling threads from stationary bobbins or spools. The gripper head of the invention is of the type comprising a clamping gap formed by a stationary stop and a movable clamping tongue, the clamping gap serving for fixedly clamping a filling thread passing through the clamping gap essentially perpendicular to the central plane of the warp threads.
Gripper heads of this type are employed at gripper looms and serve the purpose of seizing the filling thread withdrawn from a stationary bobbin by means of a first gripper head, the so-called bringer-gripper or inserting carrier, introducing such seized filling thread approximately up to the center of the shed, at that location transferring the filling thread to a second gripper head, the so-called taker-gripper or withdrawing carrier, and then, finally drawing the filling thread through the second half of the shed. After departure of the taker-gripper out of the group of warp threads, the clamped filling thread is released. In order to drive the gripper heads, there are employed oscillating rigid rods which can be moved towards one another or flexible bands or tapes, at the front ends of which there are secured the gripper heads.
These gripper heads, which also are referred to by those skilled in this technology as clamping grippers, originally were designed such that the filling thread passed through the clamping gap and also the gripper head essentially parallel to the central plane of the warp threads. However, it has been found that such horizontal thread guiding in the gripper head is not capable of operating completely satisfactorily, either at the tape gripper looms and equally at the rod gripper looms. In particular, it is extremely difficult to maintain both of the gripper heads sufficiently stable in a direction perpendicular to the central plane of the warp threads such that the thread transfer at the center of the shed can always be accomplished in a positive manner.
It is for this reason that the gripper heads, during the past years, have been replaced by gripper heads of the previously mentioned type, wherein the filling thread passes through the clamping gap essentially in vertical direction. Gripper heads of this type are known to the art, for instance, from U.S. Pat. No. 4,062,382, granted Dec. 13, 1977, and U.S. Pat. No. 4,071,055, granted Jan. 31, 1978.
In practice, these gripper heads have indeed proven themselves to be superior to the first-mentioned prior art gripper heads, but nonetheless it can happen that notwithstanding a faultless functioning of the clamping tongue, the filling thread is suddenly released, particularly by the taker-gripper, and thus, is not completely inserted into the shed. This disturbance apparently is attributable to vibrations of the gripper head during the filling or weft insertion. These vibrations also can be transmitted to the clamping tongue, and, in unfavorable situations, can result in undesirable deflection thereof.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind, it is a primary object of the present invention to provide a new and improved construction of gripper head for shuttleless looms working with removal of the filling thread from stationary bobbins, which is not associated with the aforementioned drawbacks and limitations of the prior art constructions.
Another and more specific object of the present invention aims at improving upon the heretofore known gripper heads such that disturbances of the aforementioned type can be positively eliminated, and thus, the filling thread no longer can be unintentionally released.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the gripper head of the present invention is manifested by the features that the clamping tongue is structured to be displaceable in the lengthwise direction of the gripper head in order to open and close the clamping gap.
Hence, the inventive clamping tongue is thus no longer pivoted out as was heretofore the case for the purpose of releasing the clamped filling thread, rather it is displaced, and specifically, in the lengthwise direction of the gripper head. This affords the beneficial result that the clamping gap of the gripper head no longer can be opened by vibrations in vertical direction.
With vertically deflectable clamping tongues, the opening of the clamping gap is accomplished by applying pressure from above upon the clamping tongue. Since the spring force of the clamping tongue must be relatively strong, this pressure also must have a correspondingly large value or magnitude. Due to the sudden or abrupt application of the pressure at the clamping tongue, such produces not inappreciable loading of the gripper head and the flexible tape or band which carries such gripper head. This loading, during continuous operation, can lead to rupture of the tape at the region of the rear end of the gripper head. Also this disturbance factor is completely eliminated with the displaceable clamping tongue of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a top plan view of a taker-gripper or withdrawing carrier according to the invention;
FIG. 2 is a front view of the taker-gripper shown in FIG. 1, looking in the direction of the arrow II thereof;
FIG. 3 is a front view of the gripper of FIG. 2 looking in the direction of the arrow III thereof;
FIG. 4 is a sectional view, on an enlarged scale, of the taker-gripper shown in FIG. 2, the section being taken along the line IV--IV thereof;
FIG. 5 is a fragmentary perspective view of a detail of a clamping tongue of the taker-gripper of FIG. 1;
FIG. 6 is a top plan view of a reinforcement element which is threadably connected to the rear end of the taker-gripper of FIG. 1; and
FIG. 7 is a front view of the reinforcement element shown in FIG. 6, looking in the direction of the arrow VII thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, the taker-gripper 1 illustrated in FIGS. 1 to 5, which is mounted, as shown, at the front end of a flexible tape or band 2 serving for driving the taker-gripper 1 in a manner well known in this technology, will be seen to contain a lengthwise extended form of essentially U-shaped, cross-sectional configuration. At its rear portion, which is attached to the flexible tape or band 2, the taker-gripper 1 comprises a base portion 3, a first side wall 4 which confronts the cloth fell A, (FIG. 4), and a second side wall 5. The base or bottom portion 3 is closed towards the front in the direction of the gripper tip 1" by a step-shaped raised portion or protuberance 6. Thereafter, both of the side walls 4 and 5 are connected with one another at the gripper top surface by a web 7 or the like and extend towards the gripper tip 1" so as to finally form a substantially flat hook 8.
Internally of the hollow space enclosed by the base portion 3, side walls 4 and 5, step-shaped raised portion 6 and web 7, there is arranged a lengthwise extending or elongate clamping tongue 9 which is displaceable in the lengthwise direction of the taker-gripper 1. The clamping tongue 9 possesses at its rear portion or part at the region of the base portion 3 a prismatic shape having an elongate, forwardly and rearwardly closed opening or throughpassage 10, at which merges, in the direction of the gripper tip 1", an elongate, flat band-like portion 11. At the rear closure of the opening or throughpassage 10, there is formed an entrainment projection 12. The prismatic clamping tongue portion 9' containing the opening or throughpassage 10 bears upon the base portion 3 of the taker-gripper 1, while the band-shaped or band-like portion 11 of the clamping tongue 9 extends between the web 7 and the step-raised portion 6.
During operation of the loom, the taker-gripper 1 is inserted from the left side of the loom into the shed; the flexible tape or band 2 and the plane of the hook 8 are located parallel to the central plane M of the warp threads K (FIG. 4).
At the base portion 3 there is secured by means of a fastening screw or threaded bolt 13 or equivalent structure a guide element 14 which extends into the opening or throughpassage 10 and forms a guide for the rear part of the clamping tongue 9. In this guide element or piece 14 there is inserted the one end of a spiral spring 15 or equivalent structure, the other end of which presses against the front closure of the opening or throughpassage 10. By means of the spiral spring 15 the tip of the bandshaped part 11 of the clamping tongue 9 is thus pressed into the mouth 16 of the hook 8.
At the entrainment shoulder 12, there is attached, by means of a fastening screw or threaded bolt 17 the one end of a blade or leaf spring 18 or equivalent structure, the other end of which is mounted at a double-arm pivotal lever 19. The second side wall 5 of the taker-gripper 1 is provided at the region of the screw or bolt 17 with an opening 17' rendering possible access to the screw 17. The pivotal lever 19 is pivotable about a screw or bolt 20 which is threaded into the base portion or part 3 and, as shown, consists of a circular sector-shaped portion or part 19' at which there is mounted the leaf spring 18, and an actuation finger 19" which protrudes out of the gripper internal space or region 1', through an opening or passageway 21 provided at the first side wall 4.
This actuation finger 19" is operatively associated at a location externally of the shed with a suitable stop or impact member (not shown), so that upon travel of the actuation finger 19" against this stop, the clamping tongue 9 is drawn towards the rear, away from the gripper tip 1", against the force of the spiral spring 15. At the base portion 3 there is formed an upwardly protruding shoulder 22 into which there is threaded a screw or threaded bolt 23 or equivalent structure, constituting an adjustable stop for the circular sector-shaped portion 19' of the double-arm pivotal lever 19. In order to positively guide the spiral spring 15 in the opening 10 of the clamping tongue 9 there is adhesively bonded into the opening 10 a small tube or tubular element 24 which encloses the spiral spring 15 or the like.
The hook 8 is open at the first side wall 4, as generally indicated by reference character 8'. Both of the outer edges 60 and 62 of the hook arms 8" and 8"' merge into the hook tip 64, whereas the inner edges 25 and 26 of both hook arms 8"' and 8" limit the hook mouth 16. The hook end is designated by reference character 27. The inner edge 25 facing the cloth fell A is provided with a stepped portion 28, as best seen by referring to FIG. 4, and specifically such that the hook mouth 16 at the top side of the hook 8 is narrower than at its lower side.
The clamping tongue 9 protrudes by means of the free end E of its band-like portion 11 into the hook mouth 16 and is provided at the region of such end E, at its first lengthwise or longitudinal edge 70 neighboring the hook inner edge 25, likewise with a stepped portion 29. The second longitudinal or lengthwise edge 30 of the clamping tongue end E, which is more removed or distanced from the cloth fell A, serves as a guide edge. The first lengthwise or longitudinal edge 70 containing the stepped portion 29, forms together with the hook inner edge 25 and its stepped portion 28 a clamping gap 80 for a filling or weft thread F. The end E of the band-like part or portion 11 of the clamping tongue 9 is bevelled at its first lengthwise edge 70 and possesses a clamping surface 31 of lesser inclination for thicker yarns and a further clamping surface 32 of greater inclination for thinner yarns. Both of these clamping surfaces 31 and 32 can continuously merge into one another.
By means of the clamping surfaces 31 and 32 there is formed in the clamping gap 80 a wedge action, by means of which the filling thread F, independently of its thickness, is not only always positively fixedly clamped but also upon release of the clamping action is rapidly freed. The reliability of the clamping action is additionally increased by virtue of the stepped portion 28 at the hook inner edge 25 and the corresponding stepped portion 29 at the first lengthwise edge 70 at the end E of the clamping tongue 9.
The taker-gripper 1 and the clamping tongue 9 consist of a material having an appreciably lesser specific weight or density in relation to steel, and, for instance, are cast from a light metal, such as aluminum or an aluminum alloy, or fabricated of a suitable plastic material, and at the region of the clamping gap 80 are each provided with wear-resistant inserts formed of a suitable steel or a hard metal, such as a carbide metal. Each of these inserts or insert members are preferably formed of one piece and are threadably connected with the hook 8 and with the end E of the clamping tongue 9, respectively. The insert element surrounding the hook mouth 16 has been generally designated by reference character 33, and as illustrated in FIGS. 1, 3, and 4, is mounted with the aid of a screw or bolt 34 from above at the hook 8. The clamping tongue 9 is stepped at the region of its end E at its underside, and at such stepped portion there is inserted from below the insert element or piece 35 and secured by means of two screws or bolts 36 at the end E (FIGS. 1, 3, 4, and 5). The base body of the clamping tongue 9 extends up to the line 37 and the insert element or piece 35 forms the tip of the end E of the clamping tongue 9.
The basic prerequisites for a free selection of the material of the taker-gripper 1 reside in the fact that such no longer need be soldered as previously was the case with the flexible tape or band 2, since with a steel band or tape only a relatively small amount of material can be soldered. It is for this reason that the taker-gripper 1 is secured by a threaded or screw connection at the flexible tape or band 2, which will be explained more fully hereinafter based upon the showing of FIGS. 1 to 3 and 6 and 7.
As illustrated, both of the side walls 4 and 5 of the taker-gripper 1 are guided towards one another at the region of the rear gripper end and limit by means of their inner surfaces a gap 90. In this gap 90 there protrudes the front end 38 of a rail-shaped reinforcement element 39. By means of a screw 40 or equivalent structure the side walls 4 and 5 are fixed at the end 38 of the reinforcement element 39. Additionally, the taker-gripper 1 is threadably connected with the flexible band or tape 2. The band 2 is provided at its front end with an upwardly domed bead or pleat 41 in which there is inserted from below the nut members 42 by means of which there are threadably connected the screws 43 which are inserted from above through the base portion 3 of the taker-gripper 1.
The reinforcement element 39 is of rail-like configuration and is provided over its length with a number of vertical bores 44 serving for receiving attachment screws. The taker-gripper 1 and the reinforcement element 39 are fabricated of the same material and have approximately the same length. The reinforcement element 39 is placed in an upright position and is threadably connected with the flexible band or tape 2 along the central axis of such flexible band. For this purpose, the band 2 is provided at the location of the bores 44 of the reinforcement element 39 with reinforcing fins in the form of the beads or pleats 41, serving for taking-up nuts or the like in the form of the nut members 42. For assembling the taker-gripper 1 at the band 2, the taker-gripper 1 is initially threadably connected by means of the screws 40 or the like with the reinforcement element 39 and thereafter the pair of elements forming a unit, namely the taker-gripper 1 and the reinforcement element 39, are threaded to the band or tape 2.
The mode of operation of the taker-gripper 1 is as follows: This taker-gripper 1 is transported by its band 2 from the left side of the loom up to approximately the center of the shed and at that location, at the region of the hook tip 27 engages by means of the outer edge 25 of the hook 8 which confronts the cloth fell A with the filling thread F which has been offered by a not particularly illustrated bringer-gripper in a position extending perpendicular to the plane of the hook 8. The taker-gripper 1 moves into the bringer-gripper, in a manner well-known in this technology. As a result, the filling thread F which is still fixedly retained by the bringer-gripper now slides over the aforementioned outer edge 25 of the hook 8 and the hook end 27 in the direction of the clamping gap 80. During the outward movement of the taker-gripper 1, out of the weaving shed, the filling thread F arrives at the clamping gap 80 and specifically, up to the zone or region which corresponds to its thickness. At this moment, the clamping action of the bringer-gripper is released, and the filling thread F which is now fixedly clamped by the taker-gripper 1 is pulled by such taker-gripper 1 through the second half of the shed. After completion of the insertion of the filling thread F through the shed there is released the clamping action of the taker-gripper 1 at the filling thread F by virtue of the travel of the actuation finger 19" of the pivotal lever 19 against the aforementioned stationary stop or impact member and the filling thread F is totally released.
By virtue of the fact that the clamping tongue 9 is not pivoted out as was heretofore the case in vertical direction rather is mounted so as to be displaceable or shiftable in horizontal direction within the taker-gripper 1, vertical flutter or oscillation movements of the taker-gripper 1 no longer can lead to unintentional release of the fixedly clamped filling thread F by the clamping tongue 9. Quite to the contrary, the clamping action of the clamping gap 80 is augmented by the gripper movement since the clamping tongue 9, upon withdrawal of the gripper 1 out of the shed, especially during the acceleration phase, will be pushed by virtue of its inertia into the hook mouth 16. The clamping tongue 9 however also can be drawn out of the hook mouth 16 by virtue of the very small forces for purposes of thread release. At that point in time at which the actuation finger 19" travels against the stop, the taker-gripper 1 is braked and the clamping tongue 9, owing to its inertia, has the tendency of moving out of the hook mouth 16.
A further advantage of the inventive horizontally displaceable clamping tongue 9, in relation to a vertically pivotable clamping tongue, resides in the fact that the first type of clamping tongue, even in the presence of the smallest amount of wear, need not be readjusted, rather is self-adjusting.
Although the inventive clamping tongue which is displaceable in the lengthwise direction of the taker-gripper 1, can be used and therefore has been described by way of example and not by way of limitation in conjunction with a taker-gripper 1, it of course also can be equally well employed in conjunction with bringer-grippers.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY, | A gripper head for looms working with removal of the filling thread from stationary bobbins comprises a clamping gap formed by a fixed stop and a movable clamping tongue. The clamping gap serves to fixedly clamp a filling thread which passes through the clamping gap essentially perpendicular to the central plane of the warp threads. The clamping tongue is structured to be displaceable in the lengthwise direction of the gripper head for opening and closing the clamping gap. Due to this actuation of the clamping tongue, by displacement thereof in horizontal direction, the clamping tongue is insensitive to flutter movements of the gripper head caused by vertical oscillations and there is ensured for more positive clamping of the filling thread. | 3 |
BACKGROUND OF THE INVENTION
A molded case circuit breaker containing a common trip unit and accessory module for field installation of optional accessory function is described within U.S. patent application Ser. No. 882,989, filed July 7, 1986, and entitled "Combined Trip Unit And Accessory Module For Electronic Trip Circuit Breaker". The circuit breaker uniquely contains the current sensing transformers and signal processing electronics within a common enclosure with the circuit breaker operating mechanism. The combined trip unit and accessory module provide overcurrent, shunt trip and undervoltage release facility to the breaker by means of a common trip actuator assembly. The Application is incorporated herein for reference purposes and should be reviewed for its teaching of the mechanical interaction of the trip unit and accessory module with the circuit breaker interruption mechanism.
U.S. patent application Ser. No. 817,213, filed Jan. 8, 1986, and entitled "Interchangeable Mechanism For Molded Case Circuit Breaker", describes a compact circuit breaker operating mechanism, which is automatically assembled, in part, and which is interchangable within breakers of different ampere ratings. This Application is incorporated for reference purposes and should be reviewed for its description of an operating mechanism similar to that used within the circuit breaker of the instant invention.
Molded case circuit breakers provide overcurrent protection by responding to current levels within a protected circuit in excess of predetermined current thresholds. In both residential as well as in lower rating industrial breakers, a thermal-magnetic trip unit responds to such threshold currents by contacting and articulating the operating mechanism to separate the breaker contacts. Electronic trip units are feasibly employed within those industrial circuit breakers of higher ampere ratings and require an intermediate actuator to articulate the operating mechanism, usually in the form of a magnetically-latched solenoid. A current pulse to the solenoid generates an opposing magnetic flux allowing the actuator to release under the bias provided by a charged spring. When a common overcurrent and accessory trip unit, such as described within the former referenced patent application is employed within such an industrial rated breaker, additional circuit logic must be provided for each accessory function. The overcurrent protection logic is provided by the electronic trip unit signal processor, which responds solely to overcurrent conditions. Separate logic circuits are required for undervoltage release units and shunt trip units.
One purpose of the instant invention is to provide an electronic control circuit for an undervoltage release unit coupled with a common actuator that separately provides overcurrent trip facility. The electronic circuit components for the undervoltage release unit are carried by a separate printed wiring board that is integral with the undervoltage release coil.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top perspective view, in isometric projection, of a circuit breaker having an electronic trip actuator module according to the invention;
FIG. 2 is a top view of a part of the circuit breaker depicted in FIG. 1;
FIG. 3 is a top perspective view, in isometric projection, of the electronic trip actuator module of FIG. 1;
FIG. 4 is a diagrammatic representation of the control circuit for the undervoltage release coil shown in FIG. 3;
FIG. 5 is a graphic representation of the undervoltage release current profile through the FET within the circuit of FIG. 4; and
FIG. 6 is a diagrammatic representation of an alternate control circuit for the undervoltage release coil of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A lower ampere rated molded case industrial circuit breaker of the type used, for example, in lighting panelboards is shown at 10 in FIG. 1. The breaker includes a plastic case 11 and a plastic cover 12 attached thereto by rivets or screws. A crossbar assembly 13 is arranged within the case with a movable contact arm 14 extending therefrom and carrying a movable contact 15 at one end, which connects with a fixed contact 16 to complete the electrical circuit through the breaker. An operating mechanism 9 is arranged over the crossbar and interfaced with the movable contact arm for automatic separation of the contacts when the mechanical actuator 19 arranged on the electronic actuator module 18 (hereafter "actuator module") strikes a trip bar extension 21 to articulate the operating mechanism. As described in the aforementioned patent application Ser. No. 882,989, the mechanical actuator 19 is magnetically latched against the bias of a compression spring 20 mounted on the side wall of the actuator. An operating handle 17 extends through the cover for manual opening and closing of the contacts and for resetting the operating mechanism after a tripping operation. An accessory door 23 mounted on the cover allows access to the actuator by means of an opening 22 through the cover.
The actuator module 18 is shown in FIG. 2 with its cover removed for access to the undervoltage release coil 26 and shunt trip coil 27 contained within the actuator. An undervoltage control circuit is arranged on the undervoltage printed wire board 28 integrally formed with the undervoltage coil support structure and a pair of electrical connectors 40 extend from the undervoltage printed wiring board for providing electrical input signals to the undervoltage coil. A shunt trip control circuit is arranged on the shunt trip printed wire board 29 and a pair of shunt trip electrical connectors 39 extend from the shunt trip printed wire board for providing input signals to the shunt trip coil. A pair of current transformers 25 provide electrical input from the load terminals 24 to the trip unit signal processor located on the trip unit printed wire board 51 under the actuator module 18. The magnetic latch 52 utilizes an armature 30 (FIG. 3) to control the operation of the mechanical actuator 19 with respect to the trip bar extension 21 and the circuit breaker operating mechanism 9, as fully described in referenced patent application Ser. No. 882,989.
The operative arrangement between the armature 30 positioned on the interior of the accessory cover 31 and biased against the cover by means of a compression spring 32 is best seen by referring now to FIG. 3. The integral arrangement of the undervoltage release coil 26 with the undervoltage printed wire board 28 allows the undervoltage release coil to be downloaded onto one leg 34 of the U-shaped stator 33 in a single operation. The magnet 60 mounted on top of leg 34 provides the necessary magnetic flux to the magnetic stator 33 to hold the armature 30 against the tripping bias of the compression spring. The same integral arrangement of the shunt trip coil 27 on the shunt trip printed wire board 29 allows the shunt trip coil to be downloaded onto the other leg 35 of the stator on top of the trip coil 36, which is prepositioned thereon. The leads 37 of the trip coil directly connect the trip coil with the trip unit printed wire board 51, shown earlier in FIG. 2. The U-shaped stator 33 is then positioned within the case 38 and the cover 31 is attached to automatically align the armature 30 with both legs 34, 35 of the stator to complete the assembly of the actuator module 18. The undervoltage release coil 26 includes a magnetic shunt 61 which decreases the magnetic flux through the stator 33 generated by the permanent magnet 60 arranged on the top of the stator leg 34, such that the magnetic force on the armature 30 is insufficient to hold the armature against the bias of the compression spring 32, when the undervoltage release coil is not energized.
The control circuit 41 for operating the undervoltage release coil 26 is shown in FIG. 4 and comprises a pair of terminals 43, 44, which connect with an external circuit that supplies an undervoltage release signal to a positive and negative bus 45, 46 through a bridge rectifier 42 consisting of diodes D 1 -D 4 . The positive bus connects through one leg of a voltage divider consisting of resistors R 1 , R 2 . The signal from the positive bus generates a test voltage across resistor R 1 , which is applied to the base of a bipolar transistor switch 48 through Zener diode 47 and conductor 53. The Zener diode turns on at a predetermined clamping voltage of approximately 70% of the undervoltage release signal appearing across the terminals 43, 44. Resistor R 2 forms the other leg of the voltage divider and resistor R 3 connects the Zener diode with the emitter of the transistor switch 48. When the transistor is turned on, current passes between buses 45, 46 through a field effect transistor (FET) 49 and through the undervoltage release coil 26 in series with both the FET 49 and the transistor switch 48. A diode D 5 and capacitor C 1 maintain a relatively constant voltage drop across the undervoltage release coil by forming an RC circuit with the wire resistance of the undervoltage release coil winding. The function of the FET 49 is to maintain a constant current through the undervoltage release coil over a wide range of fluctuations in the undervoltage release signal voltage in order to minimize heating effects that would otherwise occur with increased system voltages as well as to maintain a constant magnetomotive force within the magnetic circuit. The operation of the FET can be seen by referring to the current profile 50 shown in FIG. 5, which represents the current through the undervoltage release coil in series with the FET. The constant current through the FET is caused by the so-called "channel effect" within the FET which maintains the current through the FET at a constant predetermined value between an operating window defined between an initial voltage V 0 across the FET and a second voltage V 1 , as indicated.
A simplified UV control circuit 54 is shown in FIG. 6 where the terminals 43, 44 connect with the positive and negative bus 45, 46 through the bridge rectifier 42. The Zener diode 47 connects with the positive bus through a limiting resistor R 4 and with the negative bus through a programmable regulator shunt diode 58 (hereafter regulator diode), as indicated. The regulator diode is a TL431 obtained from Motorola, Inc. The cathode is connected by conductor 57 to the anode of the Zener diode 47 and the base of a bipolar transistor 56 which functions as a current regulator as well as a switch. The emitter of the transistor is connected by conductor 62 to the reference input of the regulator diode and to a feedback resistor R 5 . The collector of the transistor connects with the undervoltage release coil 26 to excite the coil when the voltage level across Zener diode 47 is above its clamping voltage. The function of the regulator diode, in conjunction with resistor R 5 and transistor 56, is to maintain a constant current through the undervoltage release coil 26 when the voltage applied to terminals 43, 44 is greater than the clamping voltage of the Zener diode. This maintains a constant current through the undervoltage release coil to both limit the amount of energy expended within the coil as well as to keep the magnetomotive force at a constant value. The filter capacitor C 2 ensures that the voltage across the regulator diode remains constant.
A circuit breaker having optional accessory features including electronic control circuits integral with the undervoltage release coil and shunt trip coil contained therein has herein been described. The circuits comprise a minimum of electronic components that are both economic to manufacture as well as economical to operate over long periods of continuous use. | A molded case circuit breaker provides both overcurrent protection as well as accessory protection function by means of a self-contained electronic trip actuator module. Undervoltage release function is provided by a separate undervoltage release assembly that includes the undervoltage coil and an electronic control circuit. Shunt trip facility is provided by the shunt trip coil and a shunt trip control circuitry. The overcurrent, shunt trip and undervoltage release coils are arranged on a magnetic circuit within the electronic actuator module. | 7 |
RELATED APPLICATION
[0001] The present disclosure relates to subject matter contained in priority Korean Application No. 10-2007-0089181, filed on Sep. 3, 2007, which is herein expressly incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a washing/drying machine, and more particularly, to mounting a washing/drying machine on a pedestal or other washing/drying machine by using a supporter.
[0004] 2. Background of the Invention
[0005] In general, a washing/drying machine is an apparatus to remove stain (dirt) from clothes, bedclothes, and the like. Such the washing/drying machine may include a washing machine for washing laundry, a drying machine for drying the laundry, a washing/drying machine for performing both the washing and drying operations, and the like. In addition, a refresher has been introduced to remove wrinkles of the laundry or to supply fragrance.
[0006] With a recent trend of the washing/drying machine equipped with a pedestal for storing items therein or a supporter, the washing/drying machine, such as the washing machine, the drying machine, the washing/drying machine, etc., is configured to be fixed to an upper surface of the pedestal.
[0007] FIG. 1 is an exploded perspective view showing a conventional washing/drying machine having a pedestal. Referring to FIG. 1 , the pedestal 20 may include a housing 21 having a certain space therein, and a drawer 22 detachably inserted into the housing 21 for receiving a variety of items therein.
[0008] Here, a main body 10 of a washing/drying machine 1 and the pedestal 20 are coupled to each other by a separate coupling member 23 (e.g., a bracket, etc.). An upper end 23 a of the coupling member 23 is fixed onto one side surface of the washing/drying machine main body 10 by a double-sided tape 24 , and a lower end 23 b of the coupling member 23 is fixed onto one side surface of the housing 21 of the pedestal 20 by screws 25 .
[0009] Here, a pair of coupling members 23 is installed at each side surface of the main body 10 of the washing/drying machine 1 and the housing 21 of the pedestal 20 . That is, the upper end 23 a of the coupling member 23 is attached to the double-sided tape 24 , and both sides of the lower end 23 b thereof are coupled by the screws 25 , thereby being installed between the side surface of a lower end of the main body 10 forming an outer aspect of the washing/drying machine 1 and the side surface of the housing 21 of the pedestal 20 .
[0010] However, such conventional pedestal 20 cannot be commonly used in the washing machine, the drying machine or the like, and the separate coupling member 23 should be used for coupling the washing/drying machine 1 and the pedestal 20 , thereby having a complicated coupling process, reducing productivity, and increasing a manufacturing cost.
[0011] In addition, when the washing/drying machine 1 is to be moved or when the coupling member 23 is to be removed so as to install other washing/drying machine to the pedestal, a spot due to the double-sided tape would remain on the surface of either the washing/drying machine 1 or the pedestal 20 , or screw holes are generated, thereby deteriorating the external appearance of the product.
[0012] In addition, in the process of removing the screws 25 in order to remove the coupling member 23 , the surface of the washing/drying machine 1 or the pedestal 20 may be damaged (e.g., dented) or the coupling member 23 may be curved.
SUMMARY OF THE INVENTION
[0013] Therefore, an object of the present invention is to provide a pedestal capable of preventing a damage to a surface of the washing/drying machine and the pedestal due to a coupling unit by coupling base ribs formed at a base for supporting a lower portion of the washing/drying machine and coupling ribs of a supporter, facilitating mounting/dismounting the supporter or the pedestal, and not requiring a separate coupling member, and a washing/drying machine having the same.
[0014] To achieve this and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a washing/drying machine, including: a washing/drying machine main body; and a pedestal for mounting the main body thereon, wherein a base having legs is coupled to a lower end of the main body, and a supporter having coupling ribs for fixing the base to the pedestal is formed at an upper surface of the pedestal.
[0015] Here, the supporter includes a main body having leg holes for mounting legs of an object to support thereon, and a plurality of coupling ribs disposed at one side of the main body so as to couple the object to support disposed above or below the main body and the main body to each other.
[0016] With such configuration, the object to support and the supporter can be coupled by the coupling ribs. Accordingly, the supporter or the pedestal may be fixed to the object to support without a separate coupling means such as a conventional coupling member, thus to increase productivity.
[0017] In addition, at least two coupling ribs are formed at the supporter so as to correspond to an edge of the upper surface of the housing, and coupling holes of a coupling means may be formed at the coupling ribs. Thusly, the coupling ribs are configured to correspond to the edges of the upper surface of the pedestal housing, thereby preventing the supporter from protruding outside of the pedestal housing. Since the coupling holes are formed at the coupling ribs, there is no need to form a separate screw coupling hole on the surface of the pedestal, and damage to the outer aspect of the housing, etc. may be prevented.
[0018] In addition, an outer aspect can be maintained in a good condition by preventing the supporter from protruding from the surface of the object to support or the pedestal.
[0019] Meanwhile, at least two leg holes for mounting the support legs of the object are formed at the supporter, and the leg holes are communicated with each other or separated from each other. That is, the at least two leg holes are applied in both the washing machine and the drying machine, thus to be commonly used.
[0020] Here, the leg holes are formed to have a different depth or size, and the leg holes are disposed on the upper surface of the housing in a diagonal direction. If an object to be coupled to the supporter is the washing machine and the drying machine, legs of the drying machine are positioned inside legs of the washing machine in the diagonal direction. Thusly, the leg holes are disposed on the upper surface of the housing in the diagonal direction, thereby achieving the general use of the components. In addition, considering that the legs of the washing machine and the drying machine have different diameter or thickness, the size or the depth of the leg holes should be formed.
[0021] There is provided a washing/drying machine, including: a washing/drying machine main body performing a washing or drying operation of laundry; a base coupled to a lower end of the main body so as to support the main body and having legs; and a pedestal disposed below the main body and for supporting the main body, wherein a supporter having coupling ribs for fixing the main body to the pedestal is mounted at an upper surface of the pedestal.
[0022] Here, base ribs coupled to the coupling ribs are formed at the base.
[0023] Coupling holes communicated with each other are formed at the coupling ribs and the base ribs. After aligning the centers of the coupling holes with each other, the base and the supporter are coupled by using a screw, etc., thereby preventing the damage to the surface of the washing/drying machine and the pedestal.
[0024] Meanwhile, the washing/drying machine main body is one of a washing machine, a drying machine or a washing/drying machine. Washing machine leg holes for receiving legs mounted at the washing machine base and drying machine leg holes for receiving legs mounted at the drying machine base are formed at the supporter.
[0025] In addition, the washing machine leg holes and the drying machine leg holes may be communicated with each other or separated from each other. The supporter includes front supporters having leg holes communicated with each other and disposed at both sides on the front end of the upper surface of the pedestal, and rear supporters having leg holes separated from each other and disposed at both sides on the rear end of the upper surface of the pedestal.
[0026] Here, at least one of the washing machine leg holes or the drying machine leg holes may be formed to be open. That is, some of the leg holes may be covered so as to prevent the leg from being seen outside, and others may remain in an opened state for facilitating mounting the leg.
[0027] The present invention provides a pedestal disposed below the washing machine or the drying machine, and equipped with a supporter having coupling ribs coupled to the base that is mounted at the lower end of the washing machine or the drying machine, thus to be commonly used in the washing machine and the drying machine.
[0028] If another washing/drying machine, in addition to the washing/drying machine, is to be placed, the two washing/drying machines may be fixed by using the supporter according to the present invention. That is, the present invention provides a washing/drying machine, including: a first washing/drying machine main body; and a second washing/drying machine main body placed on the first main body, wherein a base having legs is coupled at a lower end of the second main body, and a supporter having coupling ribs for fixing the base to the first main body is mounted at an upper surface of the first main body. Here, the first main body may be the drying machine and the second main body may be the washing machine, and vice versa.
[0029] The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] 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.
[0031] In the drawings:
[0032] FIG. 1 is an exploded perspective view showing a conventional washing/drying machine having a pedestal;
[0033] FIG. 2 is an exploded perspective view showing a washing/drying machine having a pedestal according to the present invention;
[0034] FIG. 3 is a perspective view showing a state that a supporter is mounted at the pedestal in FIG. 2 ;
[0035] FIG. 4 is a perspective view showing one exemplary supporter in FIG. 3 ;
[0036] FIG. 5 is an exploded perspective view showing a base mounted at the washing/drying machine in FIG. 2 ;
[0037] FIG. 6 is a perspective view showing a state that the base in FIG. 5 is coupled to the supporter; and
[0038] FIG. 7 is a perspective view showing another exemplary base in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0039] Description will now be given in detail of the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0040] FIG. 2 is an exploded perspective view showing a washing/drying machine having a pedestal according to the present invention. FIG. 3 is a perspective view showing a state that a supporter is mounted at the pedestal in FIG. 2 , and FIG. 4 is a perspective view showing one exemplary supporter in FIG. 3 .
[0041] Referring to FIGS. 2 through 4 , the washing/drying machine 100 according to the present invention may include a washing/drying machine main body 110 for performing cleaning operations of clothes, a pedestal 200 or a pedestal disposed at one surface of the washing/drying machine main body 110 and for receiving a variety of items required for cleaning the clothes, and a supporter 230 disposed between the pedestal 200 and the washing/drying machine main body 110 so as to connect the pedestal 200 and the main body 110 .
[0042] The washing/drying machine main body 110 may be one of the washing machine, the drying machine, and washing/drying machine. The pedestal 200 may be disposed at any one of left/right surfaces and upper/lower surfaces of the main body 110 , and most preferably, at the lower surface of the main body 110 .
[0043] Hereinafter, the present invention would describe that the pedestal 200 is disposed below the washing/drying machine main body 110 , and the main body 110 is either the washing machine or the drying machine. That is, the pedestal 200 is mounted at a position where the washing/drying machine 100 is to be installed, and then the washing/drying machine (i.e., the washing machine or the drying machine) main body 110 is placed and fixed onto an upper surface of the pedestal 200 .
[0044] Here, the washing machine as an example of the washing/drying machine 100 may include the main body 110 forming an external appearance, a tub (not shown) disposed inside the main body 110 in a horizontal direction so as to be dampered (attenuated) and for receiving water therein, a drum 113 rotatably mounted inside the tub for receiving clothes therein, and having a plurality of through-holes 113 a at an outer surface thereof so as to pass water or foam therethrough, a plurality of lifters 113 b mounted at an inner surface of the drum 113 and lifting laundry such that the laundry is dropped at a certain height by gravity, and a motor (not shown) mounted rear the tub for rotating the drum 113 .
[0045] A main body cover (not shown) is disposed at the front surface of the main body 110 , and a base 120 is mounted at a lower surface of the main body 110 . A top plate 111 is mounted at the upper surface of the main body 110 .
[0046] An entrance opening, through which the laundry is introduced into or removed from the drum 113 , is formed in the main body cover, and a door 112 for opening/closing the entrance opening is rotatably mounted at one side of the entrance opening. A gasket 114 for attenuating an impact by a rotation of the drum 113 as well as serving as a packing to prevent water from overflowing is installed between the tub and the door 112 .
[0047] A height adjustable leg 121 for supporting a load of the washing/drying machine (i.e., the washing machine) main body 110 is mounted at each of four corners of the base 120 so as to be ascendable or descendable.
[0048] The legs 121 are coupled to the base 120 by a coupling means such as screws, or the like. If the legs 121 are rotated in one direction, the legs 121 are configured to protrude from the base 120 , thereby increasing an installation height of the washing/drying machine 100 . If the legs 121 are rotated in another direction, the legs 121 are configured to be inserted into the base 120 , thereby reducing the installation height of the washing/drying machine 100 .
[0049] The pedestal 200 may include the box-shaped housing 210 formed to have an area enough to place the washing/drying machine 100 thereon, and a drawer 222 openably disposed at a front surface of the housing 210 so as to receive a variety of items inside the housing 210 .
[0050] The housing 210 and the drawer 222 may be formed of an injection molded plastic.
[0051] The supporter 230 for fixing the legs 121 of the washing/drying machine 100 may be installed at each of the four corners of the upper surface of the housing 210 , and a leg (not shown) for supporting the load of the washing/drying machine 100 and the pedestal 200 as well as for adjusting the height of the pedestal 200 may be installed at each of the four corners of the lower surface of the housing 210 .
[0052] The drawer 222 may include a front surface portion 221 disposed at the front surface of the housing 210 and having a handle 223 , and a receiving portion 220 formed at a rear surface of the front surface portion 221 for receiving a variety of items therein and openably disposed inside the housing 210 .
[0053] Accordingly, the pedestal 200 serves as a supporter of the washing/drying machine 100 as well as a container for receiving a variety of items required when using the washing/drying machine 100 , such as a detergent, a fabric conditioner, a bleach, maintenance tool, cleaning tool, and the like.
[0054] Referring to FIGS. 3 and 4 , the supporters 230 are mounted at the upper surface of the housing 210 of the pedestal 200 , and preferably, at each of the four corners of the upper surface thereof.
[0055] The supporter 230 may include a main body 240 having leg holes 231 , 232 for mounting the legs 121 of the washing/drying machine 100 as an object to support thereon, and a plurality of coupling ribs 233 disposed at one side of the main body 240 and for coupling the washing/drying machine 100 and the main body 240 to each other.
[0056] Here, if the washing/drying machine 100 is the washing machine, first leg holes 231 for mounting the legs 122 of the washing machine may be provided. If the washing/drying machine 100 is the drying machine, second leg holes 232 for mounting the legs 123 of the drying machine may be provided. If the washing/drying machine 100 is a refresher, etc., other than the washing machine or the drying machine, leg holes for receiving the legs of the refresher may also be provided. That is, the first and second leg holes 231 , 232 are not meant to be applied only to the washing machine and the drying machine. Therefore, preferably, at least two or more leg holes 231 , 232 are provided for a general use of the supporters 230 .
[0057] The plurality of supporters 230 may be divided into front supporters 230 ′ mounted at the front of the upper surface of the housing 210 , and rear supporters 230 ″ mounted at the rear of the upper surface thereof. Here, the front supporters 230 ′ include the leg holes 231 , 232 communicated with each other, and are respectively mounted at both sides of the front end of the upper surface of the housing 210 . The rear supporters 230 ″ include the leg holes 231 , 232 separated from each other, and are respectively mounted at both sides of the rear end of the upper surface of the housing 210 .
[0058] Here, the reason why the leg holes 231 , 232 of the front supporters 230 ′ and the rear supporters 230 ″ have a different configuration is that positions of each leg are different in the washing/drying machine 100 having the main body 110 of the same size.
[0059] For instance, if the washing/drying machine 100 is the washing machine and the drying machine, the front legs of the washing machine and the front legs of the drying machine are overlapped to each other. However, the rear legs of the washing machine and the rear legs of the drying machine are not overlapped to each other. Accordingly, the leg holes 231 , 232 of the front supporters 230 ′ should be communicated to each other, and the leg holes 231 , 232 of the rear supporters 230 ″ should be separated from each other, thereby being able to be used in both the washing machine and the drying machine.
[0060] Here, such described configurations of the leg holes are not meant to be limiting, and the shape of the leg holes 231 , 232 may be changed according to the shape of the legs of the washing/drying machine 100 to be used.
[0061] In addition, the leg holes 231 , 232 may be formed to have different depths or sizes. This is to receive a variety of leg shapes as much as possible even though a thickness, a diameter or a size of the legs 121 are all different according to the type of the washing/drying machine 100 , thus to enable the components to be widely (generally) used.
[0062] Meanwhile, if the leg holes 231 , 232 are formed to have the same depth, a separate member (e.g., a sheet-shaped washer) may be mounted at the legs 121 , so that the depth of the leg holes 231 , 232 and the height of the legs 121 can be adjusted.
[0063] In addition, at least one of the leg holes 231 , 232 may be formed to be open. That is, some of the leg holes 231 , 232 may have a covered upper portion, and others may remain in an opened state. This may prevent the legs 121 of the washing/drying machine 100 from being seen outside. Further, the washing/drying machine 100 may be firmly mounted at the pedestal 200 by stopping (locking) the legs 121 of the washing/drying machine 100 by the covered portion of the leg holes 231 , 232 .
[0064] Meanwhile, the leg holes 231 , 232 may be formed at the upper surface of the housing 210 in a diagonal direction. Such arrangement of the leg holes 231 , 232 may be determined by an arrangement of the legs 121 of the washing/drying machine 100 to be used.
[0065] Description of the supporters 230 will be given in detail.
[0066] As shown in FIG. 4 , the supporter 230 may include the main body 240 having an approximately rectangular or fan shape, and the leg holes 231 , 232 formed at a central portion of the main body 240 . Here, the leg holes 231 , 232 may be formed to be communicated or separated, as described above.
[0067] When the supporters 230 are mounted at the upper surface of the housing 210 of the pedestal 200 , the coupling ribs 233 are formed at a first side surface 230 a and a second side surface 230 b each corresponding to the corners of the housing 210 . That is, it is effective that the coupling rib 233 is formed at an edge of the supporter 230 so as to correspond to an edge of the upper surface of the housing 210 .
[0068] Preferably, the coupling rib 233 is formed at each of the first side surface 230 a and the second side surface 230 b. However, two or more coupling ribs 233 may be formed at each of the side surfaces 230 a, 230 b in consideration of a size of the pedestal 200 , or a size and a load of the washing/drying machine 100 to be mounted on the pedestal 200 , and the like.
[0069] Preferably, the coupling ribs 233 are disposed inside the side surfaces 230 a, 230 b with a stepped portion from the first and second side surfaces 230 a, 230 b. This is to prevent a screw head or a bolt head from being more protruded than the side surfaces 230 a, 230 b when a coupling means such as a screw, a bolt, etc. is mounted at the coupling holes 234 formed at the coupling ribs 233 for coupling to the washing/drying machine 100 .
[0070] In addition, coupling holes 235 of the coupling means to mount the supporter 230 to the pedestal 200 are formed at the main body 240 at almost the right angle to the coupling ribs 233 . It is effective that, in consideration of a thickness of a head of the coupling means, a portion where the coupling holes 235 are formed is positioned inside the surface of the supporter main body 240 .
[0071] At least one reinforcing rib 236 is disposed at the rear of the leg holes 231 , 232 . This reinforcing rib 236 is to prevent a reduction of rigidity of the leg holes 231 , 232 in the rear direction as well as to reduce an amount of the injection-molded plastic used to manufacture the supporter 230 . That is, the amount of injection-molded plastic of the supporter 230 may be reduced by having a relatively thinner thickness of the portion except the reinforcing rib 236 .
[0072] Here, the coupling ribs 233 are respectively disposed at the first and second side surfaces 230 a, 230 b in parallel, however, the coupling ribs 233 may also be disposed perpendicular to the first and second side surfaces 230 a, 230 b. This is because a shape of the coupling rib 233 is determined by a shape of the rib of the washing/drying machine 100 coupled to the coupling rib 233 .
[0073] Hereinafter, description of a base of the washing/drying machine 100 coupled to the coupling ribs 233 will be given in detail.
[0074] FIG. 5 is an exploded perspective view showing a base mounted at the washing/drying machine in FIG. 2 , FIG. 6 is a perspective view showing a state that the base in FIG. 5 is coupled to the supporter, and FIG. 7 is a perspective view showing another exemplary base in FIG. 5 .
[0075] Referring to FIG. 5 , height-adjustable legs 121 are respectively mounted at four corners of a base 120 , and base ribs 122 are respectively formed at both sides of the leg 121 . The base ribs 122 include coupling holes 123 to be communicated with the coupling holes 234 at the coupling ribs 233 of the supporter 230 .
[0076] In order for the washing/drying machine 100 to be mounted at the pedestal 200 , the supporter 230 is disposed between the washing/drying machine 100 and the pedestal 200 , and then a coupling means (e.g., a screw, etc.) is mounted at the coupling holes 123 , 234 in a state that the coupling ribs 233 of the supporter 230 and the base ribs 122 are aligned with each other.
[0077] FIG. 6 illustrates that the washing/drying machine 100 , the supporter 230 and the pedestal 200 are coupled together by using the coupling ribs 122 , 233 .
[0078] Referring to FIG. 6 , the coupling ribs 233 of the supporter 230 are positioned outside the base ribs 122 , and the coupling means (e.g., a screw, etc.) is mounted at the coupling holes 123 , 234 , thereby coupling the coupling ribs 233 and the base ribs 122 to each other. With this configuration, the coupling ribs 122 , 233 cannot protrude more than the surface of the washing/drying machine 100 or the pedestal 200 , thus to provide a good outer aspect. Besides, there is no need to use a separate component such as a bracket, etc. for mounting the washing/drying machine 100 or the pedestal 200 to the supporter 230 .
[0079] To be certain, the base ribs 122 may be positioned outside the coupling ribs 233 of the supporter 230 .
[0080] The base 120 , as shown in FIG. 5 , is formed to have a honeycomb or grid shape, and a base 120 ′, as shown in FIG. 7 , may be formed to have a plate shape having base ribs 122 ′. Such described shape of the base 120 , 120 ′ may be changed according to the washing/drying machine 100 .
[0081] As described above, by using the coupling ribs 122 of the base 120 , the pedestal 200 may be commonly used in a variety of the washing/drying machine 100 including the washing machine and the drying machine, without a separate coupling member (e.g., a bracket, etc.).
[0082] Meanwhile, the present applicant has described the washing machine and the drying machine as an example of the washing/drying machine, however, without being limited thereto, the washing/drying machine may also include other types of washing/drying machine, such as an integrated washing system, a refresher equipped with a wrinkle reduction function, and the like.
[0083] In addition, the configuration that the washing/drying machine is installed on the pedestal having the supporter therebetween has been described, however, without being limited thereto, the washing/drying machine may be disposed in a vertical direction having the supporter therebetween. For instance, the drying machine is disposed above the washing machine, and the drying machine to be placed on the washing machine may be fixed by using the supporter according to the present invention. Alternatively, the washing machine is disposed above the drying machine, and the washing machine to be placed on the drying machine may be fixed by using the supporter according to the present invention. In addition, a front loading type washing/drying machine has been described, however, a top loading type washing/drying machine is also included in the scope of the present invention.
[0084] The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the present disclosure. The present teachings can be readily applied to other types of apparatuses. This description is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. The features, structures, methods, and other characteristics of the exemplary embodiments described herein may be combined in various ways to obtain additional and/or alternative exemplary embodiments.
[0085] As the present invention may be embodied in several forms without departing from the characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalents of such metes and bounds are therefore intended to be embraced by the appended claims. | Disclosed is the washing/drying machine having a pedestal, including: a washing/drying machine main body performing a washing or drying operation of laundry; and a pedestal for mounting the main body thereon, wherein a base having legs is coupled at a lower end of the main body, and a supporter having coupling ribs for fixing the base to the pedestal is mounted at an upper surface of the pedestal, thereby preventing a damage to the surface of the pedestal or the washing/drying machine and facilitating mounting/dismounting the supporter or the pedestal. | 3 |
FIELD OF THE DISCLOSURE
This disclosure relates generally to systems for applying a sealant to a work surface and, more particularly, to a device for mixing and applying a multi-component composition, such as a surgical tissue sealant made of two fluid components, to biological tissue employing structure that facilitates controlled spray application of the sealant.
BRIEF SUMMARY OF THE DISCLOSURE
The device of the present disclosure is particularly useful for mixing and applying multi-component compositions to a work surface, such as two-component surgical sealants, while avoiding clogs, preventing cross-contamination of the components until a point of intended mixing at a location within the apparatus in close proximity to an application opening in a tip cap, decreasing pressure drop along the apparatus and system to facilitate fluid delivery, and increasing efficiency of mixing of the components. It will be appreciated that not all of these advantages need be achieved by a mixing and dispensing device made in accordance with the present disclosure.
The mixing and dispensing device maintains a physical boundary between each component of a two-component composition until it is suitable to initiate contact, which is particularly desirable for components that quickly react upon exposure to one another. In the case of multi-part surgical sealants, the components, such as a buffer (e.g., a dilute hydrogen chloride solution) and a reconstituted mix of two synthetic polyethylene glycols (PEG's), begin to react with one another almost immediately upon exposure to each other, so it is desirable to avoid premature mixing, i.e. cross-contamination or “cross-talk” of the components, while they are within the mixing and dispensing device. It is also desirable to avoid inadequate mixing of components, as failure to adequately mix the components may yield a poor mixture and cause clogging, for example. Further, premixing a desired proportion of each of the components being mixed before all of the components are mixed together just prior to application results in an improved mixture.
The mixing and dispending device includes an applicator having three sub-assemblies, namely: a luer hub sub-assembly that docks or mates with a two-barreled syringe, also referred to herein as a dual syringe (one of the syringes carrying a buffer and the other syringe receiving a mix of two PEG's prior to engagement with the luer hub sub-assembly); a malleable cannula; and a spray tip sub-assembly. The luer hub sub-assembly includes a proximal hub and a distal hub. The malleable cannula is preferably formed as an extrusion of soft thermoplastic polyurethane elastomer, such as Pellethane™ (available from The Dow Chemical Company) and includes lumens therein, preferably four lumens. Two of the lumens carry fluid, with each of the fluid carrying lumens placed in fluid communication with a respective chamber or barrel of the dual syringe. One of the lumens carries a wire, preferably a dead soft, fully annealed wire, that is used to facilitate bending of the malleable cannula, but also helps to retain the malleable cannula in a position into which it is bent. The fourth lumen may be left vacant, serving primarily to maintain substantially constant wall thickness during extrusion of the malleable cannula, but could alternatively accommodate, by way of example only, vacuum pressure (i.e., suction), pressurized gas, flushing solution, a light, a heat source, or a fiber optic camera.
The spray tip sub-assembly includes a tip insert and a tip cap. The tip insert is provided with alignment posts that are received in apertures provided in the malleable cannula, such as in the wire-carrying lumen and in the vacant lumen. If the vacant lumen instead is serving to provide, for example, a vacuum, a pressurized gas, a flushing solution, or a light, the alignment post received therein may be hollow to accommodate such lumen-delivered services.
The tip cap has a spray opening therein, and a spinner region or spin chamber is embedded in an interior surface thereof, on the underside of the end in which the spray opening is provided. Indentations that serve as feeders to the spin chamber are also provided in the interior surface of the tip cap. Angled indentations of the tip insert direct flow to sides of the tip insert, then into the spinner region. The tip cap may be provided with mating pins that are received in complementary holes on a distal face of the tip insert, ensuring proper alignment of the spin chamber with the tip insert.
In one embodiment, a webbing is provided between the alignment posts of the tip insert, with a complementary slot provided in a mating end of the malleable cannula. The webbing helps to prevent cross-talk between a substantial portion of the fluid components in the two fluid-carrying lumens as the fluids flow from the malleable cannula into the tip insert. A similar webbing, alignment post, and complementary slot arrangement may be provided where the proximal hub of the luer hub sub-assembly mates with the malleable cannula. A solvent is preferably applied to the slots to bond the tip insert to the cannula. An adhesive may also be used for bonding purposes.
In another embodiment, the malleable cannula includes a pair of notches in each of the proximal and distal ends thereof, each of the notches exposing a semi-cylindrical channel region of a corresponding one of the fluid-carrying lumens. Each of the notches extends from an end wall of the malleable cannula (at which the non-fluid carrying lumens terminate) to a stop wall spaced axially inwardly of the end wall, thereby defining a male projection of the malleable cannula at each of the proximal and distal ends. Each of the semi-cylindrical channel regions of the fluid-carrying lumens exposed at the respective notch is bounded along its lateral edges by a pair of alignment ledges extending to the outer perimeter of the malleable cannula. In this embodiment, the tip insert of the tip cap sub-assembly is provided with a complementary female mating port to receive the male projection at the distal end of the malleable cannula. Once the male projection of the malleable cannula is engaged with the female mating port of the tip insert, each of a pair of fluid path archways of the tip insert is aligned with a portion of a respective one of the semi-cylindrical channel regions.
The tip insert further includes a pair of substantially Quonset-shaped wedges, each of which occupies a portion of a respective one of the semi-cylindrical channel regions closer to the end face of the tip cap, diverting fluid from the fluid-carrying lumens radially outward, through the fluid path archways, and into flow paths defined between crescent-shaped channels running axially along an exterior of the tip insert and an inner wall of the tip cap. Similar structure may be provided at the interface of the distal hub of the luer hub sub-assembly and the proximal end of the malleable cannula in order to direct fluid from the luer hub sub-assembly (to which a double-barreled syringe is selectively secured, such as with actuable locking tabs and clips) into the respective fluid-carrying lumens of the malleable cannula.
The crescent-shaped channels of the tip insert direct fluid from the fluid carrying channels of the malleable cannula toward an area between the walls of the tip insert and the tip cap, allowing a first mixing component only to be directed between an area between the tip insert and the tip cap, a second mixing component only to be directed between a separate and distinct area between the tip insert and the tip cap, and a combination of both the first and second mixing components to be directed between yet another separate, distinct area between the tip insert and the tip cap. Thus, a plurality of isolated flow paths are provided between the tip insert and the tip cap, with one of the flow paths including a mixture of both the first and second mixing components, while the other flow paths include either the first mixing component only or the second mixing component only.
In order to assure proper alignment between the tip cap and the tip insert, the tip cap may be provided with an inwardly-directed dimple or depression in a region of the tip cap where the sidewall of the tip cap meets the end wall of the tip cap, with a corresponding interior region of the tip cap having an inwardly-directed key. A complementary alignment notch is provided in a distal end of the tip insert, which receives the inwardly-directed key when the tip insert is received in the tip cap. To facilitate assembly of the various components, fillets and rounds may be employed at interfacing surfaces. For example, at least a proximal end of each of the Quonset-shaped wedges of the tip insert may be provided with rounded corners to facilitate insertion of the male projection at the distal end of the malleable cannula.
The three sub-assemblies of the device of the present disclosure, and the manner in which they engage and cooperate with one another, are explained in greater detail in the following detailed description of the preferred embodiments, with reference to the accompanying drawing figures.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a plan view of a conventional dual syringe and elongate applicator assembly;
FIG. 2 is an exploded view of a conventional elongate applicator assembly, including a luer hub sub-assembly having a proximal hub and a distal hub, an elongate, three-lumened cannula, and a spray tip sub-assembly including a round tip insert and a tip cap;
FIG. 2A is an enlarged exploded view of the region of FIG. 2 designated as “FIG. 2 A”, illustrating the spray tip sub-assembly of the conventional elongate applicator assembly of FIG. 2 ;
FIG. 3 is an exploded view of a mixing and dispensing device of the present disclosure, including a luer hub sub-assembly having a proximal hub and a distal hub, a malleable, four-lumened cannula, and a spray tip sub-assembly including a triangular tip insert and a tip cap;
FIG. 4 is an end view of the malleable cannula of the mixing and dispensing device of the present disclosure, taken along lines 4 - 4 of FIG. 3 ;
FIG. 5 is an exploded view of the luer hub sub-assembly of the mixing and dispensing device of the present disclosure;
FIG. 6 is a cross-sectional view, taken along lines 6 - 6 of FIG. 5 , of the luer hub sub-assembly, with the proximal hub and distal hub of the luer hub sub-assembly engaged with one another, and illustrating in cross-section a proximal end of the malleable cannula received in a cannula-receiving opening of the distal hub of the luer hub sub-assembly, with each of the two fluid carrying lumens of the malleable cannula in fluid communication with a respective fluid path through the distal hub and proximal hub of the luer hub sub-assembly, through which the fluid carrying lumens of the malleable cannula may be placed in fluid communication with respective barrels of a dual syringe;
FIG. 7 is an exploded view of one embodiment of a spray tip sub-assembly of a mixing and dispensing device of the present disclosure;
FIG. 7A is an end view, taken along lines 7 A- 7 A of FIG. 7 , of the tip insert of FIG. 7 ;
FIG. 8 is an exploded view of an alternate embodiment of a spray tip sub-assembly of a mixing and dispensing device of the present disclosure;
FIG. 9 is an exploded view of the spray tip sub-assembly of the mixing and dispensing device illustrated in FIG. 3 ;
FIG. 10 is an exploded view of yet an additional embodiment of a spray tip sub-assembly of a mixing and dispensing device of the present disclosure similar to the spray tip sub-assembly of FIGS. 3 and 9 , but with an alternate tip cap;
FIG. 10A is an enlarged plan view of the end wall of the tip cap, schematically illustrating the acceleration and mixing of two components in feeders and in a spinner region provided in the end wall;
FIG. 11 is an end view and partial cross-section view of the spray tip sub-assembly of FIG. 10 ;
FIG. 12 is a cross-sectional view, taken along lines 12 - 12 of FIG. 11 , illustrating the tip insert of FIG. 10 engaged with the tip cap of FIG. 10 , and further illustrating a distal end of a malleable cannula of the mixing and dispensing device of the present disclosure received in the tip cap and engaged with the tip insert, with alignment pins of the tip insert received in a wire-carrying lumen and in a vacant lumen of the malleable cannula;
FIG. 13 is a perspective view of the exterior of the tip cap of the spray tip sub-assembly of FIG. 10 ;
FIG. 14 is an enlarged cross-sectional view, taken along lines 14 - 14 of FIG. 13 , of the spray tip sub-assembly of FIG. 10 , with directional arrows illustrating the flow of fluid onto angled indentations of the tip insert, deflected beyond the sides of the tip insert, and toward a spinner region provided in an underside of the tip cap;
FIG. 15 is an exploded perspective view of the spray tip sub-assembly of FIGS. 10-14 , with a broken-away portion of the malleable cannula and including a solid-bubbled line representing a first component exiting a first fluid-carrying lumen of the malleable cannula and a hollow-bubbled line representing a second component exiting a second fluid-carrying lumen of the malleable cannula; and
FIG. 15A is an exploded perspective view of the spray tip sub-assembly of FIG. 15 , with a portion of the tip cap cut away, and with the solid-bubbled lines representing flow paths of the first component, and the hollow-bubbled lines representing flow paths of the second component, around sides of the tip insert and into the spinner region provided in the underside of the tip cap;
FIG. 16 is an exploded perspective view of another alternate embodiment of a spray tip sub-assembly, with a broken away portion of a malleable cannula and an alternate distal end of a cannula;
FIG. 17 is an exploded rear view of a tip insert of a spray tip sub-assembly of FIG. 16 , wherein the tip insert has a substantially octagonal shape;
FIG. 18 is a perspective view of the spray tip sub-assembly of FIG. 16 , illustrating the tip insert within a tip cap of the spray tip sub-assembly and a mixed component being released from a delivery opening at a distal end of the tip cap, the mixed component illustrated by lines having both solid and hollow bubbles, the solid bubbles representing a first mixing component and the hollow bubbles representing a second mixing component;
FIG. 19 is a cross-sectional view of the spray tip sub-assembly taken along lines 19 - 19 of FIG. 18 , illustrating the tip insert keeping first and second mixing components from mixing prematurely when fluid passes from the cannula and into the tip insert of the spray tip sub-assembly;
FIG. 20 is another cross-sectional view of the spray tip sub-assembly taken along lines 20 - 20 of FIG. 18 , illustrating the angled indentations directing fluid from the fluid carrying channels of the cannula toward a space between the walls of the tip insert and the tip cap;
FIG. 21 is another cross-sectional view of the spray tip sub-assembly taken along lines 21 - 21 of FIG. 18 , illustrating the fluid even further directed from the fluid carrying channels of the cannula into the tip insert and tip cap;
FIG. 22 is another cross-sectional view of the spray tip sub-assembly taken along lines 22 - 22 of FIG. 18 , illustrating the fluid directed to feeders of the tip cap, some of which has been already mixed in one feeder, wherein other fluids will not be mixed until after the feeders deliver the fluids to the spinner region;
FIG. 23 is a plan view of the cannula of FIG. 16 ;
FIG. 24 is a cross-sectional view of the cannula taken along the lines 24 - 24 of FIG. 23 ;
FIG. 25 is a cross-sectional view of the cannula taken along the lines 25 - 25 of FIG. 23 ;
FIG. 26 is a front plan view of a tip insert of the spray tip sub-assembly of the embodiment illustrated in FIG. 16 ;
FIG. 27 is a perspective view of the tip insert of FIG. 26 ;
FIG. 28 is a bottom plan view of the tip insert of FIG. 26 ;
FIG. 29 is a top plan view of the tip insert of FIG. 26 ;
FIG. 30 is a perspective view of a tip cap of the spray tip sub-assembly of the embodiment illustrated in FIG. 16 ;
FIG. 31 is a top plan view of the tip cap of FIG. 30 ; and
FIG. 32 is a cross-sectional view, taken along lines 32 - 32 of FIG. 31 , of the tip cap of FIG. 30 ;
FIG. 33 is a top plan view of a proximal hub of a luer hub sub-assembly of the present disclosure;
FIG. 34 is a cross-sectional view of the proximal hub of FIG. 33 taken along the lines 34 - 4 of FIG. 33 ;
FIG. 35 is a perspective view of the distal hub of a luer hub sub-assembly of the present disclosure;
FIG. 36 is a top view of the distal hub of FIG. 35 ;
FIG. 37 is a cross-sectional view taken along lines 37 - 37 of FIG. 36 ;
FIG. 38 is an enlarged view of the region indicated by the circle designated “FIG. 38 ” in FIG. 37 ;
FIG. 39 is an enlarged view of the region indicated by the circle designated “FIG. 39 ” in FIG. 36 ; and
FIG. 40 is a perspective view of a syringe assembly that may be used with each of the luer hub sub-assemblies and cannulae referenced herein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIGS. 1 , 2 and 2 A, a conventional kit 10 for mixing and applying a two-component surgical sealant to a tissue site includes a dual syringe 12 , a luer hub sub-assembly 14 , a cannula 16 , and a spray tip sub-assembly 18 . The luer hub sub-assembly includes a proximal hub 20 and a distal hub 22 . The proximal hub 20 includes a pair of fluid channels 24 , 26 , each of the fluid channels 24 , 26 placed into fluid communication with a respective one of the barrels of the dual syringe 12 when the luer hub sub-assembly 14 is docked with the dual syringe 12 via slip luer connections. The distal hub 22 also includes two distinct fluid channels (not shown in FIG. 2 ), which are in fluid communication with the respective fluid channels 24 , 26 of the proximal hub 20 . The fluid channels of the distal hub 22 converge toward one another, but remain physically separated, and are in further fluid communication with respective fluid-carrying lumens 30 , 32 provided within the cannula 16 . The cannula 16 also includes a third lumen 34 .
As illustrated in FIG. 2A , the spray tip sub-assembly 18 includes a circular tip insert 28 having two alignment posts 36 , 38 extending from a proximal side of the tip insert 28 that are received in the distal ends of the fluid-carrying lumens 30 , 32 . Each of the alignment posts 36 , 38 includes at least one aperture therethrough to carry fluid from the respective lumens 30 , 32 into radially extending grooves of 39 , 41 of a recessed region 40 of the distal side of the tip insert 28 , which abuts an interior surface of a tip cap 42 . More specifically, fluid from lumen 30 is first directed into the radially extending groove 39 and fluid from lumen 32 is first directed into the radially extending groove 41 . The fluids from each of lumens 30 and 32 are kept separate from each other as they enter the radially extending grooves 39 , 41 . After the fluid enters the radially extending grooves 39 , 41 , the fluid then enters a spinning chamber or center area of the recessed region 40 by a spinning motion. It is in this spinning chamber where fluid from lumen 30 first contacts fluid from lumen 32 before mixing. Thus, the recessed region 40 cooperates with the interior surface of the tip cap 42 to form a mixing chamber where the two fluids from the dual syringe 12 , which initially came into contact with each other in the spinning chamber, are then mixed immediately prior to delivery through a delivery opening 44 provided in the tip cap 42 .
Although the conventional surgical sealant mixing and application kit 10 is intended to be suitable for one-handed operation, due at least in part to the number of connections involved, medical professionals often resort to using both hands when operating the kit 10 to mix and apply tissue sealant. The following improvements address these and other drawbacks of the conventional tissue sealant kit 10 .
Several embodiments of an improved device for mixing and applying a multi-component composition will now be described.
Referring now to FIG. 3 , an applicator 100 of a first embodiment of the present disclosure is illustrated. The applicator 100 includes a luer hub sub-assembly 114 , a cannula 116 , and a spray tip sub-assembly 118 . The luer hub sub-assembly 114 includes a proximal hub 120 and a distal hub 122 , with the proximal hub 120 including fluid channels 124 and 126 to be placed in fluid communication with respective barrels of a dual syringe (not illustrated in FIG. 3 ). The distal hub 122 includes two distinct fluid channels 146 , 148 ( FIG. 5 ) in fluid communication with the respective fluid channels 124 , 126 of the proximal hub 120 .
The cannula 116 is preferably a malleable cannula extruded from a soft thermoplastic polyurethane elastomer, such as The Dow Chemical Company's Pellethane™ with four lumens, each of which is more closely illustrated in FIG. 4 . Two of the lumens are fluid-carrying lumens 130 , 132 , each of which has a diameter preferably in the range of approximately 0.03″-0.06″, and most preferably, approximately 0.046″. A third lumen 134 may receive a wire 164 (illustrated in cross-section in FIG. 12 ), which is preferably an annealed wire. The soft thermoplastic polyurethane elastomer of the malleable cannula 116 and the annealed wire, in conjunction with one another, result in improved malleability, making the cannula 116 easier for medical personnel to bend the cannula 116 into a desired shape that is maintained after the cannula 116 is released. The diameter of the third lumen 134 is preferably in the range of approximately 0.03″-0.06″, and most preferably, approximately 0.03″, to accommodate an annealed wire 164 having a diameter of approximately 0.03″. A fourth lumen 162 may remain vacant. Alternatively, the fourth lumen 162 could be employed to accommodate supplemental features such as, by way of example only, suction, pressurized gas, flushing solution, a light, a heat source, or a fiber optic camera. The fourth lumen 162 is considered desirable to include even if it remains vacant, as providing a fourth lumen 162 in the cannula 116 helps maintain substantially uniform wall thickness in the cannula 116 during extrusion thereof. The fourth lumen 162 may have a diameter greater than the diameter of each of the two fluid-carrying lumens 130 , 132 and the third wire-carrying lumen 134 . The diameter of the fourth lumen 162 is preferably in a range of approximately 0.03″ to approximately 0.06″, and most preferably, in a range of approximately 0.030″ to approximately 0.050″. The larger diameter of the fourth lumen 162 assists in distinguishing the respective lumens of the malleable cannula 116 to facilitate assembly of the applicator 100 . The relatively large diameter of the fourth lumen 162 also helps to accommodate the optional supplemental features for which the fourth lumen 162 might be employed.
A proximal end region 154 of the malleable cannula 116 is received in a cylindrical female cannula-mating port 156 provided on a distal side of the distal hub 122 . The proximal end region 154 of the malleable cannula 116 is provided with an elongate opening or slot 158 that receives a webbing 160 ( FIG. 6 ) projecting from the distal side of the distal hub 122 within the cylindrical female cannula-mating port 156 . As illustrated in FIG. 6 , the webbing 160 may be aligned with a rib or wall 163 projecting on the proximal side of the distal hub 122 that separates the fluid channels 146 , 148 of the distal hub 122 . When received in the slot 158 , the webbing 160 extends through the third and fourth lumens 134 , 162 of the malleable cannula 116 .
Referring now to FIGS. 5 and 6 , each of the fluid-carrying lumens 130 , 132 is placed into fluid communication with a respective fluid path hole 147 , 149 of the fluid channels 146 , 148 of the distal hub 122 of the luer hub sub-assembly 114 . The fluid channels 146 , 148 are each defined by a groove 146 a , 148 a ( FIG. 6 ) in a proximal surface 150 of the distal hub 122 and by a distal surface 152 of the proximal hub 120 . In a particularly preferred embodiment, each of the fluid channels 146 , 148 of the distal hub 122 has a diameter of approximately 0.05″. Each of the fluid path holes 147 , 149 has a diameter in a range of approximately 0.02″ to approximately 0.05″, and most preferably, 0.046″.
As illustrated in FIGS. 9-15 , in certain embodiments of the present disclosure, the spray tip sub-assembly 118 of the applicator 100 includes a triangular tip insert 128 . As illustrated in FIG. 9 , the triangular tip insert 128 is received in a tip cap 142 having a delivery opening 144 through an end wall 175 . The delivery opening 144 has a length in a range of approximately 0.01″ to about 0.04″, preferably about 0.02″. The delivery opening 144 may be formed as a circular opening with an orifice diameter in a range of approximately 0.010 to 0.020″. In order to achieve a fan-type spray, the delivery opening 144 may be provided with an oval-shaped slit 199 , as illustrated in FIG. 12 . Alternately, as illustrated in FIG. 13 , a nipple 145 may be provided about the delivery opening 144 . The nipple 145 promotes dispersion of spray. Alternately, as illustrated in FIG. 9 , an elongate nipple region 145 may be provided on both sides of the delivery opening 144 . The distal, exterior surface of the end wall 175 of the tip cap 142 may vary in topography, reminiscent to a mechanical break-up unit found in conventional commercial spray applicators. The varied topography helps overcome surface tension effects of the mixed fluid and aids in atomization.
Referring now to FIGS. 10 and 10A , the triangular tip insert 128 is preferably secured to the interior of the tip cap 142 by three guide pins 182 , 184 and 186 provided on a proximal side of the end wall 175 . The guide pins 182 , 184 , 186 mate with complementary pin-receiving holes 188 , 190 , 192 provided in a distal end of the triangular tip insert 128 . The proximal side of the end wall 175 is provided with a plurality of feeders 194 , 196 , 198 .
Referring, for example, to FIG. 11 , the feeders 194 , 196 , 198 serve to deliver fluid from the three side walls 177 a , 177 b , 177 c of the triangular tip insert 128 toward the recessed spinner region 180 so the fluids can be fully mixed with one another immediately prior to passing through the delivery opening 144 through the end wall 175 . Thus, the fluids are mixed only after having been maintained in isolation from one another from the barrels of the dual syringe, through the luer hub sub-assembly 114 , the malleable cannula 116 , and into the spray tip sub-assembly 118 , all of which will be explained in more detail below.
As illustrated in FIG. 14 , the proximal side of the triangular tip insert 128 is provided with angled indentations 176 , 178 , with one of the angled indentations 176 , 178 provided on either side of the alignment posts 136 , 138 and the webbing 168 . The angled indentations 176 , 178 serve to redirect fluid flow from the two fluid-carrying lumens 130 , 132 to openings in the form of arcuate segments 171 , 172 , 173 defined between each of the three side walls 177 a , 177 b , 177 c of the triangular tip insert 128 and an inner surface 174 of the tip cap 142 , and toward a recessed spinner region 180 embedded in the proximal side of the end wall 175 of the tip cap 142 . The inner surface 174 may be the inner surface of the cylindrical wall of the tip cap 142 .
As also illustrated in FIG. 14 , rounded tips 179 (see also FIGS. 15 and 15A ) of the triangular tip insert 128 contact the inner surface 174 of the tip cap 142 , forming a seal between the interior surface 174 of the tip cap 142 and the triangular tip insert 128 . This seal helps properly direct an accurate amount of fluid coming from each of the angled indentations 176 , 178 into their respective arcuate segments 171 , 172 , and 173 . The seal also prevents fluid from inadvertently going between the inner surface 174 of the tip cap 142 and angular sections of the triangular tip insert 128 , preventing an improper amount of fluid from being directed to one of the arcuate segments 171 , 172 , 173 and resulting in an inadequate proportion of fluid components being mixed. In other words, the seals help ensure that an accurate amount of fluid from each fluid carrying lumens flows from the angled indentations into one or more of the arcuate segments 171 , 172 and 173 . If too much fluid from the angled indentations 176 and 179 inadvertently flows into any one of the arcuate segments 171 , 172 , and 173 , the resulting mixture of components will be inadequate. The rounded tips form an interference seal to the tapered internal hole of the tip cap
As indicated in FIGS. 14 , 15 and 15 A, a solid-bubbled line represents a first component exiting the first fluid-carrying lumen 130 of the malleable cannula 116 and a hollow-bubbled line represents a second component exiting the second fluid-carrying lumen 132 of the malleable cannula 116 . Notably, the angled indentation 176 deflects the first component through arcuate segment openings 171 and 172 , and into feeders 194 , 198 , while angled indentation 178 deflects the second component through arcuate segment openings 171 and 173 , and into feeders 194 and 196 . Thus, mixing of the first and second component within the spray tip sub-assembly 118 is initiated gradually, as a desired portion of the first and second components are first exposed to one another in arcuate segment opening 171 and feeder 194 . Fillets and rounds, such as rounded tips 179 of the triangular insert 128 contact the inner surface 174 of the tip cap 142 to help make sure the first and second components passing through arcuate segment openings 172 and 173 , respectively, and entering feeders 196 and 198 , are kept separate from one another. Even though only two mixing components exit the fluid carrying lumens 130 , 132 , a first component exiting the first fluid carrying lumen 130 and a second component exiting the second fluid carrying lumen 132 , there are three streams of different fluids entering each of the feeders 194 , 196 , 198 prior to mixing. Specifically, because the angled indentation 176 deflects the first component through both arcuate segments 171 and 172 and angled indentation 178 deflects the second component through both arcuate segments 171 and 173 , the first and second components first contact each other in the arcuate segment 171 before even entering the feeder 194 , as illustrated in FIG. 14 . By design, a combination of the first and second components then enters feeder 194 before mixing, only the first component enters feeder 198 before mixing, and only the second component enters feeder 196 before mixing. The first and second components are kept separate from each other in feeders 198 and 196 respectively, until all the fluid components from the separate feeders converge as they approach the center of the spinner region 180 , causing a vortex that completes the mixing of the components immediately prior to delivery through the delivery opening 144 .
The feeders 194 , 196 , 198 cooperate with the center of the spinner region 180 in such a manner as to enhance spinning so as to quickly and thoroughly mix the first, second components and mixture of components. As illustrated in FIGS. 10A and 15A , the triangular shape of each of the feeders 194 , 196 , 198 results in sidewalls that angle inward toward one another with increasing radial proximity within the passageway defined by the distal side of the triangular tip insert 128 and the feeder to the center of the spinner region 180 . In other words, as the components in the feeders 194 , 196 , 198 approach the center of the spinner region 180 , the cross-sectional area of the respective passageway defined by the distal side of the triangular tip insert 128 and the feeder decreases, causing an increase in velocity of the components, in a similar fashion to a converging nozzle. Thus, as the radial distance from the center of the spinner region 180 decreases, the cross-sectional area of the feeder decreases, causing an increase in velocity of the fluid components (represented schematically by arrows of increasing length), which reach a maximum velocity just prior to fluid entering the center of the spinner region 180 , which serves as a mixing chamber. As the fluid components exit each of the feeders 194 , 196 , 198 , they are propelled tangentially along the circular side wall 200 of the spinner region 180 to enforce the spinning, mixing action, forming a vortex, culminating in the spray of the mixed components through the delivery opening 144 .
As illustrated in FIG. 15 , the tip insert 128 includes a pair of alignment posts 136 , 138 projecting from a proximal side thereof, the alignment posts 136 , 138 received in the third and fourth lumens, 134 , 162 , respectively, at a distal end 166 of the malleable cannula 116 . The alignment post 138 preferably has a larger diameter than the alignment post 136 , to accommodate and monogamously mate with the corresponding fourth lumen 162 and third lumen 134 , respectively. One or both of the alignment posts 136 , 138 may be provided with a hollow portion, as illustrated in cross-section in FIG. 12 , in order to accommodate, for example, a distal end portion of the annealed wire 164 . If the fourth lumen 162 were to accommodate a device or fluid to be delivered or suctioned through, or otherwise exposed to, the delivery opening 144 , then the alignment post 138 could be hollow.
A webbing 168 extends laterally between the alignment posts 136 , 138 and continues beyond each of the alignment posts 136 , 138 . The webbing 168 of the tip insert 128 is received in an elongate opening or slot 170 in the distal end 166 of the malleable cannula 116 , in a similar fashion to the manner in which the webbing 160 ( FIG. 6 ) projecting from the distal end of the distal hub of the luer hub sub-assembly is received in the slot 158 in the proximal end region 158 of the cannula 116 . The webbing 168 helps isolate fluid components flowing through each of the fluid-carrying lumens 130 , 132 from one another as the fluid components pass from the malleable cannula 116 , across the interface between the cannula 116 and the tip insert 128 . In a preferred embodiment, the slots 158 , 170 have a width of approximately 0.01″, most preferably 0.012″ and a depth of approximately 0.05″, most preferably 0.049″, and may be formed by cutting the proximal and distal ends of the extruded malleable cannula 116 with a blade or utilizing forming (tipping) methods known in the catheter industry.
A solvent is preferably applied to each of the slots 158 , 170 to help prevent cross-talk between the fluids passing from the fluid channels 146 , 148 of the distal hub 122 of the luer hub sub-assembly 114 to the fluid-carrying lumens 130 , 132 of the malleable cannula 116 , in the case of slot 158 , and from the fluid-carrying lumens 130 , 132 malleable cannula 116 to the apertures 172 , 174 through the triangular tip insert 128 , in the case of slot 170 . In place of solvent an adhesive bonding (self-curing, uv-curing or thermal curing) may be used.
As illustrated in FIGS. 7 , 7 A, and 8 , the spray tip sub-assembly may take alternate forms, such as having a substantially rectangular tip insert 248 with opposing flat side walls 277 a , 277 b , and opposing rounded side walls 277 c , 277 d . In the spray tip sub-assembly 218 illustrated in FIGS. 7 and 7 a , the distal end of the substantially rectangular tip insert 248 (as opposed to the proximal surface of the end wall 275 of the tip cap 242 ) is provided with a recessed spinner region 280 . Like the triangular tip insert 128 , the substantially rectangular tip insert 248 is provided with angled indentations 276 , 278 to direct fluid from the fluid-carrying channels of a cannula toward space between the flat side walls 277 a , 277 b and the interior surface of the cylindrical wall 273 of the tip cap 242 . The substantially rectangular tip insert 248 may include alignment posts 236 , 238 , connected by a webbing 268 , as best illustrated in FIG. 7A . The substantially rectangular tip insert 248 of the embodiment illustrated in FIG. 7 further includes feeders 294 , 296 in the form of slots provided in the distal side of the tip insert 248 . A petal-shaped recessed region 281 of the interior of the end wall 275 of the tip cap 242 extending from the delivery opening 244 cooperates with the recessed spinner region 280 to further facilitate mixing.
The spray tip sub-assembly 218 A of the embodiment illustrated in FIG. 8 differs from the spray tip sub-assembly 218 illustrated in FIG. 7 , in that the distal end of the substantially rectangular tip insert 248 A has no recessed spinner region or feeders therein. Rather, the proximal surface of the end wall 275 A of the tip cap 242 A includes a recessed spinner region 280 A, with feeders 294 A, 296 A, 298 A leading thereto, to direct fluid into the spinner region 280 A for mixing immediately prior to delivery through the delivery opening 244 A.
Now referring to FIGS. 16-22 , another alternate embodiment of a spray tip sub-assembly 318 is illustrated. More specifically, FIG. 16 illustrates an exploded perspective view of the spray tip sub-assembly 318 of FIG. 16 , with a broken-away portion of a malleable cannula 316 . The spray tip sub-assembly 318 of this embodiment includes a tip insert 348 having a substantially octagonal distal portion, with three substantially flat side walls 377 a , 377 b , and 377 c , and five concave or rounded side walls 377 d , 377 e , 377 f , 377 g , 377 h . A tip cap 342 of the spray tip sub-assembly 318 includes a cylindrical wall 373 and an end wall 375 .
Like the malleable cannula 116 of FIG. 3 , the malleable cannula 316 includes four lumens and is preferably a malleable cannula 316 extruded from a soft thermoplastic polyurethane elastomer, such as The Dow Chemical Company's Pellethane™. Two of the lumens are fluid carrying lumens 330 , 332 , each of which may also be placed into fluid communication with the respective fluid path hole 147 , 149 (see FIG. 6 ) of the fluid channels 146 , 148 of the distal hub 122 of the luer hub sub-assembly 114 . The malleable cannula 316 also includes a third lumen 334 , which may receive a wire resulting in improved malleability of the cannula 316 , and a fourth lumen 362 , which may be employed to accommodate, for example, suction, pressurized gas, flushing solution, a light, a heat source, or a fiber optic camera.
As illustrated in FIG. 16 , a distal end region 366 of the malleable cannula 316 includes a pair of elongate notches where portions of the malleable cannula 316 are shaved or otherwise cut back to expose semi-cylindrical channel regions 330 a and 332 a , each of which is an extension of a respective one of the fluid carrying lumens 330 , 332 . The notches each extend axially along the malleable cannula 316 , from a distal end wall 400 of the malleable cannula 316 to a stop wall 402 spaced axially inwardly (i.e., proximally) of the distal end wall 400 . The semi-cylindrical channel regions 330 a , 332 a are each bounded along their lateral edges by alignment ledges 404 , 406 , 408 , 410 (also illustrated in FIGS. 19 and 20 ) extending to the outer perimeter of the malleable cannula 316 . The third and fourth lumens 334 , 362 run between the alignment ledges 404 , 408 , and 406 , 410 , with the remaining portion of the malleable cannula 316 that surrounds the third and fourth lumens 334 , 362 along the notches, and defining the semi-cylindrical channel regions 330 a , 332 b , forming a male projection 370 of the malleable cannula 316 . The male projection 370 is received in a female mating port 379 (as illustrated in FIG. 17 ) of the tip insert 348 .
Like the triangular tip insert 128 , the tip insert 348 includes structural features to direct fluid from the fluid carrying lumens 330 , 332 of the malleable cannula 316 toward space between the tip insert 348 and the tip cap 342 when the tip insert 348 is secured to the distal end section 366 of the malleable cannula 316 . As indicated in FIG. 17 , these structural features include a pair of fluid path archways 381 , 383 , each of which align with a portion of a respective one of the semi-cylindrical channel regions 330 a , 332 a ( FIG. 16 ) of the cannula 316 .
FIGS. 26-29 illustrate the additional structural features of the tip insert 348 . For example, the tip insert 348 also includes a pair of substantially Quonset-shaped wedges 412 , 414 , both of which are illustrated in FIG. 26 , that are axially aligned with a respective one of the fluid path archways 381 , 383 . As further illustrated in FIG. 26 , each substantially Quonset-shaped wedge 412 , 414 has a proximal surface 416 that includes fillets 417 or curved or rounded edges. When the male projection 370 of the malleable cannula 316 is engaged with the tip insert 348 , each of these substantially Quonset-shaped wedges 412 , 414 occupies a portion of a respective one of the semi-cylindrical channel regions 330 a , 332 a closer to the end wall 375 of the tip cap 342 . While in this position, the fillets 417 of the proximal surfaces 416 of the Quonset-shaped wedges 412 , 414 divert fluid from the fluid-carrying lumens through the fluid path archways 381 , 383 , into flow paths defined between crescent-shaped channels 376 , 378 ( FIG. 29 ) running axially along an exterior of the tip insert 348 , and an inner surface 373 a of the cylindrical wall 373 of the tip cap 342 . The fillets 417 of the proximal surfaces 416 further help direct the male projection 370 of the malleable cannula 316 into engagement with the female mating port 379 of the tip insert 348 during assembly. Specifically, the concave or rounded corners of the fillets 417 enable the male projection 370 of the cannula 316 to easily glide into the female mating port 379 of the tip insert without getting caught on any angular edges or surfaces of the Quonset-wedges 412 , 414 , for example. By facilitating registration for assembly, the fillets 417 of the proximal surfaces 416 of the wedges 412 , 414 allow a user to easily assemble the cannula 316 and the tip insert.
As illustrated in FIGS. 30 , 31 , and 32 , the tip cap 342 may be provided with an inwardly-directed registration dimple or depression 420 in a region of the tip cap 342 where the cylindrical wall 373 of the tip cap 342 meets the end wall 375 of the tip cap 342 . As further illustrated in FIG. 32 , a corresponding interior region of the tip cap 342 has an inwardly-directed registration key 422 . A complementary alignment keyway notch 424 (see FIGS. 26 , 27 and 29 ) is provided in a distal end of the tip insert 348 , which receives the inwardly-directed registration key 422 when the tip insert 348 is received in the tip cap 342 . Engagement of the inwardly-directed registration key 422 of the tip cap 342 with the alignment notch 424 of the tip insert 348 assures proper alignment between the tip cap 342 and the tip insert 348 .
As described in more detail below, FIGS. 19-21 illustrate a series of cross-sections through the spray tip sub-assembly 318 , beginning with FIG. 19 at interface between the male projection 370 of the malleable cannula 316 and the spray tip sub-assembly 318 , and continuing distally until a location immediately proximate the end wall 375 of the tip cap 342 . Fluid components from each of the fluid carrying lumens 330 , 332 flow into the respective semi-cylindrical channels 330 a , 332 a , contact the proximal surface 416 and fillet 417 of the Quonset-shaped wedges 412 , 414 , and are directed radially outwardly through the fluid path archways 381 , 383 (i.e., in a direction radially opposite the fluid component from the other fluid carrying lumen 332 , 330 , which helps to prevent premature cross-talk between the fluid components in the two fluid carrying lumens 330 , 332 ). The fluid components then flow distally, toward the spaces between the flat side walls 377 a , 377 b , and 377 c and the rounded side walls 377 d , 377 e , 377 g , and 377 h of the substantially octagonal distal portion of the tip insert 348 and the interior surface 373 a of the cylindrical wall 373 of the tip cap 342 .
As further illustrated in FIG. 16 , the tip cap 342 includes a spinner region 380 with feeders 394 , 396 , and 398 leading thereto. As in the previous embodiment, the feeders 394 , 396 , 398 are generally triangular in shape, with sidewalls that taper inwardly toward one another as they approach the center of the spinner region 380 . The diminishing cross-sectional area of the feeders 394 , 396 , 398 as they approach the spinner region 380 causes an increase in the velocity of the fluid components, as in a converging nozzle. As the fluid components enter the spinner region 380 from the three feeders 394 , 396 , 398 , a vortex effect is created, serving to mix the fluid flows immediately prior to spraying the mixed components through a delivery opening 344 of the tip cap 342 .
FIG. 18 is a perspective view of the tip insert 348 within the tip cap 342 of the spray tip sub-assembly 318 . A mixed component is being released from the delivery opening 344 at a distal end of the tip cap 342 . The mixed component is shown by an alternating pattern of solid-bubbled and hollow-bubbled lines, wherein the solid bubbles represent a first component and the hollow bubbles represent a second component. Thus, the component is already mixed together before it is released from the delivery opening 344 . The tip cap 342 is also provided with an elongate nipple region 345 on a distal side of the end wall 375 of the tip cap 342 , intersecting the delivery opening 344 . This elongate nipple region 345 serves to cause the tissue sealant formed of the mixed fluid components to disperse in a fan-like pattern, thereby promoting spraying of a desired tissue surface. As illustrated in FIG. 3 , the tip cap 142 of that embodiment may likewise be provided with such an elongate nipple region 145 .
FIG. 19 is a cross-sectional view of the spray tip sub-assembly taken along the lines 19 - 19 of FIG. 18 . The view shows the male projection 370 of the cannula 316 and the crescent-shaped channels 376 and 378 of the tip insert 348 . The crescent-shaped channels 376 and 378 each carry only one mixing component from the fluid carrying lumens 330 , 332 . Specifically, the crescent-shaped channel 376 of the tip insert 348 is filled with solid bubbles representing a first mixing component, and the crescent-shaped channel 378 of the tip insert 348 is filled with hollow bubbles representing a second mixing component. At this point, the crescent-shaped channels 376 , 378 of the tip insert 348 help keep the first and second mixing components from prematurely mixing when fluid passes from the malleable cannula 316 and into the tip insert 348 of the spray tip sub-assembly 318 .
FIG. 20 is a cross-sectional view of the spray tip sub-assembly 318 taken along the lines 20 - 20 of FIG. 18 . Here, the crescent-shaped channels 376 , 378 of the tip insert 348 have directed the fluid from the fluid carrying channels 330 , 332 of the malleable cannula 316 toward a space between walls of the tip insert 348 and the tip cap 342 . The two mixing components are still separate from each other.
FIG. 21 is a cross-sectional view of a spray tip sub-assembly 318 taken along the lines 21 - 21 of FIG. 18 . As illustrated in this view, the fluid has been even further directed from the fluid carrying channels 330 , 332 of the malleable cannula 316 into the tip insert 348 and the tip cap 342 . The first mixing component, indicated by solid bubbles, is now found in the space between the substantially flat side walls 377 a , 377 b and the rounded side walls 377 g , 377 h of the tip insert 348 and the interior surface 373 a of the cylindrical wall 373 of the tip cap 342 . The second mixing component is represented by hollow bubbles and is found in the space between the substantially flat side walls 377 b , 377 c and rounded side walls 377 d , 377 e of the tip insert 348 and the interior surface 373 a of the cylindrical wall 373 of the tip cap 342 . The solid-bubbled mixing component is about to mix with the hollow-bubbled mixing component in an area between the substantially flat side wall 377 b of the tip insert 348 and the interior surface 373 a of the tip cap 342 .
As illustrated in FIGS. 21 and 29 , for example, like the rounded tips 179 of the triangular tip insert 128 , the octagonal tip insert 328 includes rounded areas at each point where the substantially flat side walls 377 a , 377 b , and 377 c connect to each other or to a rounded side wall 377 d , 377 h and at each point where the rounded side walls 377 d , 377 e , 377 g and 377 h connect to either each other or to a substantially flat side wall 377 a , 377 c . These rounded areas of the octagonal tip insert 328 contact the inner surface of the tip cap 34 , forming a seal between the interior surface of the tip cap 342 and the octagonal tip insert 328 and ensuring a correct proportion of each fluid component is being properly directed into areas between the tip insert 348 and the tip cap 342 . These sealed areas between the tip insert 348 and the tip cap 342 are designed such that a desired mixture of the first and second mixing components may be forced together in the area between the substantially flat side wall 377 b of the tip insert 348 and the interior surface 373 a of the tip cap 342 , forming a third fluid flow path having a mixture of the first and second mixing components before entry into the feeder 394 . See, e.g., FIGS. 21 and 22 .
More specifically, the configuration of the tip insert 348 and the tip cap 342 is such that three fluid streams are created before each of the fluid streams enters one of the three feeders 394 , 396 , and 398 disposed in the tip cap 342 . A ratio can be set by dimensioning an interface between the tip insert 348 and the tip cap 342 , such that a desired proportion of the first mixing component only becomes one fluid stream, a desired proportion of the second mixing component only becomes a second fluid stream, and a desired proportion of both the first and second mixing components become a third fluid stream, each of the fluid streams being created before entering the feeders 394 , 396 , and 398 . By separating some portions of the first and second mixing components and premixing other portions of the first and second mixing components before any component enters the feeders 394 , 396 and 398 , mixing is optimized without leading to increased clogging.
FIG. 22 illustrates another cross-sectional view of a spray tip sub-assembly 318 this time taken along the lines 22 - 22 of FIG. 18 . Here, the fluid has been directed to feeders 394 , 396 , and 398 . The feeder 394 includes fluid components that have already begun to mix with one another, as illustrated by a combination of both the solid- and hollow-bubbled mixing components in that feeder 394 . The feeder 396 includes the hollow-bubbled (second) mixing component only, and the feeder 398 includes the solid-bubbled (first) mixing component only. Thus, the two fluid components have already begun to mix with one another before the feeder 394 delivers the fluid to the spinner region 380 ; however, the other feeders 396 and 398 respectively deliver first and second mixing components that have not started mixing with one another. Instead, the first mixing component included in feeder 398 and the second mixing component included in feeder 396 are not mixed until the feeders 396 , 398 deliver the respective components to the spinner region 380 , at a relatively high velocity, wherein they are mixed in a vortex. This configuration allows the fluid components to gradually begin mixing with one another, since that portion of each of the fluid components flowing into the feeder 394 begins mixing with the other fluid component prior to entry into the spinner region 380 . The remaining portions of the fluid components flowing into one or the other of the feeders 396 , 398 remain isolated from the other fluid component until reaching the spinner region 380 . Thus, the remaining portions of the fluid components are mixed only immediately before passing through the delivery opening 344 of the tip cap 342 and have been maintained in isolation from one another from the barrels of the dual syringe 12 , through the luer hub assembly 114 and the malleable cannula 316 , and into the spray tip sub-assembly 318 .
Referring now to FIG. 23 , the malleable cannula 316 further includes a proximal end region 354 having two elongate notches where portions of the malleable cannula 316 are shaved or otherwise cut back to expose semi-cylindrical channel regions 330 b and 332 b , each of which is an extension of a respective one of the fluid carrying lumens 330 , 332 . Like the male projection 370 at the distal end region 366 , a male projection 430 is defined at the proximal end region 354 by that area of the malleable cannula 316 between the two elongate notches. The notches at the proximal end region 354 extend axially along the malleable cannula from a proximal end wall 432 of the malleable cannula 316 to a stop wall 434 spaced axially inwardly (i.e., distally) of the proximal end wall 432 .
The male projection 358 may engage a complementary female cannula mating port (not shown) of the distal hub of a luer sub-assembly, in a manner that directs the fluid components into the respective fluid carrying lumens 330 , 332 , without cross-talk between the fluid components.
FIG. 24 is a cross-sectional view of the malleable cannula 316 taken along the lines 24 - 24 of FIG. 23 . The view illustrates all four lumens of the malleable cannula 316 , the two fluid carrying lumens 330 , 332 , the third lumen 334 , which may receive an annealed wire 164 , and the fourth lumen 362 .
FIG. 25 is a cross-sectional view of the malleable cannula 316 taken along the lines 25 - 25 of FIG. 23 . The view illustrates the third and fourth lumens 334 , 362 , wherein the third lumen 334 may accommodate an annealed wire 164 , helping to preserve a desired shape of the malleable cannula 316 .
FIGS. 33 and 34 illustrate a proximal hub 320 of a luer hub sub-assembly 114 that may be used with the distal hub 122 and any of the malleable cannulae 116 , 316 referred to herein. A top plan view of the proximal hub 320 is illustrated in FIG. 33 , and a cross-sectional view of the proximal hub 320 taken along the lines 34 - 34 of FIG. 33 is illustrated in FIG. 34 . Like the proximal hub 120 of FIG. 5 , the proximal hub 320 includes two fluid channels 324 , 326 to be placed in fluid communication with respective barrels of a dual syringe. The fluid channels 146 , 148 ( FIG. 5 ) of the distal hub 122 may alternatively be placed in fluid communication with the respective fluid channels 324 , 326 of the proximal hub 320 . A blade 325 , as illustrated in FIG. 34 , extends rearward adjacent to fluid channel 324 and fits into a slot 502 of a syringe assembly 500 , as indicated in FIG. 40 , to securely anchor the proximal hub 320 to the syringe assembly 500 . Fitting the blade 325 into the slot 502 enables a surgeon to move the syringe assembly 500 around without leading to a disconnection of the syringe assembly 500 and the proximal hub 320 during use. The engagement is further strengthened by tabs 327 extending out sides adjacent to each of the fluid channels 324 , 326 of the proximal hub 320 , as shown in FIGS. 33 and 34 , and actuable clips 504 shown on either side of the syringe assembly 500 of FIG. 40 . More specifically, after the blade 325 is inserted into the slot 502 of the syringe assembly, the clips 504 on either side of the syringe assembly are placed on the tabs 327 of the proximal hub 320 , thereby resulting in a reinforced, secure connection between the proximal hub 320 and the syringe assembly 500 .
As illustrated in FIG. 40 , the syringe assembly may include two push tabs 506 connected to and below each of the clips 504 to enable movement of the clips to an open position that allow the proximal hub 320 and the blade 325 to be easily inserted within the syringe assembly 500 . More specifically, to insert the blade 325 into the slot 502 of the syringe assembly 500 , a user may first place her thumb and forefinger on each of the push tabs 506 connected to the clips 504 , thereby placing the clips 504 in an open position. With her other hand, the user may insert the blade 325 of the proximal hub 320 into the slot 502 , and further insert the fluid channels 324 , 326 into the fluid containing barrels of the syringe assembly 500 . The user may then release her thumb and forefinger from the tabs 506 attached to the clips 504 of the syringe, resulting in the clips 504 being easily placed on the tabs 327 of the proximal hub 320 and securely fastening the proximal hub 320 to the syringe assembly 500 .
FIGS. 35-39 illustrate a distal hub of a luer-hub subassembly 322 intended to interface with the male projection at the proximal end of malleable cannula 316 . As best illustrated in FIGS. 37 and 38 , a projection-receiving channel is provided at the proximal end of the female cannula mating port of the distal hub. Fluid from each the channels within the luer-hub subassembly is diverted into a respective one of the semi-cylindrical channel regions along the male projection of the malleable cannula 316 , facilitated by complementary wedges 321 , 323 within the cylindrical female cannula mating port of the distal hub.
While the applicator of the present disclosure has been described with respect to certain embodiments thereof, it will be understood that variations may be made thereto that are still within the scope of the appended claims. | An applicator for mixing and applying multi-component compositions to a work surface, such as two-component surgical sealants, while avoiding clogs, preventing cross-contamination of the components until a point of intended mixing at a location within the apparatus immediately upstream of an application opening in a tip cap, decreasing pressure drop along the applicator to facilitate fluid delivery, and increasing efficiency of mixing of the components. A luer hub sub-assembly having a proximal hub and a distal hub, an elongate, four-lumened cannula, and a spray tip sub-assembly are provided, with interconnections between the sub-assemblies preserving isolation of the fluid components from one another. The tip cap sub-assembly includes registration structure to assure proper alignment between tip cap and tip insert. The end wall of the tip cap includes a spinner region with three feeders leading thereto, the fluid components remaining isolated from one another in two of the feeders, and initiating mixing with one another in a third of the feeders. | 0 |
The invention described herein was made in the course of work under a grant or award from the Department of Health and Human Services.
This is a continuation, of application Ser. No. 803,269, filed June 3, 1977, now abandoned which is a continuation of Ser. No. 508,854, filed Sept. 24, 1974 abandoned.
BACKGROUND OF THE INVENTION
Various platinum coordination compounds useful as anti-tumor agents are disclosed in co-pending application Ser. No. 405,184, filed Oct. 10, 1973 (which is a continuation application of application Ser. No. 230,533, filed Feb. 29, 1972, which is a continuation application of application Ser. No. 30,239, filed Apr. 20, 1970). Another class of platinum coordination compounds, i.e., malanato-platinum compounds, useful as anti-tumor agents are disclosed in co-pending application Ser. No. 260,989 (filed June 8, 1972). A method for the treatment of viral conditions utilizing platinum coordination compounds is disclosed in co-pending application Ser. No. 350,924, filed Apr. 13, 1973.
While extremely effective against a variety of tumors, the above-described platinum coordination compounds suffer from the disadvantages of (1) having a high level of renal toxicity, and (2) a low solubility in water. The latter characteristic renders the preparation of therapeutically useful compositions difficult.
It has been discovered that a certain class of platinum "blue" complexes have a high anti-tumor activity, are soluble in water, and have a low level of renal toxicity.
The prior art has long been aware of the so-called "platinblau" complexes. Credit for the discovery of "Platinblau", as these blue complexes were designated, is usually given to Hofmann and Bugge (Ber. 41: 312-314, 1908). They reacted Ag 2 SO 4 with the yellow platinum (II) coordination compound, Pt(CH 3 CN) 2 Cl 2 in aqueous solution and isolated a deep blue, amorphous material. It was thought to be monomeric in nature, containing platinum in the divalent state. Since this discovery only a few papers have appeared concerning further studies on "Platinblau" and similar blue products. Gillard and Wilkinson (J. Chem. Soc., 2835-37, 1964) postulated that "Platinblau" had the empirical formula Pt(CH 3 CONH) 2 .H 2 O with polymeric chains, bridging acetamide groups, and divalent platinum. Brown et al. (J.A.C.S. 91:11: 2895-2902, 1969 and 90:20: 5621-5622, 1968) have attempted to demonstrate that it is a platinum (IV) complex containing chelating acetamide ligands, and hydroxyl groups in the other two coordination positions. We have found that both blue and purple products could be isolated from the "Platinblau" reaction, with the purple species being the more highly oxidized (vide infra). Thus, there is considerable controversy over the exact nature of this complex. Brown et al (ibid.) have also reported the preparation of highly colored amide complexes of platinum by heating, for example, trimethylacetamide and either Pt(CH 3 CN) 2 Cl 2 or K 2 [PtCl 4 ] (a reddish colored salt). From this reaction three components were identified by chromatography. These were two yellow crystalline materials and a blue amorphous powder. Although they reported that they could not identify any of these blue products in a positive manner, they postulated that the blue material contained tetravalent platinum, which bidentate anide anions and chloride ligands completing the coordination sphere.
The only other reference to anomalously colored platinum compounds containing cis-amino groups as ligands rather than amides is that concerning mixture of cis-dichlorodiammineplatinum (II) and sulfuric acid (Gillard et al, ibid.). Crystals of this blue black material were obtained and a preliminary X-ray diffraction study showed that the Pt-Pt distance was 3.06 Å, suggesting strong interaction. They concluded that this complex contained layers of cis-dichlorodiammineplatinum (II) held together by Pt-Pt bonds, with the sulfate ion hydrogen bonded to the coordinated ammonia groups.
SUMMARY OF THE INVENTION
The invention is predicated on the discovery that the "platinum blue" complexes formed by the reaction of cis-diaquodiammineplatinum II with a 2,4-dioxopyrimidine are anti-tumor, anti-viral and anti-bacterial agents with a low level of renal toxicity and a high degree of solubility in water.
Suitable 2,4-dioxopyrimidines include those having the formula: ##STR2## wherein:
R 1 and R 2 may be the same or different and are selected from the group consisting of H, lower alkyl, dilower alkyl amino, di-halo lower alkyl amino, halogen, hydroxy, hydroxy lower alkyl, carboloweralkoxy,
R 3 and R 4 may be the same or different and are selected from the group consisting of H, lower alkyl ribosyl, deoxyribosyl, triacetyl, tribenzoyl or 2',3'-loweralkylidine ribosyl, ribosyl, ribosyl phosphates or deoxyribosyl phosphates,
or the 5,6-2H derivatives thereof.
The invention also relates to a method for preparing the platinum-[2,4-dioxopyrimidine] complexes by reacting the above-described 2,4-dioxopyrimidines with cis-diaquodiammineplatinum (II) wherein the molar ratio of pyrimidine to platinum compound is from about 2:1 to about 1:1 at a temperature of from about 0° to about 55° C., and for a time sufficient to form the complex.
The invention also relates to a pharmaceutical composition adapted for the treatment of tumors, bacterial and viral infections and arthritic conditions comprising, in dosage unit form, a pharmaceutically acceptable carrier and from about 1 mg/ml to about 50 mg/ml of a complex of 2,4-dioxopyrimidine and platinum compound as described above.
The present invention also relates to a method for the treatment of tumors and bacterial and viral infections comprising the administration to a living being afflicted with the malady from about 1 mg/kg to about 800 mg/kg of body weight of the above-described complex.
DETAILED DESCRIPTION OF THE INVENTION
Although the complexes of the invention are referred to as "platinum blue" complexes for purposes of convenience, the products of some of the above-described reactions are in reality mixtures which are extremely difficult to separate. Analysis and molecular weight determinations have enabled certain conclusions to be drawn.
Generally, the complexes contain one pyrimidine molecule per molecule of platinum. For the most part, each complex contains two ammonia ligands, one pyrimidine anion and one hydroxide ion per platinum molecule, but with two additional oxygen atoms at an unspecifiable location. The 5-fluorouracil complex is an exception in that it does not contain excess oxygen.
The cis-diammino configuration of platinum appears to be essential for forming the complexes of the invention.
Although the 2,4-dioxopyrimidine moiety of the platinum complex may be variously substituted in the 1,3,5, and 6 positions as set forth above, the preferred complexes are those wherein R 1 , R 2 , R 3 and R 4 are each hydrogen and wherein R 1 , R 2 and R 3 are each hydrogen and R 2 is CH 3 . These compounds are uracil and thymine. The complexes formed by the reaction of uracil and thymine with cis-diaquodiammmineplatinum (II) have been found to be especially effective anti-tumor, anti-bacterial and anti-viral agents.
As noted above, the exact structure of these complexes is at present unknown. They are, however, extremely soluble in water. They may be prepared by reacting the appropriate 2,4-dioxopyrimidine with cis-diaquodiammineplatinum (II) in an aqueous solution wherein the molar ratio of 2,4-dioxopyrimidine to the platinum complex is from about 2:1 to about 1: at a temperature in the range of from about 0° to about 55° C., preferably at room temperature, for a time sufficient for the complex to form, preferably from about 1 to about 21 days. The method is preferably carried out in an aqueous medium wherein the pH ranges from about 3 to about 8, preferably about 6.5.
The most notable characteristic of the compounds of the invention is their extreme solubility in water, i.e., on the order of 1 g per 10 ml of water. Their extreme solubility renders them particularly adapted for the treatment of tumors and bacterial and viral infections in living beings.
For example, the cis-diaquodiammineplatinum(II)-uracil complex was found to be particularly effective against the ascites Sarcoma-180 tumor in the Swiss white mouse. The toxicity of the complex was extremely low and the mice tolerated up to 500 mg per kg of body weight as a single dose injection of the complex without any deaths.
The complex described above was also found to be effective against the Fowl Pox virus when incubated therewith for extremely short periods of time prior to innoculation into an embryonated egg as a system. It was also found that the complex could be injected into the egg well after the innoculation with the virus and still prevent development of the pox formation typical of a live virus attack upon the membrane.
As another example of the diversified activity of the platinum-uracil complex, it was tested against E. coli growing in test tube cultures. Even at very low concentrations, i.e., 5 ppm, tha bacteria formed clumps and did not show filamentation. At higher concentrations, i.e., greater than 40 ppm, the bacteria were completely killed.
The platinum-uracil complex has also been found to be effective against the ADJ/PC6 tumor system.
The complexes of the invention may be compounded with conventional pharmaceutical carriers in the preparation of pharmaceutical compositions for the treatment of tumors, bacterial and viral infections. The compositions should comprise, in dosage unit form, a pharmaceutically acceptable carrier and from about 0.1 mg/ml to about 50 mg/ml of the above-described complex.
The mode of administration of the platinum-uracil and related complexes will depend upon the particular malady to be treated. Solutions may be administered by injection via the intraperitoneal, intramuscular, subcutaneous or intravenal routes, or as a solid, per oz.
The invention is illustrated by the following non-limiting Examples:
EXAMPLE 1
3 grams of cis-dichlorodiammineplatinum (II) (0.01 moles) and 0.02 moles of silver nitrate in 100 ml of water were stirred overnight at 23° C. in the dark. The silver removes the chlorides from the platinum complex and produces 100% yields of the cis-diaquodiammineplatinum (II). The silver chloride is then filtered off. It is necessary to remove all of the silver ions from solution. A small aliquot of the remaining solution is tested for excess silver by adding a small amount of 0.1 molar HCl. If the solution turns cloudy the reaction has not yet proceeded to completion. When the solution remains clear, the reaction is considered complete. The solution is then neutralized with 2.0 normal sodium hydroxide to yield a final pH value of between 6 and 7. Then, 1.12 grams of uracil is dissolved in 100 milliliters of water to form a slurry. The pH is then adjusted to 9 with 2.0 normal sodium hydroxide and warmed to 50° C. to dissolve the uracil to give a solution containing 0.01 moles of uracil. The uracil solution is then mixed with the cis-diaquodiammineplatinum(II) complex to provide a 1 to 1 ratio on a molecular basis of the two reactants. The pH is adjusted to between 6 and 7. The vessel is stoppered, covered with aluminum foil, and placed in a water bath at 37° C. for a period of one week to complete the reaction. A blue color forms after approximately 24 hours. After one week there is a small amount of blue precipitate. The solution is cooled to near 0° overnight and a large amount of a blue precipitate forms. This is filtered, and washed with a very small amount of cold water. The filtrate is washed three times with large amounts (approximately 150 milliliters each time) of 200 proof, boiling ethanol to remove excess uracil that may be present. After the third wash the ethanol when cooled should remain clear, indicating no further free uracil in solution. The filtrate is air dried, then vacuum dried for 12 hours at 40° C. The result is a dark blue, powdery, pure sample of the Platinum-Uracil complex.
The supernatent liquid from the initial filtration was evaporated to about 25% of its original volume and an equal volume of ethanol was added. Cooling to 0° C. gave more blue precipitate and a dark-green solution. The blue precipitate was filtered and the filtrate further concentrated. The addition of more ethanol gave a pale-green precipitate.
Obviously, therefore, the method of the invention yields a complex mixture of "platinum blue" compounds. It is to be understood, however, that the invention includes all of the diverse components of the reaction mixture, whether in admixture or in isolated form.
Generally, the first derived precipitate, i.e., the blue precipitates are less soluble in water-ethanol mixtures. The second derived component is more soluble in water-ethanol.
EXAMPLE 2
The procedure of Example 1 was followed utilizing 2',3',5'-triacetyluridine except that the solution was evaporated to dryness and the complex dissolved in ethanol. Addition of ether gave a dark-blue hygroscopic precipitate which was collected and washed with ether.
EXAMPLES 3-13
The procedure of Example 1 was followed in preparing the complexes set forth in Table 1. The Elemental Analyses of the complexes of Examples 1 and 3-14 are also set forth in Table 1.
TABLE 1__________________________________________________________________________Elemental Analyses of ComplexesCompound % C % H % N % O % Cl % F % Pt M W__________________________________________________________________________CLASS IA ("blue" or 1st precipitate)uracil (Ex. 1) 12.31 2.49 14.55 20.65 -- -- 50.00* 805thymine (Ex. 3) 14.05 3.26 15.65 18.97 -- -- 48.07* --5,6-dihydro-6-methyluracil (Ex. 4) 13.07 3.36 15.60 17.21 -- -- 50.76* --5,6-dihydrothymine (Ex. 5) 11.65 2.69 13.29 10.55 -- -- 61.82* 2831-methyluracil (Ex. 6) 14.65 2.63 14.08 19.77 -- -- 48.87* --5,6-dimethyluracil (Ex. 7) 16.96 3.38 15.07 15.78 -- -- 48.81* --5-carbethoxyuracil (Ex. 8) 17.94 3.07 13.91 15.86 -- -- 49.22* --5-chlorouracil (Ex. 9) 10.16 2.17 14.91 17.98 8.76 -- 46.02* --6-chlorouracil (Ex. 10) 11.24 2.45 13.37 18.63 8.28 -- 46.03* 4335-hydroxymethyluracil (Ex. 11) 12.25 1.68 14.47 20.48 -- -- 50.12* 379CLASS IB (" green" or 2nd precipitate)uracil (Ex. 1) 11.68 2.59 14.23 23.95 -- -- 47.55* --thymine (Ex. 3) 14.55 3.20 15.45 19.63 -- -- 47.17* 3881-methylthymine (Ex. 12) 16.17 3.05 15.53 17.81 -- -- 47.44* 371CLASS IA ("blue")5-fluorouracil (Ex. 13)calc. for PtC.sub.4 H.sub.9 N.sub.4 O.sub.3 F 12.80 2.42 14.93 -- -- 5.06 -- 375found 12.65 2.26 14.75 -- -- 509 -- 381CLASS IB ("green")5-fluorouracil (Ex. 13)calc. for PtC.sub.4 H.sub.9 N.sub.4 O.sub.3 F 12.80 2.42 14.93 -- -- 5.06 -- 375found 13.05 2.36 15.09 -- -- 5.17 -- 374__________________________________________________________________________ *calculated by difference
Some of the "platinum blue" complexes of the invention are believed to be mixtures of oligomeric species including monomers, dimers and trimers.
It is, for this reason, difficult to interpret the infrared spectra of the complexes with regard to structural features. They are characterized by the fact that they have an absorption band in the visible red region, consisting either of a single or a double peak which imparts the characteristic green, blue or violet color to the various complexes. An absorption spectrum of the cis-diaquodiammineplatinum (II)-uracil complex as prepared above is shown in FIG. I. It can be assumed from the infrared spectra that the ammine ligands are present and that a ring structure still exists. While possessing high solubilities in water, the complexes have very limited solubilities in solvents such as dimethylformamide and dimethylsulfoxide.
X-ray diffraction and electron diffraction analyses of the platinum-uracil complex show a completely amorphous material.
Conductivity tests suggest that the complexes are neutral species.
The visible spectra of a number of different samples of the platinum-uracil complexes were measured on a Cary 15 Spectrophotometer in aqueous solution in 1 cm quartz cells at concentrations of 10 mg/10 ml (1 mg/ml). For a sample which analyzed to have a M.W.=1200 the spectrum contained a broad band centered at 722 nm with absorbance ≅0.9 and a broad shoulder at 582 nm (O.D.=0.74). A sample believed to be a monomeric species (m.w.≅400) had a broad shoulder at 617 nm (O.D.=0.6), a broad band at 563 nm (O.D.=0.62) and a band at 468 nm (O.D.=0.42).
The proton magnetic resonance spectra of the platinum-uracil, thymine and 5,6-dimethyluracil complexes samples were recorded in a Varian A56/60 Spectrometer in D 2 O solution using DSS (a water soluble form of TMS) as internal reference (set to 0 ppm). The platinum-uracil complex exhibited a sharp doublet centered at 2.84 ppm (peaks at 2.76 and 2.92 ppm), a peak due to the solvent at 4.47 ppm and a weak broad (1 ppm width at half height) at 7.69 ppm. For the Pt-Thymine complex, with the solvent peak adjusted to 4.47 ppm, the spectrum showed a broad (2 ppm width at half height) peak at 1.71 ppm, a sharp doublet centered at 2.85 ppm (peaks at 2.77 and 2.93 ppm) and a weak broad peak (1 ppm wide) at 7.5 ppm (possibly due to unreacted free base). Free uridine in D 2 O gives pmr spectrum with a doublet assigned to the uracil H 6 protons at 7.65 ppm and a doublet due to the H 5 protons at 5.8) ppm (solvent peak 4.54 and DDS at 0 ppm). Free thymine in d 7 -DMF solutions has a sharp peak at 1.72 ppm assigned to methyl protons and a broad weak peak at 7.20 ppm (assigned to H 6 ) with TMS set at 0 ppm. The spectrum of the 5,6-dimethyluracil compound contained peaks at 1.76 and 2.07 ppm relative to HDO at 4.47 ppm. From these spectra we can only conclude that the magnetic environment of the protons in the bases changes when they become coordinated in these blue complexes to increase the shielding of the protons.
The electron scattering for chemical analysis (ESCA) measurements on the binding energy of the 4f electrons in a platinum from X-ray Photoelectron Spectroscopy yields a value for cis-Pt(NH 3 ) 2 CL 2 of 73.02 Ev. The platinum in the platinum-uracil complex gave a value of 73.6 eV. This suggests that the valence state of platinum in the platinum-uracil is II and not IV.
The electronic absorption spectra of the blue precipitate of the platinum-uracil complex contain broad absorption bands in the vicinity of 550-650 nm with molar extinction coefficients on the order of 500-1000 1 mole -1 cm -1 . The green precipitate fraction of the platinum uracil complex contains a single broad band near 720 nm of similar intensity. These blue and green compounds contain a very intense band near 290 nm.
The chemotherapeutic activities of the "Platinum Blue" complexes were determined using the ascites Sarcoma-180 tumor in Swiss White mice. The protocols for these tests were as follows: Random bred female Swiss White mice (Spartan Laboratory, Williamston, Mich.) of 18-20 grams weight were randomized in groups of six. The ascites cells were removed from the peritoneal cavities of animals with approximately 10 day old ascites tumors. The cells were washed several times with 0.85% saline and spun down each time in a refrigerated centrifuge for 3-5 minutes at 750 r.p.m. After the blood was removed from the cells, they were diluted with 0.85% saline solution and counted in a hemocytometer. A final dilution of 2×10 7 cells/ml. in saline was made. Each animal received 0.2 ml. of this suspension (4×10 6 cells/animals). This was injected intraperitoneally on day 0 of each test. Two groups (12 animals) were kept as negative controls, and the test was terminated at twice the mean day of death of the negative controls. Two groups (12 animals) were the positive controls which were injected i.p. on day 1 with solution of cis-dichlorodiammineplatinum(II) in saline at a dose of 7 mg/kg. All test compounds were injected i.p. on day one as a 0.5 ml. volume of the compound in a carrier of water, physiologic saline or arachis oil (peanut oil). Soluble compounds were always tested in appropriate solutions, the insoluble ones as a slurry. The slurry was sonicated for periods of up to 10 minutes to insure uniformity of dispersion just prior to injections. Generally, four dose levels, in a doubling escalation, were tested for each compound. Retests were performed if a sufficient level of drug toxicity at the highest dose was not reached. Animals still alive at the completion of the tests were considered to have died on the day of evaluation. Animals showing no abdominal distention (by palpation, or visibly) on this day were considered cured. Some cured animals later developed a solid tumor around the site of injection of the cells. This is believed to be due to a leakage of cells along the route of the needle on injection, or a later leak of cells through the injection hole in the peritoneum. In any case, this is considered an adventitious effect, which, when care is used in injections and smaller needles are used, becomes negligible.
The compounds tested were usually freshly prepared and purified. The compounds kept for further testing were stored in a vacuum dessicator in a dark refrigerator to prevent deterioration. In general, compounds of all classes tested had toxic levels at 200 mg/kg or greater. Toxic levels are considered to be that concentration where 2 or more of the 6 animals at the dose died within 8 days of injection. Animals dying after this time overlap with the early deaths of the negative controls.
For some of the complexes tested, the animals exhibited an excessive extension of the hind legs shortly after injection at high dose levels. The animals surviving the first two days, however, usually survived past the eight-day limit for toxic deaths. Some, however, did show an early death. Consistent with early experience with platinum complexes, gross hepatic damage was minimal or non-existent (with the exceptions of Pt(CH 3 CN) 2 Cl 2 , the platinum-1-methyluracil and the platinum-5-bromo-1-methyluracil complexes. Peritonitis occurred in a similar number of cases at later times (day of evaluation, and up to 3 months later in cured animals). Symptoms of neuromuscular disorders were observed with a few compounds, shortly after high dose injections (i.e. platinum-uracil green precipitate). No symptoms of central nervous system disorders were ever observed in the test animals.
Unlike the solid Sarcoma-180, the ascites tumor in the Swiss White mice elicits no spontaneous regression (0/336), all tumored mice die, and the percent of no-takes is zero. The mean day of death is 17.5, with a small standard deviation (±2.2 days).
The results of the survey tests are presented in Table 2. The letter A indicates the "blue" or first isolated precipitate, the letter B, the "green" or second precipitate. The data shown includes the carrier; the dose range tested; the toxic level (see above); the best percent increase in lifespan (% ILS), the maximum being 100% since the experiments were terminated at twice the mean life span of the negative controls; the dose level giving the best % ILS; the physical state of the inoculum (solution or slurry); and finally, the number of cured animals (out of 6 in each group).
TABLE 2__________________________________________________________________________Survey Results of Antitumor Activity of Platinum BlueComplexes Against the Ascites Sarcoma 180 Tumor in Swiss White Mice Toxic Best Dose of Physical # ofCompound Carrier.sup.b Range Level % ILS Best % ILS State.sup.c cures.sup.d__________________________________________________________________________negative control - average day of death = 17.5 (S.D. ± 2.16)positive controlcis-Pt(II)(NH.sub.3).sub.2 Cl.sub.2 S 7 10 49 (S.D ± 2.82) 7 S 1 (of 12)CLASS IA.sup.auracil W 50-400 400 92 200 S 5uracil S 50-400 400 80 100 S 15,6-dihydrouracil W 20-800 400 92 200 S 4thymine W 150-600 450 72 300 S 2thymine S 50-200 >200 67 150 S 15,6-dihydro-6-methyl W 50-400 200 89 50 S 2uracil6-methyluracil S 200-800 >800 87 600 S 35,6-dimethyluracil W 50-400 >400 100 400 S 55,6-dihydrothymine S 50-400 400 87 200 S 21-methyluracil S 50-400 >400 85 400 S 31-methylthymine S 50-400 400 94 100 S 31-ethyluracil S 50-400 200 38 50 S 05-fluorouracil W 50-400 200 90 100 S 45-chlorouracil W 50-400 200 67 50 S 36-chlorouracil S 25-200 >200 88 200 S 35-bromo-methyl- S 50-400 >400 88 200 S 1uracil5-iodouracil P.O. 25-600 500 8 250 Sl 05-hydroxymethyluracil S 50-400 200 98 100 S 25-carbethoxyuracil S 25-200 200 56 200 S 06-carbomethoxyuracil S 25-200 >200 38 25 S 0uridine deoxyribose S 25-200 >200 46 200 S 0thymidine S 50-400 200 46 50 S 15-iodouridine P.O. 50-200 >200 23 200 Sl 0deoxyribose2',3',5'-triacetyl- S 50-1000 800 79 600 S 2uridine2',3',5'-tribenzoyl- S 50-400 >400 19 100 & 200 S 0uridine2',3'-isopropylidine- S 50-400 400 61 50 S 2uridineCLASS IBuracil W 25-675 500 95 340 S 4thymine S 50-400 >400 60 200 S 01-methylthymine (yellow) S 50-400 400 -14 100 S 01-ethyluracil S 50-400 100 15 50 Sl 05-fluorouracil S 25-200 >200 37 200 S 0MISC.Pt(CH.sub.3 CN).sub.2 Cl.sub.2 S 6.3-50 50 83 25 S 1__________________________________________________________________________ *Prepared by hydrolysis of Pt(CH.sub.3 CN).sub.2 Cl.sub.2 .sup.a Refer to section IV for a description of the Class .sup.b W = water, S = saline, P.O. = peanut oil .sup.c S = solution, Sl = slurry .sup.d 6 animals per test, cures are considered as having no distention o abdominal cavity but do include formation of solid tumors at site of injection in some cases.
The results in Table 2 were obtained using a single i.p. injection on day 1. Since this may not be the best schedule for treatment, samples of the drugs were selected for schedule dependency tests. These are described in Table 3. The cis-dichlorodiammineplatinum(II) given as 8 injections of 1 mg/kg each every 3 hours for the first day showed a surprisingly improved result over the single injection of 7 mg/kg (positive control).
TABLE 3__________________________________________________________________________Results of Schedule Dependency Tests of AntitumorActivity of Selected Platinum Blue Complexes Frequency of Number of Toxic Best Dose of Physical.sup.c # ofCompound.sup.a Injections Injections Carrier.sup.b Range Level % ILS Best % ILS State cures.sup.d__________________________________________________________________________Negative Control - Average Day of Death 19.3 (S.D. ± 3.2)Positive Controlcis-Pt(II)(NH.sub.3).sub.2 Cl.sub.2 day 1 1 S 7 10 42 (S.D. ± 3.1) 7 S 1cis-Pt(II)(NH.sub.3).sub.2 Cl.sub.2 every 3 hrs. 8 S 1 >1 86 1 S 5 every day 5 S 3 3 19* 3 S 3 every 5th day 5 S 45 >5 83 5 S 3Uracil Class IA every 3 hrs. 8 S 50-125 100 80 50 S 1 every day 5 S 50-150 >150 100 100 S 6 every 5th day 5 S 75-300 >300 100 150 S 3Uracil Class IB every 3 hrs. 4 S 100-250 >250** 73 100 S 3 every day 5 S 25-200 200 68 100 S 5 every 5th day 5 S 100-400 400 84 200 S 5Thymine Class IA every 3 hrs. 8 S 50-200 200** 77 100 S 4 every day 5 S 50-150 150** 91 50 S 5 every 5th day 5 S 75-300 300 100 150 S 5__________________________________________________________________________ *Three animals died within 9 days of start remainder cured. **Number of injections varied because of severe animal response. Therefore, toxicity probably would have been reached had all animals received the same number of injections. .sup.a Refer to section 4 for a description of the classes. .sup.b S = saline .sup.c S = solution, Sl = slurry .sup.d 6 animals per test, cures are considered as having no distention o abdominal cavity but do include formation of solid tumors at site of injection in some cases.
Tables 4-7, respectively, tabulate the results achieved when employing the complexes of the invention against the L1210, MCDV 12, (Rauscher Leukemia, virus-induced), Ehrlich Ascites and the ADJ PC6A (myeloma) tumors.
TABLE 4______________________________________Effects of `Platinum Blue` Complexes on theL1210 Tumor in BDF Mice.sup.a Sur-Compound Dose and Schedule % ILS vivors______________________________________uracil Class IA 50 mg/kg qid × 5 16 0/3 100 mg/kg qid × 5 26 0/3 61.25 mg/kg q3 hr × 8 30 0/3 30.63 mg/kg q3 hr × 8 0 0/3 250 mg/kg × 1 27 0/3 500 mg/kg × 1 -58 0/3thymine Class IA 100 mg/kg qid × 5 25 0/3 30.63 mg/kg q3 hr × 8 32 0/3 61.25 mg/kg q3 hr × 8 32 0/35,6-dihydrothymine 50 mg/kg qid × 5 36 0/3Class IA 100 mg/kg qid × 5 45 0/3 30.63 mg/kg q3 hr × 8 30 0/3 61.25 mg/kg q3 hr × 8 0 0/31-methyluracil 50 mg/kg qid × 5 10 0/3Class IA 100 mg/kg qid × 5 28 0/3 30.63 mg/kg q3 hr × 8 10 0/3 61.25 mg/kg q3 hr × 8 22 0/3______________________________________ .sup.a All experiments were terminated arbitrarily at 200% ILS and any survivors were tabulated at that time. All therapy was started on the third day after tumor transplant. Untreated tumor controls died 10-11 day after transplant. In some instances efforts to reproduce above results have shown considerable variability.
TABLE 5______________________________________Effects of cis-Dichlorodiammineplatinum (II) and`Platinum Blues` on MCDV 12(Rauscher Leukemia, Virus Induced) in BALB/C Mice.sup.a % Sur-Compound Dose and Schedule ILS vivors______________________________________cis-Dichlorodiammine- 5 mg/kg × 1 146 2/3platinum (II) 8 mg/kg × 1 62 0/2 16 mg/kg × 1 -15 0/3uracil Class IA 50 mg/kg qid × 5 200 3/3 100 mg/kg qid × 5 166 2/3 25 mg/kg qid × 5 85 1/3 125 mg/kg × 1 107 1/3 61.25 mg/kg q3 hr × 5 137 1/3 30.63 mg/kg q3 hr × 8 37 0/3 250 mg/kg × 1 -10 0/3 500 mg/kg × 1 -60 0/3thymine Class IA 100 mg/kg qid × 5 124 1/3 30.63 mg/kg q3 hr × 7 156 2/3 61.25 mg/kg q3 hr × 7 103 1/35,6-dihydrothymine 50 mg/kg qid × 5 157 2/3Class IA 100 mg/kg qid × 5 0 0/3 30.63 mg/kg q3 hr × 8 75 1/3 61.25 mg/kg q3 hr × 6 121 2/31-methyluracil 50 mg/kg qid × 5 88 1/3Class IA 100 mg/kg qid × 5 19 0/3 30.63 mg/kg q3 hr × 8 34 0/3 61.25 mg/kg q3 hr × 8 110 1/3______________________________________ .sup.a All experiments were terminated arbitrarily at 200% ILS and survivors tabulated at that time. All therapy was started on third day after tumor transplant. Untreated tumor controls died 10-11 days after transplant. In some instances, efforts to reproduce above results have shown considerable variability.
TABLE 6______________________________________Effects of cis-Dichlorodiammineplatinum (II) and`Platinum-Uracil Blue` onSurvival Times of Mice Bearing the Ehrlich Ascites Tumor.sup.a Mean Survival % Increase Dose Time days in MeanCompound (mg/kg) (+ S.D.) Survival Time______________________________________Control -- 8.3 ± 1.8 --cis-Dichlorodiam- 7 33.8 ± 16.9 .sup. 307.sup.bmineplatinum (II)uracil Class IA 100 24.7 ± 7.6 198uracil Class IA 200 25.2 ± 7.4 204uracil Class IA 300 36.0 ± 14.2 334Control 10.1 ± 2.8 --cis-Dichlorodiam- 7 29.7 ± 4.2 194mineplatinum (II)uracil Class IA 200 25.7 ± 4.5 154uracil Class IA 300 30.3 ± 6.3 200uracil Class IA 400 28.5 ± 4.2 182______________________________________ .sup.a 6 mice/group; each mouse received 10.sup.7 ascites tumor cells on day 0; treatment was as a single i. p. injection on day 3. .sup.b 2 animals in this group survived > 60 days.
TABLE 7______________________________________Effects of cis-Dichlorodiammineplatinum (II) and"Platinum Blues" on theADJ/PC6A Tumor in Female, C.sup.- Mice.sup.a ID 90 (90% TherapeuticCompound LD.sub.50 Inhibition) Index______________________________________cis-dichlorodiammine- 13 mg/kg 1.6 mg/kg 8.1platinum (II)uracil Class IA.sup.b 225 mg/kg 94 mg/kg 2.45,6-dihydrothymine 135 mg/kg 25 mg/kg 5.4Class IA6-chlorouracil Class IA 200 mg/kg 190 mg/kg 1.055-carbethoxyuracil 670 mg/kg 250 mg/kg 2.7Class IA1-methyluracil Class IA 670 mg/kg 50 mg/kg 13.45-hydroxymethyluracil 40 mg/kg 42 mg/kg 0.95Class IA______________________________________ .sup.a Injections, i.p. started 24 days after tumor implant, as single doses. .sup.b Injections, i.p. started 24 days after tumor implant, given daily for 5 days.
Renal toxicity is the dose limiting side effect in higher animals and man under treatment with cis-dichlorodiammineplatinum(II). It is desirable to find other platinum drugs which cause much less severe renal toxicity. Described here are the results of histopathological examinations indicating that the "Platinum-Uracil Blue", Class IA, causes far less impairment of the kidneys than does cis-dichlorodiammineplatinum(II) or cis-dichloro(bis) cyclopantylamineplatinum(II), at roughly comparable therapeutic levels.
The protocols for these tests were as follows: Each group contained six female Swiss White mice; the tumored animals were given a transplant of a solid Sarcoma-180 tumor on day 0 and treatment was initiated on day 1; the animals were sacrificed on day 10 and the kidneys removed and prepared for histological evaluation; control groups were non-tumored, non-treated animals, and tumored, non-treated animals. Multiple sections of each kidney were examined. Since cis-dichloro(bis)cyclopentylamineplatinum(II) is a very insoluble compound, and usually tested as a slurry in arachis oil, we felt it necessary to test it as saturated solutions in saline in order to be comparable with the other drugs. The saturation concentration cannot be specified other than an estimate of less than 1 mg/100 ml. A very brief summary of the results are compiled in Table 8. The histopathologic degenerative changes are dose dependent in all cases. While the higher dose levels of cis-dichlorodiammineplatinum (II) and cis-dichloro(bis)cyclopentylamineplatinum (II) caused generalized vacuolar (hydropic) degeneration of the proximal convoluted tubules, the higher doses of the "Platinum-Uracil Blue" Class IA, produced mild degenerative changes generally, with some severe, multiple small foci of necrosis.
Since the function of a kidney containing foci of degenerative tissue should be less seriously impaired than kidneys in which entire anatomic/physiologic areas (i.e., proximal convoluted tubules) are involved, it is judged that the "Platinum-Uracil Blue" Class IA, is less nephrotoxic, (based upon renal histopathologic evidence) than the other two complexes, when compared at roughly equivalent therapeutic doses.
TABLE 8__________________________________________________________________________Observed Renal Histopathological Changes in Mice Kidneys[Limited to the proximal convoluted tubules]__________________________________________________________________________1. cis-dichlorodiammineplatinum (II)Number of injectionsand time sequences Dosage Rate (mg/kg)between doses 0.5 1.0 2.0 3.0 7.0__________________________________________________________________________8 normal normal -- -- --(every 3 hours)7 -- normal mild degenerative mild degenerative -- (every 24 hours) changes (cloudy changes (cloudy swelling) swelling)1 -- -- -- -- extensive degenerative[tumored animal] changes (hydropic de- generation)1 -- -- -- -- extensive degenerative[non-tumored changes (hydropic de-animal] generation)__________________________________________________________________________2. uracil Class IANumberof injectionsand time sequence Dosage Rate (mg/kg)between doses 50 100 150 400__________________________________________________________________________6 -- -- focal areas of de- --(every 3 hours) generation and nec- rosis. Hyaline casts also present.8 -- focal areas of -- --(every 3 hours) -- degeneration and -- -- necrosic. Hyaline casts also present.7 mild congestion extensive focal areas isolated focal areas -- (every 24 hours) of renal cortex, of degenerative of degenerative otherwise normal. change (hydropic de- change (hydropic generation) generation)1 -- -- -- mild degenerative changes (cloudy swelling) cortical hyperemia__________________________________________________________________________3. cis-dichloro(bis-cyclopentylamine)platinum (II)Number of injections and Dosage Rate (mg/kg)time sequence between doses Saturated Solution__________________________________________________________________________10 normal(every 3 hours)13 normal(every 3 hours)16 Mild to moderate degenerative changes.(every 3 hours) Hydropic degeneration.20 Moderate generalized degenerative(every 3 hours) changes. Hydropic degeneration. 7 Mild generalized degenerative changes. (every 24 hours) Cloudy swelling.__________________________________________________________________________
The following procedure was utilized to test the anti-microbal activity of the platinum complexes. The tests were performed with Escherichia coli-wild type, growing in test tube cultures. Using standardized techniques, growth in the medium was examined after the incorporation of the various test chemicals, using the increase in the optical density of the medium as against time. The bacteria were also periodically examined under a phase contrast microscope for evidence of elongation (filmentation). The results of the tests are set forth in Table 9.
TABLE 9__________________________________________________________________________Summary of Bacterial Studies with "Platinum-Uracil Blues"__________________________________________________________________________ Optical Density of Bacterial Cultures 11:45 a.m. 12:45 p.m. 1:45 p.m. 2:45 p.m.Compound ppm 9:30 a.m. 10:45 a.m. microscopic microscopic microscopic microscopic__________________________________________________________________________Control 0 .19 .32 .46 normal .62 normal .85 normal .95 normalcis-Pt(NH.sub.3).sub.2 Cl.sub.2 7 .19 .31 .44 2× 50% .62 2-4× 20% .74 2-6× 40% .78 2-6× 20%cis-diaquodiammine-Pt(II)- 5 .16 .30 .43 normal .54 normal .77 normal .90 normal6-methyluracil(prepared as in Ex. 1) 10 .18 .32 .45 normal .72 normal .90 normal 1.00 normal 20 .18 .32 .45 normal .74 normal .96 normal 1.00 normal 40 .17 .31 .42 normal .68 < normal .90 normal .90 normalcis-diaquodiammine-Pt(II)- 5 .19 .25 .39 clumping .64 clumping .80 some .90 someuracil clumping clumping(Ex. 1) 10 .21 .28 41 clumping .68 clumping .85 clumping 1.00 clumping 20 .23 .29 40 clumping .68 clumping .90 clumping .97 clumping 40 .25 .30 42 clumping .53 clumping .72 extreme .75 extreme clumping clumping__________________________________________________________________________ 12:00 p.m. 1:00 p.m. 3:20 p.m.Compound ppm 9:30 a.m. 11:00 a.m. microscopic microscopic 2:00 p.m. microscopic__________________________________________________________________________Control 0 .14 .29 .49 normal .75 normal .94 .95 normalcis-Pt(NH.sub.3).sub.2 Cl.sub.2 10 .12 .26 .37 2-4× 60% .49 2-8× 60% .55 .60 1-10× 90%cis-diaquodiammine-Pt(II)- 5 .13 .24 .44 normal .73 normal 1.00 1.00 normal5,6-dihydrouracil 10 .13 .23 .39 clumping .72 clumping .95 .95 normal(prepared as in Ex. 1) 20 .15 .26 .43 extreme .69 clumping .81 1.00 some clumping clumping 40 .18 .27 .40 extreme .66 clumping .82 1.00 some clumping clumping"Platinum-Acetamide Blue" 5 .19 .32 .48 normal .78 normal 1.00 1.00 normal 10 .27 .32 .32 normal .32< normal .32 .31 < normal 20 .33 .43 .41 tiny cells .41 tiny cells .41 .41 tiny cells 40 .64 .95 .95 tiny cells .81 tiny cells .85 .85 tiny__________________________________________________________________________ cells
The platinum complexes of the invention cause a clumping of the bacteria at fairly low concentrations. For example, the platinum-uracil complex causes clumping at levels of 5 ppm. Higher concentrations increase the clumping and result in eventual killing of the bacteria. The results would appear to indicate that the platinum complexes of the invention are potent anti-bacterial agents at low concentrations on the order of about 40 ppm.
The anti-viral activity of the platinum complexes of the invention was tested according to the following system. The system utilizes the Fowl Pox Virus and the embryonated egg. In the first type, a known viral concentration is incubated with a known amount of a drug to be tested for various periods of time. The innoculum is then injected into the embryonated egg and on approximately day 10, the egg is opened, the chorioallantoic membrane removed and the number of pock lesions counted. This type of test measures the in vitro inactivation of the Fowl Pox Virus by direct interaction with the new drug in a test tube. The second type of tests involves the innoculation of the embryonated egg with a known titer of Fowl Pox Virus. At various times thereafter, a single dose of the compound to be tested is injected onto the chorioallantoic membrane. Since after a period of a few hours the viral particles have disappeared and gone into the "eclipse phase" wherein the virion has been incorporated into the cell and begun its replication cycle, this test demonstrates the ability of the compound tested to enter into the cell and to disrupt the viral multiplication process. The results of these two types of tests are set forth in Tables 10 and 11.
TABLE 10______________________________________In Vitro Viral Inactivation of Fowl Pox Viruswith Platinum-Uracil.sup.x Complex(6 × 10.sup.2 μmg/ml of Pt.Uracil in incubation mixture)Length of incubation (hrs.) Average numberprior to incubation of mixture of pock lesionsinto embryonating eggs. counted per egg % Reduction.sup.1______________________________________0 Virus-Pt. 0 100% Virus-H.sub.2 O 7.51/6 Virus-Pt. 0.3 96.2% Virus-H.sub.2 O 8.01/2 Virus-Pt. 0.5 92.6% Virus-H.sub.2 O 6.81 Virus-Pt. 0 100% Virus-H.sub.2 O 5.42 Virus-Pt. 0.6 90.9% Virus-H.sub.2 O 6.64 Virus-Pt. 0.25 94.7% Virus-H.sub.2 0 4.756 Virus-Pt. 0.3 94.3% Virus-H.sub.2 O 5.28 Virus-Pt. 0 100% Virus-H.sub.2 O 8.026 Virus-Pt. 0 100% Virus-H.sub.2 O 4.6______________________________________ .sup.1 Percent Reduction = (1Pt Blue/H.sub.2 O) × 100 .sup.x cisdiaquodiammine Pt (II)Uracil (Ex. 1)
TABLE 11______________________________________In Vivo Anti-Viral Activity of Platinum-Uracil.sup.xComplex Against Fowl Pox Virus(0.36 mg Pt. Complex/eggElasped time (hrs.) betweeninoculation of FPV onto chorio-allantoic membrane, and subsequent Average number oftreatment with either Pt-Uracil pock lesions counted % Re-complex or sterile distilled H.sub.2 O per egg. duction______________________________________0 Virus-Pt. 0 100% Virus-H.sub.2 O 6.751/6 Virus-Pt. 1.25 78.3% Virus-H.sub.2 O 5.751/2 Virus-Pt. 1.0 76.8% Virus-H.sub.2 O 4.31 Virus-Pt. 0 100% Virus-H.sub.2 O 7.52 Virus-Pt. 0.4 99.9% Virus-H.sub.2 O 6.84 Virus-Pt. 1.6 79.5% Virus-H.sub.2 O 7.8______________________________________ .sup.x cisdiaquodiammine Pt (II)Uracil (Ex. 1)
For the tube inactivation tests, it was found that the virus is completely inactivated almost immediately upon exposure to the platinum-uracil complex. The inactivation of viable virions closely approaches 100%. This level remains at approximately 100% for up to 26 hours of incubation. This in vitro test demonstrates the extremely effective anti-viral activity of the platinum complexes of the invention.
In Table 12, the in vivo inactivation results indicate that up to four hours after the viral innoculation, the platinum-uracil complex is still inhibiting the number of pock lesions to provide a 68% reduction in the number of such lesions. A repetition of this test is given in Table 12.
TABLE 12______________________________________In Vivo Anti-Viral Activity of Platinum-Uracil.sup.xComplex Against Fowl Pox Virus(0.36 mg Pt. Blue/egg)Elapsed time (hrs.) betweeninoculation of FPV onto chorio-allantoic membrane, and subsequent Average number oftreatment with either Pt-Uracil pock lesions counted % Re-complex or sterile distilled H.sub.2 O. per egg. duction______________________________________0 Virus-Pt 0.6 91.1 Virus-H.sub.2 O 6.81/6 Virus-Pt 0.7 90.4 Virus-H.sub.2 O 7.01/2 Virus-Pt 1.0 88.1 Virus-H.sub.2 O 8.41 Virus-Pt 1.6 82.6 Virus-H.sub.2 O 9.22 Virus-Pt 2.5 69.5 Virus-H.sub.2 O 8.24 Virus-Pt 3.25 68.3 Virus-H.sub.2 O 10.25______________________________________ .sup.x Cisdiaquodiammine Pt (II)Uracil (Ex. 1)
Again, after four hours, approximately 80% reduction in the number of pock lesions is apparent after innoculation of the virus. | A platinum-[2,4-dioxopyrimidine] complex and pharmaceutical composition suitable as an anti-tumor, anti-bacterial and anti-viral agent and process for the manufacture thereof comprising reacting a 2,4-dioxopyrimidine having the formula: ##STR1## wherein R 1 , R 2 , R 3 and R 4 are suitable substituents with cis-diaquodiamineplatinum (II). | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to the art of magnetic resonance spectroscopy. It finds particular application in conjunction with in-vivo examinations and will be described with particular reference thereto. However, it is to be appreciated that the invention may find further application in conjunction with the spectroscopic examination of localized regions for imaging, chemical shift analysis, and the like.
When examining a complex structure, such as a region of a human patient, there are numerous different chemical compounds within the magnetic resonance examination region. To isolate a small volume of the region of interest, or voxel, two techniques are commonly employed--phase encoding techniques and voxel localization techniques. In phase encoding techniques, phase encoding gradients are applied across the sample such that phase can be used to obtain spatial encoding. In voxel localization, the signal is only recovered from a small volumetric element, or voxel.
More specifically, phase encoding techniques typically provide spatial definition over a region whose size is defined by the sensitive volume of the receiver coil. Because this sensitive volume is determined by the receiver coil geometry, it is substantially fixed from study to study. There is little latitude for defining or adjusting the region over which phase encoding occurs. This presents difficulties for spectroscopy because no allowance is made for avoiding regions of large magnetic field inhomogeneities, such as the boundaries between materials with different susceptibilities. These field inhomogeneities degrade water suppression and spatial resolution. Also, it is often desirable to avoid certain regions of the sample. For example, if fat layers are included in the sensitive volume, they can obscure the spectra due to "leakage" of the point-spread function between neighboring voxels. Fat signals are also much larger than the metabolites commonly of interest. Thus, the fat signals can degrade the dynamic range required to detect low concentrations of metabolites.
Voxel localization techniques, such as the technique described in U.S. Pat. No. 4,771,242, recover the signal only from a small voxel in the sample. To map or measure chemical concentrations over an extended region, a plurality of single voxel experiments are conducted. In each repetition, the voxel is defined at a different location within the sample. Although this technique is accurate, it tends to be time consuming.
In another voxel localization technique described in "In Vivo 1H NMR Spectroscopy of the Human Brain by Spatial Localization and Imaging Techniques", by P. Luyten, et al., SMRM Book of Abstracts, page 327 (1988), a volume is selected with refocused stimulated echoes. This volume selection technique utilizes a series of 90° refocusing pulses. Phase encoding for one or two dimensional spectroscopic imaging is combined with the volume selection in order to suppress unwanted lipid signals from surrounding tissues. Although this technique enables subvoxels to be defined in the voxel, the Luyten technique has several drawbacks. First, the 90° refocussing pulses only recover half the signal--the other half is lost. Further, spoiler gradient pulses for dephasing spurious echoes must be primarily the same polarity. Unlike opposite polarity spoiler pulses which provide for cancellation of gradient eddy currents, the unipolar spoiler pulses tend to promote eddy current degradation of the linewidths.
The present invention contemplates a new and improved spectroscopy technique which overcomes the above referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method of phase encoding localized magnetic resonance spectroscopy is provided. A binomial 90° excitation pulse is applied to excite resonance at certain frequencies without exciting resonance at other frequencies. Magnetic field gradients and radio frequency pulses are applied to manipulate the nuclei such that only nuclei within a selected volumetric element contribute to a recovered magnetic resonance signal. The applied magnetic field gradients include phase encoding gradients along one, two, or three axes such that the magnetic resonance signal is phase encoded relative to at least one spatial dimension of the volumetric element. The procedure is repeated with a plurality of phase encoding gradient steps.
In accordance with a more limited aspect of the present invention, bipolar spoiler magnetic field gradients are applied to dephase spurious echoes.
In accordance with another aspect of the present invention, an apparatus is provided including means for performing each of the foregoing steps.
One advantage of the present invention is that it improves the signal-to-noise ratio.
Another advantage of the present invention is that it optimizes field homogeneity. The size of the region of interest is selectively restrictable which avoids regions that have components that may degrade the dynamic range or introduce unwanted peaks.
Another advantage of the present invention is that it provides greater flexibility in defining spatial resolution. Aliasing signals from outside of the region of interest can be eliminated.
A further advantage of the present invention is that it reduces eddy current signal degradation. Antisymmetric spoiler pulses provide for self-cancellation of eddy currents.
Yet another advantage of the present invention is that it produces metabolic maps over a selected region. The region of interest is subdivided by phase encoding to define a plurality of subvoxels.
Another advantage is that sub-voxels may be added to improve signal-to-noise ratio over defined regions.
Still further advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various steps or arrangements of steps and in various components or arrangements of components. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a diagrammatic illustration of a magnetic resonance spectroscopy apparatus in accordance with the present invention; and,
FIG. 2 is a diagrammatic illustration of a radio frequency and magnetic field gradient pulse sequence applied by the apparatus of FIG. 1 to collect spectral data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a main magnetic field means A generates a substantially uniform, main magnetic field through an examination region 10. The main magnetic field causes a preferential alignment of the magnetization of nuclei, such as the protons in hydrogen nuclei, within the examination region. The main magnetic field means includes a plurality of annular magnets 12, such as resistive or superconducting magnets, and a main field control means 14. The main magnetic field means may also include various shimming structures and coils, as are known in the art, for improving the uniformity of the main magnetic field.
A gradient magnetic field means B selectively causes magnetic field gradients across the main magnetic field in the examination region. In the preferred embodiment, the gradients are caused along three orthogonal axes, commonly denoted x, y, and z. The magnetic field is generated by a plurality of gradient coils 20 that are controlled by a gradient control means or circuit 22. The gradient control means applies current pulses to the gradient coils of the appropriate magnitude, duration, and periodicity to cause the gradient magnetic field pulses denoted in FIG. 2. Each applied gradient varies linearly across the examination region 10 and defines a corresponding continuum of planar regions thereacross, each with a unique magnetic field strength. The rate of change or steepness of the gradient is controlled by the amplitude or strength of the corresponding magnetic field gradient pulse. The gradient control B under control of a sequence controller C applies slice-selecting, phase encoding, and/or spoiler pulses on each of the x,y, or z gradients.
A radio frequency means D transmits radio frequency signals into the examination region. More particularly, a radio frequency coil 30 surrounds the patient or subject portion in the examination region. A radio frequency transmitter 32 sends appropriate current pulses to the radio frequency coil to cause binomial 90° radio frequency pulses, 180° magnetization refocusing pulses, and the like. More specifically, the sequence controller C includes a means for generating a 1331 90° binomial excitation pulse and a refocusing pulse means for generating 180° refocusing pulses.
The resonance frequency for a given nuclei is proportional to the product of its gyromagnetic ratio and the strength of the surrounding magnetic field. The binomial excitation pulse includes bands of frequencies relative to the surrounding magnetic field strength which are excited and bands of frequencies which are suppressed. The frequency bands of the binomial pulse are selected relative to the main magnetic field and the gyromagnetic ratio of the nuclei such that resonance is selectively excited at frequencies of interest and suppressed in other selected frequencies. The excited and suppressed nuclei can both be the same atom, such as hydrogen, but bound to surrounding atoms in different ways. The chemical bonding sufficiently affects the resonance frequency that, for example, hydrogen atoms in water or brain tissue can be distinguished from hydrogen atoms in fat, or hydrogen atoms in certain metabolites.
When the refocusing pulses are applied in the presence of a magnetic field gradient, the surrounding magnetic field is the sum of the gradient and the main magnetic fields. Accordingly, the 180° refocusing pulses have a range or spectrum of frequencies which refocus the magnetization of the resonating nuclei in only a limited region. The width or size of the limited region along the gradient direction is determined by the strength of the magnetic field gradient and the frequency bandwidth of the refocusing pulse. For simplicity, it is preferred that the 180° pulse generator generate a fixed frequency bandwidth refocusing pulse and that the slice select gradient field control means 22 apply a slice select gradient of selectable magnitude. The magnitude of the slice select gradient is then adjusted in order to select the width of the defined region or voxel. The voxel can be shifted by applying an offset to the transmitted frequency during each of the slice selecting 180° pulses.
A sequence control means D controls the gradient and radio frequency means in accordance with the sequence of FIG. 2. The binomial pulse generating means selectively excites resonance of the nuclei of interest and suppresses other selected nuclei within the examination region by applying a binomial 90° excitation pulse 40, such as a 1331 pulse. The numerals of the pulse designation indicate the relative pulse length at constant height or height of constant length and the bars indicate the polarity. Once the selected nuclei are excited to resonance, phase encoding gradient pulses 42, 44 and 46 are applied along the axes which are to be subdivided.
Spoiler gradients 50, 52 are applied symmetrically to either side of a concurrently applied refocusing pulse 54 and slice select gradient 56. In the illustrated embodiment, the x axis slice select gradient is relatively small, i.e. not very steep. This causes a relatively wide slice or slab to be defined along the x axis. The x phase encoding gradient enables this relatively large dimension to be subdivided.
Spoiler pulses 60 and 62 along the x axis and spoiler pulses 64 and 66 along the z axis are applied symmetrically to either side of a concurrently applied 180° refocusing pulse 68 and a y axis slice select gradient 70. This selectively refocuses the magnetization within a rectangular continuum defined at the intersection of the x axis slice and the y axis slice.
The first refocusing pulse 54 causes the magnetization vectors within the x axis slice to commence rephasing while those outside of the slice continue to dephase. Normally, the rephasing magnetizations would come completely back into phase, creating a first spin echo.
The second refocusing pulse 68 is applied after the first refocusing pulse 54. The second pulse refocuses the magnetization of nuclei in the region at the intersection of the x and y gradient planes toward a spin echo. The second refocusing pulse refocuses the magnetization in the y axis defined planar region causing it to rephase toward a spin echo. The magnetizations lying in the second planar region, which are not in the first planar region, have been dephasing since the excitation pulse 40. However, the magnetization vectors which were first refocused by the first refocusing pulse 54 and were subsequently refocused by the second refocusing pulse 68 will refocus into an echo. Thus, the magnetization of nuclei in the region of intersection between the first and second slices refocuses toward a spin echo at a different time from other nuclei in the examination region and are readily segregated.
The volume of interest is further defined by applying a third refocusing pulse 72 concurrently with a z gradient slice select pulse 74. The magnitude of the slice select gradient 74 again determines the width of the slice or slab within which the magnetizations are refocused. Spoiler pulses 76, 78 are applied along the x axis and spoiler pulses 80, 82 applied along the z axis are applied to either side of the third slice select pulse. Again, the third refocusing pulse refocuses the magnetization of all the nuclei within the third or z axis slice. The magnetization from within the volume produces a spin echo 84 at a different time from magnetization outside of the voxel defined by the intersection of the three slices. A radio frequency receiver 90 receives the resultant radio frequency spin echo signal data.
The phase encoded gradient 42 causes a phase encoding along the x axis and the phase encoding gradient 46 causes an analogous phase encoding along the z axis. These two encoded phases enable relative position along the x and z axis to be resolved. The x and z phase encodings each vary in steps in accordance with the steps applied by the phase encode gradients 42, 46 in subsequent repetitions. When the phase encode gradient 44 is applied along the y axis, the magnetic resonance echo signals can be resolved along all three dimensions. Analogously, the phase encoding may be limited to one direction leaving the other two directions limited by the respective slice widths or voxel dimensions.
In addition, oblique voxels may be contained by defining slice select and phase encoding pulses simultaneously on more than one axis such that the vector sum of the gradient pulses defines a voxel that is oriented oblique to the physical gradient axes.
The effective spatial resolution is controlled by changing the amplitude and/or number of phase encoding steps which change the size and/or number of sub-voxels. The dimensionality of the sub-voxels is determined by the number of axes along which phase encoding is performed.
A processor 92 Fourier transforms the resulting data to provide a set of chemical shift spectra where each spectrum represents the chemical composition of a sub-voxel centered at a particular point in space. The effective spatial resolution and signal-to-noise can also be manipulated by adjusting the size of the Fourier transform, e.g. by zero-padding, as is known in the art, or by combining the signal from adjacent sub-voxels in order to increase the signal-to-noise. The resultant spectra are stored in an image spectra memory means 94.
The spectra may be displayed on a video monitor 96 in a two dimensional array in order to visualize the distribution of chemical compounds over a region of space. Each element in the array may be a single value, indicative of a color, two values - one to be displayed as color or hue and the other to control intensity, or the like. The values are based on a spectral analysis performed by the processor. The analysis preferably generates values, a color or hue value, which substance(s) are present in the sub-voxel, and an intensity value, which is indicative of the concentration of the substance(s), or the like. In this manner, a "map" is generated of the sample, showing the distribution of chemicals within the sample.
The invention has been described with reference to the preferred embodiment. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such alterations and modifications insofar as they come within the scope of the appended claims or the equivalents thereof. | Magnetic resonance is excited in first selected dipoles and suppressed in second selected dipoles in an examination region (10) by the application of a binomial 90° pulse (40). The induced resonance is phase encoded along at least two axes by phase encode gradients (42, 44). Concurrently, an RF refocussing pulse (54) and a slice select gradient pulse (56) are applied. Analogous pulse pairs (68, 70; 72, 74) are applied once with the slice select gradient along each of three mutual orthogonal axes such that a voxel or volume defined by the intersection of the three slices is defined. A magnetic resonance echo (84) is allowed to form, which echo is attributable to the resonating dipoles within the defined voxel. The phase encoding gradients have divided the voxel into subvoxels along the respective axes. The resultant magnetic resonance echo signals are Fourier transformed (92) into sets of chemical spectra corresponding to each subvoxel and displayed in a two dimensional image representation on a video monitor (96). | 6 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of United Kingdom Application No. 1013266.0, filed Aug. 6, 2010, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a fan assembly. In a preferred embodiment, the present invention relates to a fan heater for creating a warm air current in a room, office or other domestic environment.
BACKGROUND OF THE INVENTION
[0003] A conventional domestic fan typically includes a set of blades or vanes mounted for rotation about an axis, and drive apparatus for rotating the set of blades to generate an air flow. The movement and circulation of the air flow creates a ‘wind chill’ or breeze and, as a result, the user experiences a cooling effect as heat is dissipated through convection and evaporation.
[0004] Such fans are available in a variety of sizes and shapes. For example, a ceiling fan can be at least 1 m in diameter, and is usually mounted in a suspended manner from the ceiling to provide a downward flow of air to cool a room. On the other hand, desk fans are often around 30 cm in diameter, and are usually free standing and portable. Floor-standing tower fans generally comprise an elongate, vertically extending casing around 1 m high and housing one or more sets of rotary blades for generating an air flow. An oscillating mechanism may be employed to rotate the outlet from the tower fan so that the air flow is swept over a wide area of a room.
[0005] Fan heaters generally comprise a number of heating elements located either behind or in front of the rotary blades to enable a user to heat the air flow generated by the rotating blades. The heating elements are commonly in the form of heat radiating coils or fins. A variable thermostat, or a number of predetermined output power settings, is usually provided to enable a user to control the temperature of the air flow emitted from the fan heater.
[0006] A disadvantage of this type of arrangement is that the air flow produced by the rotating blades of the fan heater is generally not uniform. This is due to variations across the blade surface or across the outward facing surface of the fan heater. The extent of these variations can vary from product to product and even from one individual fan heater to another. These variations result in the generation of a turbulent, or ‘choppy’, air flow which can be felt as a series of pulses of air and which can be uncomfortable for a user. A further disadvantage resulting from the turbulence of the air flow is that the heating effect of the fan heater can diminish rapidly with distance.
[0007] In a domestic environment it is desirable for appliances to be as small and compact as possible due to space restrictions. It is undesirable for parts of the appliance to project outwardly, or for a user to be able to touch any moving parts, such as the blades. Fan heaters tend to house the blades and the heat radiating coils within a cage or apertured casing to prevent user injury from contact with either the moving blades or the hot heat radiating coils, but such enclosed parts can be difficult to clean. Consequently, an amount of dust or other detritus can accumulate within the casing and on the heat radiating coils between uses of the fan heater. When the heat radiating coils are activated, the temperature of the outer surfaces of the coils can rise rapidly, particularly when the power output from the coils is relatively high, to a value in excess of 700° C. Consequently, some of the dust which has settled on the coils between uses of the fan heater can be burnt, resulting in the emission of an unpleasant smell from the fan heater for a period of time.
[0008] Our co-pending patent application PCT/GB2010/050272 describes a fan heater which does not use caged blades to project air from the fan heater. Instead, the fan heater comprises a base which houses a motor-driven impeller for drawing a primary air flow into the base, and an annular nozzle connected to the base and comprising an annular mouth through which the primary air flow is emitted from the fan. The nozzle defines a central opening through which air in the local environment of the fan assembly is drawn by the primary air flow emitted from the mouth, amplifying the primary air flow to generate an air current. Without the use of a bladed fan to project the air current from the fan heater, a relatively uniform air current can be generated and guided into a room or towards a user. In one embodiment a heater is located within the nozzle to heat the primary air flow before it is emitted from the mouth. By housing the heater within the nozzle, the user is shielded from the hot external surfaces of the heater.
SUMMARY OF THE INVENTION
[0009] In a first aspect the present invention provides a nozzle for a fan assembly for creating an air current, the nozzle comprising an air inlet for receiving an air flow, means for heating a first portion of the air flow, means for diverting a second portion of the air flow away from the heating means, first channel means for conveying the first portion of the air flow to at least one air outlet of the nozzle, the nozzle defining an opening through which air from outside the nozzle is drawn by the air flow emitted from the at least one air outlet, and second channel means for conveying the second portion of the air flow along an internal surface of the nozzle.
[0010] To cool part of the nozzle, the nozzle includes means for diverting a second portion of the air flow away from the heating means, and second channel means for conveying the second portion of the air flow along an internal surface of the nozzle.
[0011] The dividing means may be arranged to divert both a second portion and a third portion of the air flow away from the heating means. The second channel means may be arranged to convey the second portion of the air flow along a first internal surface of the nozzle, for example the internal surface of an inner annular section of the nozzle, whereas third channel means may be arranged to convey the third portion of the air flow along a second internal surface of the nozzle, for example the internal surface of the outer annular section of the nozzle.
[0012] In a second aspect, the present invention provides a nozzle for a fan assembly for creating an air current, the nozzle comprising an air inlet for receiving an air flow, means for heating a first portion of the air flow, means for diverting a second portion of the air flow away from the heating means, and for diverting a third portion of the air flow away from the heating means, first channel means for conveying the first portion of the air flow to at least one air outlet of the nozzle, the nozzle defining an opening through which air from outside the nozzle is drawn by the air flow emitted from the at least one air outlet, and second channel means for conveying the second portion of the air flow along a first internal surface of the nozzle, and third channel means for conveying the third portion of the air flow along a second internal surface of the nozzle.
[0013] It may be found that, depending on the temperature of the first portion of the air flow, sufficient cooling of the external surfaces of the nozzle may be provided without having to emit the both the second and the third portions of the air flow through separate air outlets. For example, the first and the third portions of the air flow may be recombined downstream from the heating means.
[0014] This second portion of the air flow may also merge with the first portion of the air flow within the nozzle, or it may be emitted through at least one air outlet of the nozzle. Thus, the nozzle may have a plurality of air outlets for emitting air at different temperatures. One or more first air outlets may be provided for emitting the relatively hot first portion of the air flow which has been heated by the heating means, whereas one or more second air outlets may be provided for emitting relatively cold second portion of the air flow which has by-passed the heating means.
[0015] The different air paths thus present within the nozzle may be selectively opened and closed by a user to vary the temperature of the air flow emitted from the fan assembly. The nozzle may include a valve, shutter or other means for selectively closing one of the air paths through the nozzle so that all of the air flow leaves the nozzle through either the first air outlet(s) or the second air outlet(s). For example, a shutter may be slidable or otherwise moveable over the outer surface of the nozzle to selectively close either the first air outlet(s) or the second air outlet(s), thereby forcing the air flow either to pass through the heating means or to by-pass the heating means. This can enable a user to change rapidly the temperature of the air flow emitted from the nozzle.
[0016] Alternatively, or additionally, the nozzle may be arranged to emit the first and second portions of the air flow simultaneously. In this case, at least one second air outlet may be arranged to direct at least part of the second portion of the air flow over an external surface of the nozzle. This can keep that external surface of the nozzle cool during use of the fan assembly. Where the nozzle comprises a plurality of second air outlets, the second air outlets may be arranged to direct substantially the entire second portion of the air flow over at least one external surface of the nozzle. The second air outlets may be arranged to direct the second portion of the air flow over a common external surface of the nozzle, or over a plurality of external surfaces of the nozzle, such as front and rear surfaces of the nozzle.
[0017] The, or each, first air outlet is preferably arranged to direct the first portion of the air flow over the second portion of the air flow so that the relatively cold second portion of the air flow is sandwiched between the relatively hot first portion of the air flow and the external surface of the nozzle, thereby providing a layer of thermal insulation between the relatively hot first portion of the air flow and the external surface of the nozzle.
[0018] All of the first and second air outlets are preferably arranged to emit the air flow through the opening in order to maximize the amplification of the air flow emitted from the nozzle through the entrainment of air external to the nozzle. Alternatively, at least one second air outlet may be arranged to direct the air flow over an external surface of the nozzle which is remote from the opening. For example, where the nozzle has an annular shape, one of the second air outlets may be arranged to direct a portion of the air flow over the external surface of an inner annular section of the nozzle so that that portion of the air flow emitted from that second air outlet passes through the opening, whereas another one of the second air outlets may be arranged to direct another portion of the air flow over the external surface of an outer annular section of the nozzle.
[0019] The diverting means may comprise at least one baffle, wall or other air diverting surface located within the nozzle for diverting the second portion of the air flow away from the heating means, and at least one other baffle, wall or other air diverting surface located within the nozzle for diverting the third portion of the air flow away from the heating means. The diverting means may be integral with or connected to one of the casing sections of the nozzle. The diverting means may conveniently form part of, or be connected to, a chassis for retaining the heating means within the nozzle. Where the diverting means is arranged to divert both a second portion of the air flow and a third portion of the air flow away from the heating means, the diverting means may comprise two mutually spaced parts of the chassis.
[0020] Preferably, the nozzle comprises means for separating the first channel means from the second channel means. The separating means may be integral with the diverting means for diverting the second portion of the air flow away from the heating means, and thus may comprise at least one side wall of a chassis for retaining the heating means within the nozzle. This can reduce the number of separate components of the nozzle. The nozzle preferably also comprises means for separating the first channel means from the third channel means. This separating means may be integral with the diverting means for diverting the third portion of the air flow away from the heating means, and thus may also comprise at least one side wall of a chassis for retaining the heating means within the nozzle.
[0021] The chassis may comprise first and second side walls configured to retain a heating assembly therebetween. The first and second side walls may form a first channel therebetween, which includes the heating assembly, for conveying the first portion of the air flow to an air outlet of the nozzle. The first side wall and a first internal surface of the nozzle may form a second channel for conveying the second portion of the air flow along the first internal surface, preferably to a second air outlet of the nozzle. The second side wall and a second internal surface of the nozzle may form a third channel for conveying a third portion of the air flow along the second internal surface. This third channel may merge with the first or second channel, or it may convey the third portion of the air flow to an air outlet of the nozzle.
[0022] As mentioned above, the nozzle may comprise an inner annular casing section and an outer annular casing section surrounding the inner casing section, and which together define the opening, and so the separating means may be located between the casing sections. Each casing section is preferably formed from a respective annular member, but each casing section may be provided by a plurality of members connected together or otherwise assembled to form that casing section. The inner casing section and the outer casing section may be formed from plastics material or other material having a relatively low thermal conductivity (less than 1 Wm −1 K −1 ), to prevent the external surfaces of the nozzle from becoming excessively hot during use of the fan assembly.
[0023] The separating means may also define in part one or more air outlets of the nozzle. For example, the, or each, first air outlet for emitting the first portion of the air flow from the nozzle may be located between an internal surface of the outer casing section and part of the separating means. Alternatively, or additionally, the, or each, second air outlet for emitting the second portion of the air flow from the nozzle may be located between an external surface of the inner casing section and part of the separating means. Where the separating means comprises a wall for separating a first channel means from a second channel means, a first air outlet may be located between the internal surface of the outer casing section and a first side surface of the wall, and a second air outlet may be located between the external surface of the inner casing section and a second side surface of the wall.
[0024] The separating means may comprise a plurality of spacers for engaging at least one of the inner casing section and the outer casing section. This can enable the width of at least one of the second channel means and the third channel means to be controlled along the length thereof through engagement between the spacers and said at least one of the inner casing section and the outer casing section.
[0025] The direction in which air is emitted from the air outlet(s) is preferably substantially at a right angle to the direction in which the air flow passes through at least part of the nozzle. Preferably, the air flow passes through at least part of the nozzle in a substantially vertical direction, and the air is emitted from the air outlet(s) in a substantially horizontal direction. The, or each, air outlet is preferably located towards the rear of the nozzle and arranged to direct air towards the front of the nozzle and through the opening. Consequently, each of the first and second channel means may be shaped so as substantially to reverse the flow direction of a respective portion of the air flow.
[0026] The nozzle is preferably annular, and is preferably shaped to divide the air flow into two air streams which flow in opposite directions around the opening. For example, the nozzle may have an interior passage shaped to divide the air flow into these two streams. In this case the heating means is arranged to heat a first portion of each air stream and the diverting means is arranged to divert at least a second portion of each air stream, preferably both a second portion and a third portion of each air stream, away from the heating means. Therefore, in a third aspect the present invention provides a nozzle for a fan assembly for creating an air current, the nozzle comprising an interior passage for receiving an air flow, and for dividing a received air flow into a plurality of air streams, means for heating a first portion of each air stream, means for diverting a second portion of each air stream away from the heating means, first channel means for conveying the first portions of the air streams to at least one air outlet of the nozzle, the nozzle defining an opening through which air from outside the nozzle is drawn by the air flow emitted from the at least one air outlet, and second channel means for conveying the second portions of the air streams along an internal surface of the nozzle.
[0027] These first portions of the air streams may be emitted from a common first air outlet of the nozzle, or they may each be emitted from a respective first air outlet of the nozzle, and together form the first portion of the air flow. These first air outlets may be located on opposite sides of the opening. The second portions of the air streams may be conveyed along a common internal surface of the nozzle, for example the internal surface of the inner casing section of the nozzle, and emitted either from a common second air outlet of the nozzle, or from a respective second air outlet of the nozzle, and together form the second portion of the air flow. Again, these second air outlets may be located on opposite sides of the opening.
[0028] At least part of the heating means may be arranged within the nozzle so as to extend about the opening. Where the nozzle defines a circular opening, the heating means preferably extends at least 270° about the opening and more preferably at least 300° about the opening. Where the nozzle defines an elongate opening, that is, an opening having a height greater than its width, the heating means is preferably located on at least the opposite sides of the opening.
[0029] The heating means may comprise at least one ceramic heater located within the interior passage. The ceramic heater may be porous so that the first portion of the air flow passes through pores in the heating means before being emitted from the first air outlet(s). The heater may be formed from a PTC (positive temperature coefficient) ceramic material which is capable of rapidly heating the air flow upon activation.
[0030] The ceramic material may be at least partially coated in metallic or other electrically conductive material to facilitate connection of the heating means to a controller within the fan assembly for activating the heating means. Alternatively, at least one non-porous, preferably ceramic, heater may be mounted within a metallic frame located within the interior passage and which is connectable to a controller of the fan assembly. The metallic frame preferably comprises a plurality of fins to provide a greater surface area and hence better heat transfer to the air flow, while also providing a means of electrical connection to the heating means.
[0031] The heating means preferably comprises at least one heater assembly. Where the air flow is divided into two air streams, the heating means preferably comprises a plurality of heater assemblies each for heating a first portion of a respective air stream, and the diverting means preferably comprises a plurality of walls each for diverting a second portion of a respective air stream away from a heater assembly. The diverting means may also comprise a second plurality of walls each for diverting a third portion of a respective air stream away from a heater assembly.
[0032] Each air outlet is preferably in the form of a slot, and which preferably has a width in the range from 0.5 to 5 mm. The width of the first air outlet(s) is preferably different from that of the second air outlet(s). In a preferred embodiment, the width of the first air outlet(s) is greater than the width of the second air outlet(s) so that the majority of the air flow passes through the heating means.
[0033] The nozzle may comprise a surface located adjacent the air outlet(s) and over which the air outlet(s) are arranged to direct the air flow emitted therefrom. Preferably, this surface is a curved surface, and more preferably is a Coanda surface. Preferably, the external surface of the inner casing section of the nozzle is shaped to define the Coanda surface. A Coanda surface is a known type of surface over which fluid flow exiting an output orifice close to the surface exhibits the Coanda effect. The fluid tends to flow over the surface closely, almost ‘clinging to’ or ‘hugging’ the surface. The Coanda effect is already a proven, well documented method of entrainment in which a primary air flow is directed over a Coanda surface. A description of the features of a Coanda surface, and the effect of fluid flow over a Coanda surface, can be found in articles such as Reba, Scientific American, Volume 214, June 1966 pages 84 to 92. Through use of a Coanda surface, an increased amount of air from outside the fan assembly is drawn through the opening by the air emitted from the air outlets.
[0034] In a preferred embodiment an air flow is created through the nozzle of the fan assembly.
[0035] In the following description this air flow will be referred to as the primary air flow. The primary air flow is emitted from the air outlet(s) of the nozzle and preferably passes over a Coanda surface. The primary air flow entrains air surrounding the nozzle, which acts as an air amplifier to supply both the primary air flow and the entrained air to the user. The entrained air will be referred to here as a secondary air flow. The secondary air flow is drawn from the room space, region or external environment surrounding the mouth of the nozzle and, by displacement, from other regions around the fan assembly, and passes predominantly through the opening defined by the nozzle. The primary air flow directed over the Coanda surface combined with the entrained secondary air flow equates to a total air flow emitted or projected forward from the opening defined by the nozzle.
[0036] Preferably, the nozzle comprises a diffuser surface located downstream of the Coanda surface. The diffuser surface directs the air flow emitted towards a user's location while maintaining a smooth, even output. Preferably, the external surface of the inner casing section of the nozzle is shaped to define the diffuser surface.
[0037] In a fourth aspect, the present invention provides a fan assembly comprising a nozzle as aforementioned. The fan assembly preferably comprises a base housing said means for creating the air flow, with the nozzle being connected to the base. The base is preferably generally cylindrical in shape, and comprises a plurality of air inlets through which the air flow enters the fan assembly.
[0038] The means for creating an air flow through the nozzle preferably comprises an impeller driven by a motor. This can provide a fan assembly with efficient air flow generation. The motor is preferably a DC brushless motor. This can avoid frictional losses and carbon debris from the brushes used in a traditional brushed motor. Reducing carbon debris and emissions is advantageous in a clean or pollutant sensitive environment such as a hospital or around those with allergies. While induction motors, which are generally used in bladed fans, also have no brushes, a DC brushless motor can provide a much wider range of operating speeds than an induction motor.
[0039] The nozzle is preferably in the form of a casing, preferably an annular casing, for receiving the air flow.
[0040] The heating means need not be located within the nozzle. For example, both the heating means and the diverting means may be located in the base, with the first channel means being arranged to receive a relatively hot first portion of the air flow and to convey the first portion of the air flow to the at least one air outlet, and the second channel means being arranged to receive a relatively cold second portion of the air flow from the base, and to convey the second portion of the air flow over an internal surface of the nozzle. The nozzle may comprise internal walls or baffles for defining the first channel means and second channel means.
[0041] Alternatively, the heating means may be located in the nozzle but the diverting means may be located in the base. In this case, the first channel means may be arranged both to convey the first portion of the air flow from the base to the at least one air outlet and to house the heating means for heating the first portion of the air flow, while the second channel means may be arranged simply to convey the second portion of the air flow from the base over the internal surface of the nozzle.
[0042] Therefore, in a fifth aspect the present invention provides a fan assembly for creating an air current, the fan assembly comprising means for creating an air flow, a casing comprising at least one air outlet, the casing defining an opening through which air from outside the fan assembly is drawn by the air flow emitted from the at least one air outlet, means for heating a first portion of the air flow, means for diverting a second portion of the air flow away from the heating means, first channel means for conveying the first portion of the air flow to said at least one air outlet, and second channel means for conveying the second portion of the air flow along an internal surface of the casing.
[0043] The fan assembly is preferably in the form of a portable fan heater.
[0044] Features described above in connection with the first aspect of the invention are equally applicable to any of the second to fifth aspects of the invention, and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0046] FIG. 1 is a front perspective view, from above, of a fan assembly;
[0047] FIG. 2 is a front view of the fan assembly;
[0048] FIG. 3 is a sectional view taken along line B-B of FIG. 2 ;
[0049] FIG. 4 is an exploded view of the nozzle of the fan assembly;
[0050] FIG. 5 is a front perspective view of the heater chassis of the nozzle;
[0051] FIG. 6 is a front perspective view, from below, of the heater chassis connected to an inner casing section of the nozzle;
[0052] FIG. 7 is a close-up view of region X indicated in FIG. 6 ;
[0053] FIG. 8 is a close-up view of region Y indicated in FIG. 1 ;
[0054] FIG. 9 is a sectional view taken along line A-A of FIG. 2 ;
[0055] FIG. 10 is a close-up view of region Z indicated in FIG. 9 ;
[0056] FIG. 11 is a sectional view of the nozzle taken along line C-C of FIG. 9 ; and
[0057] FIG. 12 is a schematic illustration of a control system of the fan assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0058] FIGS. 1 and 2 illustrate external views of a fan assembly 10 . The fan assembly 10 is in the form of a portable fan heater. The fan assembly 10 comprises a body 12 comprising an air inlet 14 through which a primary air flow enters the fan assembly 10 , and a nozzle 16 in the form of an annular casing mounted on the body 12 , and which comprises at least one air outlet 18 for emitting the primary air flow from the fan assembly 10 .
[0059] The body 12 comprises a substantially cylindrical main body section 20 mounted on a substantially cylindrical lower body section 22 . The main body section 20 and the lower body section 22 preferably have substantially the same external diameter so that the external surface of the upper body section 20 is substantially flush with the external surface of the lower body section 22 . In this embodiment the body 12 has a height in the range from 100 to 300 mm, and a diameter in the range from 100 to 200 mm.
[0060] The main body section 20 comprises the air inlet 14 through which the primary air flow enters the fan assembly 10 . In this embodiment the air inlet 14 comprises an array of apertures formed in the main body section 20 . Alternatively, the air inlet 14 may comprise one or more grilles or meshes mounted within windows formed in the main body section 20 . The main body section 20 is open at the upper end (as illustrated) thereof to provide an air outlet 23 through which the primary air flow is exhausted from the body 12 .
[0061] The main body section 20 may be tilted relative to the lower body section 22 to adjust the direction in which the primary air flow is emitted from the fan assembly 10 . For example, the upper surface of the lower body section 22 and the lower surface of the main body section 20 may be provided with interconnecting features which allow the main body section 20 to move relative to the lower body section 22 while preventing the main body section 20 from being lifted from the lower body section 22 . For example, the lower body section 22 and the main body section 20 may comprise interlocking L-shaped members.
[0062] The lower body section 22 comprises a user interface of the fan assembly 10 . With reference also to FIG. 12 , the user interface comprises a plurality of user-operable buttons 24 , 26 , 28 , 30 for enabling a user to control various functions of the fan assembly 10 , a display 32 located between the buttons for providing the user with, for example, a visual indication of a temperature setting of the fan assembly 10 , and a user interface control circuit 33 connected to the buttons 24 , 26 , 28 , 30 and the display 32 . The lower body section 22 also includes a window 34 through which signals from a remote control 35 (shown schematically in FIG. 12 ) enter the fan assembly 10 . The lower body section 22 is mounted on a base 36 for engaging a surface on which the fan assembly 10 is located. The base 36 includes an optional base plate 38 , which preferably has a diameter in the range from 200 to 300 mm.
[0063] The nozzle 16 has an annular shape, extending about a central axis X to define an opening 40 . The air outlets 18 for emitting the primary air flow from the fan assembly 10 are located towards the rear of the nozzle 16 , and arranged to direct the primary air flow towards the front of the nozzle 16 , through the opening 40 . In this example, the nozzle 16 defines an elongate opening 40 having a height greater than its width, and the air outlets 18 are located on the opposite elongate sides of the opening 40 . In this example the maximum height of the opening 40 is in the range from 300 to 400 mm, whereas the maximum width of the opening 40 is in the range from 100 to 200 mm.
[0064] The inner annular periphery of the nozzle 16 comprises a Coanda surface 42 located adjacent the air outlets 18 , and over which at least some of the air outlets 18 are arranged to direct the air emitted from the fan assembly 10 , a diffuser surface 44 located downstream of the Coanda surface 42 and a guide surface 46 located downstream of the diffuser surface 44 . The diffuser surface 44 is arranged to taper away from the central axis X of the opening 38 . The angle subtended between the diffuser surface 44 and the central axis X of the opening 40 is in the range from 5 to 25°, and in this example is around 7°. The guide surface 46 is preferably arranged substantially parallel to the central axis X of the opening 38 to present a substantially flat and substantially smooth face to the air flow emitted from the mouth 40 . A visually appealing tapered surface 48 is located downstream from the guide surface 46 , terminating at a tip surface 50 lying substantially perpendicular to the central axis X of the opening 40 . The angle subtended between the tapered surface 48 and the central axis X of the opening 40 is preferably around 45°.
[0065] FIG. 3 illustrates a sectional view through the body 12 . The lower body section 22 houses a main control circuit, indicated generally at 52 , connected to the user interface control circuit 33 . The user interface control circuit 33 comprises a sensor 54 for receiving signals from the remote control 35 . The sensor 54 is located behind the window 34 . In response to operation of the buttons 24 , 26 , 28 , 30 and the remote control 35 , the user interface control circuit 33 is arranged to transmit appropriate signals to the main control circuit 52 to control various operations of the fan assembly 10 . The display 32 is located within the lower body section 22 , and is arranged to illuminate part of the lower body section 22 . The lower body section 22 is preferably formed from a translucent plastics material which allows the display 32 to be seen by a user.
[0066] The lower body section 22 also houses a mechanism, indicated generally at 56 , for oscillating the lower body section 22 relative to the base 36 . The operation of the oscillating mechanism 56 is controlled by the main control circuit 52 upon receipt of an appropriate control signal from the remote control 35 . The range of each oscillation cycle of the lower body section 22 relative to the base 36 is preferably between 60° and 120°, and in this embodiment is around 80°. In this embodiment, the oscillating mechanism 56 is arranged to perform around 3 to 5 oscillation cycles per minute. A mains power cable 58 for supplying electrical power to the fan assembly 10 extends through an aperture formed in the base 36 . The cable 58 is connected to a plug 60 .
[0067] The main body section 20 houses an impeller 64 for drawing the primary air flow through the air inlet 14 and into the body 12 . Preferably, the impeller 64 is in the form of a mixed flow impeller. The impeller 64 is connected to a rotary shaft 66 extending outwardly from a motor 68 . In this embodiment, the motor 68 is a DC brushless motor having a speed which is variable by the main control circuit 52 in response to user manipulation of the button 26 and/or a signal received from the remote control 35 . The maximum speed of the motor 68 is preferably in the range from 5,000 to 10,000 rpm. The motor 68 is housed within a motor bucket comprising an upper portion 70 connected to a lower portion 72 . The upper portion 70 of the motor bucket comprises a diffuser 74 in the form of a stationary disc having spiral blades.
[0068] The motor bucket is located within, and mounted on, a generally frusto-conical impeller housing 76 . The impeller housing 76 is, in turn, mounted on a plurality of angularly spaced supports 77 , in this example three supports, located within and connected to the main body section 20 of the base 12 . The impeller 64 and the impeller housing 76 are shaped so that the impeller 64 is in close proximity to, but does not contact, the inner surface of the impeller housing 76 . A substantially annular inlet member 78 is connected to the bottom of the impeller housing 76 for guiding the primary air flow into the impeller housing 76 .
[0069] A flexible sealing member 80 is mounted on the impeller housing 76 . The flexible sealing member prevents air from passing around the outer surface of the impeller housing to the inlet member 78 . The sealing member 80 preferably comprises an annular lip seal, preferably formed from rubber. The sealing member 80 further comprises a guide portion in the form of a grommet for guiding an electrical cable 82 to the motor 68 . The electrical cable 82 passes from the main control circuit 52 to the motor 68 through apertures formed in the main body section 20 and the lower body section 22 of the body 12 , and in the impeller housing 76 and the motor bucket.
[0070] Preferably, the body 12 includes silencing foam for reducing noise emissions from the body 12 . In this embodiment, the main body section 20 of the body 12 comprises a first annular foam member 84 located beneath the air inlet 14 , and a second annular foam member 86 located within the motor bucket.
[0071] The nozzle 16 will now be described in more detail with reference to FIGS. 4 to 11 . With reference first to FIG. 4 , the nozzle 16 comprises an annular outer casing section 88 connected to and extending about an annular inner casing section 90 . Each of these sections may be formed from a plurality of connected parts, but in this embodiment each of the casing sections 88 , 90 is formed from a respective, single molded part. The inner casing section 90 defines the central opening 40 of the nozzle 16 , and has an external surface 92 which is shaped to define the Coanda surface 42 , diffuser surface 44 , guide surface 46 and tapered surface 48 .
[0072] The outer casing section 88 and the inner casing section 90 together define an annular interior passage of the nozzle 16 . As illustrated in FIGS. 9 and 11 , the interior passage extends about the opening 40 , and thus comprises two relatively straight sections 94 a , 94 b each adjacent a respective elongate side of the opening 40 , an upper curved section 94 c joining the upper ends of the straight sections 94 a , 94 b , and a lower curved section 94 d joining the lower ends of the straight 94 a , 94 b . The interior passage is bounded by the internal surface 96 of the outer casing section 88 and the internal surface 98 of the inner casing section 90 .
[0073] As also shown in FIGS. 1 to 3 , the outer casing section 88 comprises a base 100 which is connected to, and over, the open upper end of the main body section 20 of the base 12 . The base 100 of the outer casing section 88 comprises an air inlet 102 through which the primary air flow enters the lower curved section 94 d of the interior passage from the air outlet 23 of the base 12 . Within the lower curved section 94 d , the primary air flow is divided into two air streams which each flow into a respective one of the straight sections 94 a , 94 b of the interior passage.
[0074] The nozzle 16 also comprises a pair of heater assemblies 104 . Each heater assembly 104 comprises a row of heater elements 106 arranged side-by-side. The heater elements 106 are preferably formed from positive temperature coefficient (PTC) ceramic material. The row of heater elements is sandwiched between two heat radiating components 108 , each of which comprises an array of heat radiating fins 110 located within a frame 112 . The heat radiating components 108 are preferably formed from aluminium or other material with high thermal conductivity (around 200 to 400 W/mK), and may be attached to the row of heater elements 106 using beads of silicone adhesive, or by a clamping mechanism. The side surfaces of the heater elements 106 are preferably at least partially covered with a metallic film to provide an electrical contact between the heater elements 106 and the heat radiating components 108 . This film may be formed from screen printed or sputtered aluminium. Returning to FIGS. 3 and 4 , electrical terminals 114 , 116 located at opposite ends of the heater assembly 104 are each connected to a respective heat radiating component 108 . Each terminal 114 is connected to an upper part 118 of a loom for supplying electrical power to the heater assemblies 104 , whereas each terminal 116 is connected to a lower part 120 of the loom. The loom is in turn connected to a heater control circuit 122 located in the main body section 20 of the base 12 by wires 124 . The heater control circuit 122 is in turn controlled by control signals supplied thereto by the main control circuit 52 in response to user operation of the buttons 28 , 30 and/or use of the remote control 35 .
[0075] FIG. 12 illustrates schematically a control system of the fan assembly 10 , which includes the control circuits 33 , 52 , 122 , buttons 24 , 26 , 28 , 30 , and remote control 35 . Two or more of the control circuits 33 , 52 , 122 may be combined to form a single control circuit. A thermistor 126 for providing an indication of the temperature of the primary air flow entering the fan assembly 10 is connected to the heater controller 122 . The thermistor 126 may be located immediately behind the air inlet 14 , as shown in FIG. 3 . The main control circuit 52 supplies control signals to the user interface control circuit 33 , the oscillation mechanism 56 , the motor 68 , and the heater control circuit 124 , whereas the heater control circuit 124 supplies control signals to the heater assemblies 104 . The heater control circuit 124 may also provide the main control circuit 52 with a signal indicating the temperature detected by the thermistor 126 , in response to which the main control circuit 52 may output a control signal to the user interface control circuit 33 indicating that the display 32 is to be changed, for example if the temperature of the primary air flow is at or above a user selected temperature. The heater assemblies 104 may be controlled simultaneously by a common control signal, or they may be controlled by respective control signals.
[0076] The heater assemblies 104 are each retained within a respective straight section 94 a , 94 b of the interior passage by a chassis 128 . The chassis 128 is illustrated in more detail in FIG. 5 . The chassis 128 has a generally annular structure. The chassis 128 comprises a pair of heater housings 130 into which the heater assemblies 104 are inserted. Each heater housing 130 comprises an outer wall 132 and an inner wall 134 . The inner wall 134 is connected to the outer wall 132 at the upper and lower ends 138 , 140 of the heater housing 130 so that the heater housing 130 is open at the front and rear ends thereof. The walls 132 , 134 thus define a first air flow channel 136 which passes through the heater assembly 104 located within the heater housing 130 .
[0077] The heater housings 130 are connected together by upper and lower curved portions 142 , 144 of the chassis 128 . Each curved portion 142 , 144 also has an inwardly curved, generally U-shaped cross-section. The curved portions 142 , 144 of the chassis 128 are connected to, and preferably integral with, the inner walls 134 of the heater housings 130 . The inner walls 134 of the heater housings 130 have a front end 146 and a rear end 148 . With reference also to FIGS. 6 to 9 , the rear end 148 of each inner wall 134 also curves inwardly away from the adjacent outer wall 132 so that the rear ends 148 of the inner walls 134 are substantially continuous with the curved portions 142 , 144 of the chassis 128 .
[0078] During assembly of the nozzle 16 , the chassis 128 is pushed over the rear end of the inner casing section 90 so that the curved portions 142 , 144 of the chassis 128 and the rear ends 148 of the inner walls 134 of the heater housings 130 are wrapped around the rear end 150 of the inner casing section 90 . The inner surface 98 of the inner casing section 90 comprises a first set of raised spacers 152 which engage the inner walls 134 of the heater housings 130 to space the inner walls 134 from the inner surface 98 of the inner casing section 90 . The rear ends 148 of the inner walls 134 also comprise a second set of spacers 154 which engage the outer surface 92 of the inner casing section 90 to space the rear ends of the inner walls 134 from the outer surface 92 of the inner casing section 90 .
[0079] The inner walls 134 of the heater housing 130 of the chassis 128 and the inner casing section 90 thus define two second air flow channels 156 . Each of the second flow channels 156 extends along the inner surface 98 of the inner casing section 90 , and around the rear end 150 of the inner casing section 90 . Each second flow channel 156 is separated from a respective first flow channel 136 by the inner wall 134 of the heater housing 130 . Each second flow channel 156 terminates at an air outlet 158 located between the outer surface 92 of the inner casing section 90 and the rear end 148 of the inner wall 134 . Each air outlet 158 is thus in the form of a vertically-extending slot located on a respective side of the opening 40 of the assembled nozzle 16 . Each air outlet 158 preferably has a width in the range from 0.5 to 5 mm, and in this example the air outlets 158 have a width of around 1 mm.
[0080] The chassis 128 is connected to the inner surface 98 of the inner casing section 90 .
[0081] With reference to FIGS. 5 to 7 , each of the inner walls 134 of the heater housings 130 comprises a pair of apertures 160 , each aperture 160 being located at or towards a respective one of the upper and lower ends of the inner wall 134 . As the chassis 128 is pushed over the rear end of the inner casing section 90 , the inner walls 134 of the heater housings 130 slide over resilient catches 162 mounted on, and preferably integral with, the inner surface 98 of the inner casing section 90 , which subsequently protrude through the apertures 160 . The position of the chassis 128 relative to the inner casing section 90 can then be adjusted so that the inner walls 134 are gripped by the catches 162 . Stop members 164 mounted on, and preferably also integral with, the inner surface 98 of the inner casing section 90 may also serve to retain the chassis 128 on the inner casing section 90 .
[0082] With the chassis 128 connected to the inner casing section 90 , the heater assemblies 104 are inserted into the heater housings 130 of the chassis 128 , and the loom connected to the heater assemblies 104 . Of course, the heater assemblies 104 may be inserted into the heater housings 130 of the chassis 128 prior to the connection of the chassis 128 to the inner casing section 90 . The inner casing section 90 of the nozzle 16 is then inserted into the outer casing section 88 of the nozzle 16 so that the front end 166 of the outer casing section 88 enters a slot 168 located at the front of the inner casing section 90 , as illustrated in FIG. 9 . The outer and inner casing sections 88 , 90 may be connected together using an adhesive introduced to the slot 168 .
[0083] The outer casing section 88 is shaped so that part of the inner surface 96 of the outer casing section 88 extends around, and is substantially parallel to, the outer walls 132 of the heater housings 130 of the chassis 128 . The outer walls 132 of the heater housings 130 have a front end 170 and a rear end 172 , and a set of ribs 174 located on the outer side surfaces of the outer walls 132 and which extend between the ends 170 , 172 of the outer walls 132 . The ribs 174 are configured to engage the inner surface 96 of the outer casing section 88 to space the outer walls 132 from the inner surface 96 of the outer casing section 88 . The outer walls 132 of the heater housings 130 of the chassis 128 and the outer casing section 88 thus define two third air flow channels 176 . Each of the third flow channels 176 is located adjacent and extends along the inner surface 96 of the outer casing section 88 . Each third flow channel 176 is separated from a respective first flow channel 136 by the outer wall 132 of the heater housing 130 . Each third flow channel 176 terminates at an air outlet 178 located within the interior passage, and between the rear end 172 of the outer wall 132 of the heater housing 130 and the outer casing section 88 . Each air outlet 178 is also in the form of a vertically-extending slot located within the interior passage of the nozzle 16 , and preferably has a width in the range from 0.5 to 5 mm. In this example the air outlets 178 have a width of around 1 mm.
[0084] The outer casing section 88 is shaped so as to curve inwardly around part of the rear ends 148 of the inner walls 134 of the heater housings 130 . The rear ends 148 of the inner walls 134 comprise a third set of spacers 182 located on the opposite side of the inner walls 134 to the second set of spacers 154 , and which are arranged to engage the inner surface 96 of the outer casing section 88 to space the rear ends of the inner walls 134 from the inner surface 96 of the outer casing section 88 . The outer casing section 88 and the rear ends 148 of the inner walls 134 thus define a further two air outlets 184 . Each air outlet 184 is located adjacent a respective one of the air outlets 158 , with each air outlet 158 being located between a respective air outlet 184 and the outer surface 92 of the inner casing section 90 . Similar to the air outlets 158 , each air outlet 184 is in the form of a vertically-extending slot located on a respective side of the opening 40 of the assembled nozzle 16 . The air outlets 184 preferably have the same length as the air outlets 158 . Each air outlet 184 preferably has a width in the range from 0.5 to 5 mm, and in this example the air outlets 184 have a width of around 2 to 3 mm. Thus, the air outlets 18 for emitting the primary air flow from the fan assembly 10 comprise the two air outlets 158 and the two air outlets 184 .
[0085] Returning to FIGS. 3 and 4 , the nozzle 16 preferably comprises two curved sealing members 186 , 188 each for forming a seal between the outer casing section 88 and the inner casing section 90 so that there is substantially no leakage of air from the curved sections 94 c , 94 d of the interior passage of the nozzle 16 . Each sealing member 186 , 188 is sandwiched between two flanges 190 , 192 located within the curved sections 94 c , 94 d of the interior passage. The flanges 190 are mounted on, and preferably integral with, the inner casing section 90 , whereas the flanges 192 are mounted on, and preferably integral with, the outer casing section 88 . As an alternative to preventing the air flow from leaking from the upper curved section 94 c of the interior passage, the nozzle 16 may be arranged to prevent the air flow from entering this curved section 94 c . For example, the upper ends of the straight sections 94 a , 94 b of the interior passage may be blocked by the chassis 128 or by inserts introduced between the inner and outer casing sections 88 , 90 during assembly.
[0086] To operate the fan assembly 10 the user presses button 24 of the user interface, or presses a corresponding button of the remote control 35 to transmit a signal which is received by the sensor of the user interface circuit 33 . The user interface control circuit 33 communicates this action to the main control circuit 52 , in response to which the main control circuit 52 activates the motor 68 to rotate the impeller 64 . The rotation of the impeller 64 causes a primary air flow to be drawn into the body 12 through the air inlet 14 . The user may control the speed of the motor 68 , and therefore the rate at which air is drawn into the body 12 through the air inlet 14 , by pressing button 26 of the user interface or a corresponding button of the remote control 35 . Depending on the speed of the motor 56 , the primary air flow generated by the impeller 52 may be between 10 and 30 litres per second. The primary air flow passes sequentially through the impeller housing 76 and the open upper end of the main body portion 22 to enter the lower curved section 94 d of the interior passage of the nozzle 16 . The pressure of the primary air flow at the outlet 23 of the body 12 may be at least 150 Pa, and is preferably in the range from 250 to 1.5 kPa.
[0087] The user may optionally activate the heater assemblies 104 located within the nozzle 16 to raise the temperature of the first portion of the primary air flow before it is emitted from the fan assembly 10 , and thereby increase both the temperature of the primary air flow emitted by the fan assembly 10 and the temperature of the ambient air in a room or other environment in which the fan assembly 10 is located. In this example, the heater assemblies 104 are both activated and de-activated simultaneously, although alternatively the heater assemblies 104 may be activated and de-activated separately. To activate the heater assemblies 104 , the user presses button 30 of the user interface, or presses a corresponding button of the remote control 35 to transmit a signal which is received by the sensor of the user interface circuit 33 . The user interface control circuit 33 communicates this action to the main control circuit 52 , in response to which the main control circuit 52 issues a command to the heater control circuit 124 to activate the heater assemblies 104 . The user may set a desired room temperature or temperature setting by pressing button 28 of the user interface or a corresponding button of the remote control 35 . The user interface circuit 33 is arranged to vary the temperature displayed by the display 34 in response to the operation of the button 28 , or the corresponding button of the remote control 35 . In this example, the display 34 is arranged to display a temperature setting selected by the user, which may correspond to a desired room air temperature. Alternatively, the display 34 may be arranged to display one of a number of different temperature settings which has been selected by the user.
[0088] Within the lower curved section 94 d of the interior passage of the nozzle 16 , the primary air flow is divided into two air streams which pass in opposite directions around the opening 40 of the nozzle 16 . One of the air streams enters the straight section 94 a of the interior passage located to one side of the opening 40 , whereas the other air stream enters the straight section 94 b of the interior passage located on the other side of the opening 40 . As the air streams pass through the straight sections 94 a , 94 b , the air streams turn through around 90° towards the air outlets 18 of the nozzle 16 . To direct the air streams evenly towards the air outlets 18 along the length of the straight section 94 a , 94 b , the nozzle 16 may comprises a plurality of stationary guide vanes located within the straight sections 94 a , 94 b and each for directing part of the air stream towards the air outlets 18 . The guide vanes are preferably integral with the internal surface 98 of the inner casing section 90 . The guide vanes are preferably curved so that there is no significant loss in the velocity of the air flow as it is directed towards the air outlets 18 . Within each straight section 94 a , 94 b , the guide vanes are preferably substantially vertically aligned and evenly spaced apart to define a plurality of passageways between the guide vanes and through which air is directed relatively evenly towards the air outlets 18 .
[0089] As the air streams flow towards the air outlets 18 , a first portion of the primary air flow enters the first air flow channels 136 located between the walls 132 , 134 of the chassis 128 . Due to the splitting of the primary air flow into two air streams within the interior passage, each first air flow channel 136 may be considered to receive a respective first sub-portion of the primary air flow. Each first sub-portion of the primary air flow passes through a respective heating assembly 104 . The heat generated by the activated heating assemblies is transferred by convection to the first portion of the primary air flow to raise the temperature of the first portion of the primary air flow.
[0090] A second portion of the primary air flow is diverted away from the first air flow channels 136 by the front ends 146 of the inner walls 134 of the heater housings 130 so that this second portion of the primary air flow enters the second air flow channels 156 located between the inner casing section 90 and the inner walls of the heater housings 130 . Again, with the splitting of the primary air flow into two air streams within the interior passage each second air flow channel 156 may be considered to receive a respective second sub-portion of the primary air flow. Each second sub-portion of the primary air flow passes along the internal surface 92 of the inner casing section 90 , thereby acting as a thermal barrier between the relatively hot primary air flow and the inner casing section 90 . The second air flow channels 156 are arranged to extend around the rear wall 150 of the inner casing section 90 , thereby reversing the flow direction of the second portion of the air flow, so that it is emitted through the air outlets 158 towards the front of the fan assembly 10 and through the opening 40 . The air outlets 158 are arranged to direct the second portion of the primary air flow over the external surface 92 of the inner casing section 90 of the nozzle 16 .
[0091] A third portion of the primary air flow is also diverted away from the first air flow channels 136 . This third portion of the primary air flow by the front ends 170 of the outer walls 132 of the heater housings 130 so that the third portion of the primary air flow enters the third air flow channels 176 located between the outer casing section 88 and the outer walls 132 of the heater housings 130 . Once again, with the splitting of the primary air flow into two air streams within the interior passage each third air flow channel 176 may be considered to receive a respective third sub-portion of the primary air flow. Each third sub-portion of the primary air flow passes along the internal surface 96 of the outer casing section 88 , thereby acting as a thermal barrier between the relatively hot primary air flow and the outer casing section 88 . The third air flow channels 176 are arranged to convey the third portion of the primary air flow to the air outlets 178 located within the interior passage. Upon emission from the air outlets 178 , the third portion of the primary air flow merges with this first portion of the primary air flow. These merged portions of the primary air flow are conveyed between the inner surface 96 of the outer casing section 88 and the inner walls 134 of the heater housings to the air outlets 184 , and so the flow directions of these portions of the primary air flow are also reversed within the interior passage. The air outlets 184 are arranged to direct the relatively hot, merged first and third portions of the primary air flow over the relatively cold second portion of the primary air flow emitted from the air outlets 158 , which acts as a thermal barrier between the outer surface 92 of the inner casing section 90 and the relatively hot air emitted from the air outlets 184 . Consequently, the majority of the internal and external surfaces of the nozzle 16 are shielded from the relatively hot air emitted from the fan assembly 10 . This can enable the external surfaces of the nozzle 16 to be maintained at a temperature below 70° C. during use of the fan assembly 10 .
[0092] The primary air flow emitted from the air outlets 18 passes over the Coanda surface 42 of the nozzle 16 , causing a secondary air flow to be generated by the entrainment of air from the external environment, specifically from the region around the air outlets 18 and from around the rear of the nozzle. This secondary air flow passes through the opening 40 of the nozzle 16 , where it combines with the primary air flow to produce an overall air flow projected forward from the fan assembly 10 which has a lower temperature than the primary air flow emitted from the air outlets 18 , but a higher temperature than the air entrained from the external environment. Consequently, a current of warm air is emitted from the fan assembly 10 .
[0093] As the temperature of the air in the external environment increases, the temperature of the primary air flow drawn into the fan assembly 10 through the air inlet 14 also increases. A signal indicative of the temperature of this primary air flow is output from the thermistor 126 to the heater control circuit 124 . When the temperature of the primary air flow is above the temperature set by the user, or a temperature associated with a user's temperature setting, by around 1° C., the heater control circuit 124 de-activates the heater assemblies 104 . When the temperature of the primary air flow has fallen to a temperature around 1° C. below that set by the user, the heater control circuit 124 re-activates the heater assemblies 104 . This can allow a relatively constant temperature to be maintained in the room or other environment in which the fan assembly 10 is located. | A fan assembly includes a motor-driven impeller for creating an air flow, at least one heater for heating a first portion of the air flow, and a casing comprising at least one air outlet for emitting the first portion of the air flow, and first channel means for conveying the first portion of the air flow to said at least one air outlet. To cool part of the casing, the casing includes means for diverting a second portion of the air flow away from said at least one heater, and second channel means for conveying the second portion of the air flow along an internal surface of the casing. This second portion of the air flow may merge with the first portion within the casing, or it may be emitted through at least one second air outlet of the casing. | 5 |
FIELD OF THE INVENTION
This invention relates to propulsion motors, such as rocket and similar thrust motors, and in particular relates to such motors using a fine particulate material as a major part of the thrust producer.
BACKGROUND OF THE INVENTION
Various forms of rocket and similar propulsion motors exist, the primary ones comprising solid fuel and liquid fuel motors which use a chemical reaction between two or more materials to produce a jet of matter for propulsion. The present motors are complex, expensive, and dangerous. The cost of putting a payload into low earth orbit is somewhere between $3000 and $6000 per Kg. In addition to the high cost, the availability of launches is restricted.
The number of man-hours in space continues to increase and consequently the amount of payload in orbit increases. The number of payloads per year increases and also the weight per payload. The capability of launches is increasing but demand rises faster.
It has been proposed to build a propellant plant on the moon to extend the capacity of launcher and possibly reduce costs of space usage. It takes approximately one-tenth of the energy to bring material from the moon to low earth orbit in comparison to the energy required from the surface of the earth. Producing such propellant on the moon could be expensive.
SUMMARY OF THE INVENTION
In accordance with the present invention, propulsion is obtained by using fine particulate material produced from the regolith on the moon or other launch position using a minimal amount of processing. The particulate material is given energy content in the form of heat and is ejected through a nozzle by a flow of pressurized fluid. The particulate material heats up the fluid, causing the fluid to expand in volume, and speed, causing ejection of the particulate material and producing thrust.
Broadly, in accordance with the invention, there is disclosed a propulsion motor using heated fine particulate material, comprising; a propulsion nozzle having a throat; a convergent portion upstream of and adjacent to the throat; a container for the heated fine particulate material; a tank for holding a fluid; means for feeding the heated fine particulate material and the fluid to the convergent portion to mix the fluid and the particulate material and heating the fluid by the particulate material for issue through the throat and from the nozzle.
The invention also includes a method of propulsion comprising; feeding a heated fine particulate material from a container of the heated fine particulate material to a convergent portion upstream of and adjacent to the throat of a propulsion nozzle; feeding a fluid under pressure from a tank of the fluid to the convergent portion; mixing the heated fine particulate material and the fluid and increasing the temperature and volume of the fluid by heat exchange between the particulate material and the fluid, and ejecting the particulate material and the fluid at an increased speed from the nozzle.
The invention will be readily understood by the following description of certain embodiments, by way of example, in conjunction with the accompanying diagrammatic drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section through one form of motor in a vehicle;
FIG. 2 is a cross-section similar to that of FIG. 1, of another form of motor in a vehicle;
FIG. 3 is an enlarged cross-section of the nozzle position as in FIG. 1;
FIG. 4 is an enlarged cross-section of the nozzle position as in FIG. 2; and
FIG. 5 illustrates a modification of the arrangement of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, a vehicle is indicated generally at 10. A payload is shown at 11, and a propulsion nozzle at 12. A container or vessel 13 contains fine particulate material 14 and a tank 15 holds a fluid, for example, liquid hydrogen. Fluid is fed from the tank 15 via a pipe 16 to a high pressure pump 17. A branch 18 feeds fluid from the pipe 16 to a low pressure pump 19.
The outlet from the high pressure pump 17 is fed via pipe 20 to an outlet 21, adjacent to the throat 22, the speed of the fluid at the exit of the outlet 21 injecting and pressurizing the material 14 into the convergent part of the nozzle. The fluid from the low pressure pump is fed to the rear of the container 13 to pressurize the particulate material towards the nozzle. Conveniently the container 13 and propulsion nozzle 12 are a unitary member but not necessarily so. The container can have a light insulating wall 23.
In FIG. 2, the two pumps 17 and 19 of FIG. 1 are replaced by a single high pressure pump. Items common with FIG. 1 are given the same reference numerals. In FIG. 2, the fluid is fed from the tank 15 via pipe 30 to a high pressure pump 31. From the pump 31 fluid is fed via pipe 32 to a position adjacent to the throat 22 of the nozzle and also to the rear of the container 13 by pipe 33. A servo-valve 34 can be provided in the pipe 32 to control the flow. In the example, the container or vessel 13 is a high pressure construction and may have an insulating wall 23. The particulate material 14 is given a heat content. This can be obtained in various ways. It can be heated in a storage system, for example, by solar heating. A heat source can be provided in the vehicle, or heat, such as solar heat and can be applied to the material as it is used. Other ways of providing heat can be provided. It is also possible to use material that has a heat content at its source, using its actual temperature, a martian moon for example.
FIGS. 3 and 4 illustrate, to a larger scale, the throat regions of the nozzles, in the arrangements of FIGS. 1 and 2, respectively. In FIG. 3 and FIG. 4, a mixing area or chamber 35 is provided immediately upstream of the throat 22. This provides for initial mixing of the particulate material and the pressurized fluid, raises the temperature and increases the speed of the fluid and the particulate material in the nozzle. Preferably a fluidizing lining 36 is provided in the wall of the convergent portion 37, to ensure that the particulate material will flow into the mixing chamber 35. In FIG. 3, a separate fluid supply 38 can be provided, also illustrated in FIG. 1 and in FIG. 4, fluid can feed into the fluidizing lining from the pipe 32. Mixing and heating continues beyond the throat 22 into the divergent portion 39.
The insulating material used for the wall 23 can be the same material as the propulsion particulate material 14. The wall is hollow and filled with the particulate material and then can afterwards be used. It can become part of the payload for example, or could be used as the propulsion particulate material for a return flight, if it contained sufficient heat content, or is heated.
The material 14 is intended to be a fine particulate material produced at the launch site, for example the moon, from local material as by mechanical separation of fine particulate material from the regolith, crushing, milling or other processes. The material car be stored and heated by solar heat, for example, by a concentrating mirror. The payload 11 could also be material produced at the launch site and could be the same as material 14. It could be used for the manufacture of articles in space, for example, solar cells for a solar power satellite system. The material is readily heated to around 1000° C. by solar heat.
The fluid in tank 15 is generally a liquified gas, and hydrogen is particularly effective. Oxygen and carbon dioxide are also usable. Other fluids can be used. The molecular weight of the fluid used affects the exit speed at the nozzle. Hydrogen has the best attainable speed, oxygen has a lower attainable speed and carbon dioxide has an even lower attainable speed, at nozzle exit.
In the examples illustrated in FIGS. 1 and 2, 1.2 tonnes of hydrogen, with 110 tonnes of particulate material would enable 25 tonnes of payload 11 with an empty ship weight of 5 tonnes, to be put into moon orbit. Subsequent propulsion using the same propulsion system on a low thrust or other system can then be used to bring the payload to a low earth orbit. The following data relates to these arrangements-flow at high pressure pump, 17 or 31, 2.0 Kg/sec; fine particulate material flow 200 Kg/sec; temperature of particulate material 1000° C.; total thrust 284000N; and a specific thrust of 1400 N/Kg. The container 13 and nozzle 12, with tank 15 and associated pipes and pumps, would form a reusable module and about 13 tonnes of material 14, and the related amount of fluid, would be required for landing back on the moon.
As stated previously, the heat content of the particulate material can be obtained in various ways. It can be heated in storage and then transferred to the container 13. It can have an inherent heat content depending upon its source. For example, on a Martian moon, the material would be at a temperature of around 250° C. This would be sufficient to produce an exhaust speed of around 300 to 400 meters/second without addition of heat and would be sufficient for intermoon travel.
A further heating arrangement is by an on-board heater. One example is illustrated in FIG. 5, a modification of FIG. 1, with common references used. In FIG. 4, a heat source 40, for example, a nuclear heat source in conjunction with a heat exchanger, can be used. The heat exchanger can be positioned at the mixing chamber. The nuclear heat source can heat the particulate material, and/or the fluid. The heat exchanger could be positioned at or adjacent to the mixing area or chamber. A further alternative is to provide some form of solar heat collector around the vehicle and feed the heat to the material 14, perhaps adjacent to the mixing chamber 35.
It is also possible for heat to be conducted into the fluid container to produce the pressure necessary. However, this would require some heavier construction.
Other ways of injecting the particulate material and fluid into the mixing chamber can also be used.
Although specific embodiments of the present invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope for the claimed and described invention. | A propulsion motor using a fine particulate material, having a heat content, the material being fed to a convergent portion upstream of and adjacent to the throat of a propulsion nozzle. A fluid under pressure is also fed to the convergent portion, to mix with the particulate material. The fluid is heated by the particulate material, increasing volume and speed, the particulate material and the fluid ejecting from the nozzle. A particular use of such a motor would be on the moon, or some other body, where a fine particulate material can be made available locally. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending application Ser. No. 056,190 filed July 10, 1979, now abandoned entitled "A Method of Manufacturing a Piston By Means of Fusion Welding".
BACKGROUND OF THE INVENTION
This invention relates to pistons for internal combustion engines and more particularly to pistons and a method of making the same of forged aluminum with a fusion welded wear-resistant ferrous alloy crown insert.
The advantages of light weight pistons for internal combustion engines have been appreciated for a long time as shown in U.S. Pat. No. 1,727,119. Very early it was suggested that the pistons be made of aluminum whose defects of uneven expansion and poor hot-strength were recognized in the aforesaid U.S. Pat. No. 1,727,119. Also recognized was the feasibility of providing cast aluminum pistons with iron elements such as inserts and skirts to improve the wear and strength as shown in U.S. Pat. Nos. 1,717,916; 3,012,831; and 3,305,916. In the latter patent the aluminum piston is cast around a ring insert positioned in a mold and the interior of the piston is then formed by a forging operation.
The better mechanical and thermal properties of forged aluminum alloy pistons for meeting the requirements of internal combustion engines is recognized. However completely forged aluminum alloy pistons having ferrous metal ring inserts have not been successful due to the absence of an integral metal bond between the iron insert and the pre-forged piston. The previous method of making pistons with ring inserts, as shown in the mentioned prior art, required casting of the piston with the ring in place to form a metallic bonding between the ring insert and the cast piston body.
However, as mentioned, the joining of the iron insert to the pre-forged aluminum piston does not provide the required bonding.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a light weight composite piston for internal combustion engines comprising a forged aluminum piston body integrally joined to an iron crown insert ring and a method for making such composite pistons.
Other objects and advantages of the present invention will be apparent from a further reading of the specification and of the appended claims.
With the above and other objects in view, the present invention mainly comprises the method of:
(a) forging a piston body of aluminum alloy with a configuration adapted for a ring insert,
(b) positioning a ring insert of an iron alloy in the configuration to form an assembly,
(c) inserting the assembly into a confining mold,
(d) heating the surface of the assembly to temperatures below the melting point of the forging, and
(e) directing the flow of a molten aluminum alloy, at an oxide-removing angle, into the space formed by the configuration in the piston body-forging and the ring insert to fusion weld the insert to the piston body at the configuration.
The invention further comprises as a new product, a forged aluminum piston body having an iron insert fusion-welded to the body via an intermetallic alloy layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more completely described with reference to the drawings, in which:
FIG. 1 is a sectional view of the forged piston body with a configuration adapted to conform with a ring insert.
FIG. 1a is a sectional view of the iron ring insert dipped in a vessel containing a molten alloy,
FIG. 2 is a sectional view showing the positioning of the forged aluminum body in a mold,
FIG. 3 is a sectional view showing the mold assembly of FIG. 2 after the addition of the molten alloy, and
FIG. 4 is a sectional view of the mold similar to that of FIG. 3 but showing a variation thereof.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring more particularly to the drawing, FIG. 1 shows a sectional view of the forged piston body with the configuration a formed thereon adapted to conform to the ring insert. In FIG. 1a there is a sectional view of the iron ring insert b dipped in a vessel containing a molten alloy suitable for coating the ring insert with an alloy capable of forming an intermetallic fusion bond between the coated insert and the aluminum alloy. FIG. 2 shows the positioning of the forged piston body a in a mold c, with ring insert b in place and supported by pins d to provide a flow clearance between the forged body a and ring b.
FIG. 3 shows the mold assembly of FIG. 2 after the addition of molten aluminum alloy to form the fusion weld joint in the clearance between forged piston body a and ring b. The oxides g dislodged from the surfaces of forged piston body a and ring b by the pouring of the alloy into the mold c are swept and accumulated at the periphery of the mold as a result of spin imparted to the mold during the pouring operation.
FIG. 4 is similar to FIG. 3 but shows a variant wherein solidification of the alloy forming the fusion weld is encouraged by cooling the forged piston by blowing a cooling gas into the hollow interior of the forged piston.
The forged piston can be made of any of the recognized aluminum forging alloys such as SAE 39 corresponding to STM-CN 42A; SAE 332 corresponding to SC 103A and alloy M-138 equivalent to AFNOR-AS 20U which is a hyper-eutectic (18% Si) alloy useful for diesel engine pistons. Any of the traditional commonly used aluminum forging techniques may be used for fashioning the piston bodies.
The modification of the upper portions of the piston body to provide a suitable configuration for accommodating the ring insert may be made roughly during the forging step and then finish machined or it may be directly machined in the forging. A suitable clearance between the ring insert and the piston body to enable dislodging and sweeping of the oxides from the metal surfaces by the molten alloy forming the fusion weld between the insert and the piston body is essential to a proper configuration.
The forged piston adapted to receive the insert is then placed in a mold of greater volume than the final piston volume, the insert is properly positioned relative to the piston body and the piston and mold are preferably (but not necessarily) heated in an inert atmosphere to a convenient temperature, preferably about 500° C. This temperature is below the melting point of the alloy used for the forging and also below the temperature of the molten alloy used for the fusion welding of the insert to the piston body.
The heated mold with the assembly, consisting of the forged piston body and the positioned insert ring, is rotated about the axis perpendicularly passing through the assembly. The molten alloy is introduced into the rotating mold via a funnel or any similar channel at an angle of about 30° C. to the axis of rotation. Introduction of the molten alloy flow in this manner has been found to provide complete dislodging of any oxides from the surfaces of the piston body and insert ring. This dislodging flow together with the forces resulting from the rotation of the mold removes the dislodged oxides to the upper periphery of the mold into the excess volume of the mold, where, upon solidification, the accumulated oxides can be removed by machining.
The speed of rotation of the mold is adjusted to provide sufficient forces to sweep the oxides floating on the molten surface to the peripheral portion of the mold before the molten metal congeals.
As a typical characteristic of aluminum alloys is the formation of an Al 2 O 3 oxide layer on its solid surfaces, it is essential that this oxide layer be removed from those areas where a fusion weld is to be formed. To this end the pouring of the molten alloy at the most effective impingement angle (about 30°) and the rotation of the mold washes the oxidized surface free from oxide and promotes the dragging of the oxides from the areas where the fusion weld takes place. Any molten aluminum alloy will serve for this washing and dragging deoxidation step.
The speed of mold rotation of course depends on the piston size. The smaller the piston the greater the speed of mold rotation. In the range of piston sizes commonly used for internal combustion engines rotational speeds in the range 12 to 60 rpm are adequate.
That portion of the assembly consisting of the configured forged aluminum piston body and the iron ring insert positioned therein is filled with a suitable molten alloy. As mentioned above, the filling alloy should wash the surfaces to be joined free from oxides and should bond to both the aluminum forging and the iron insert by fusion welding. Thus a perfect intermetallic bond is formed between the iron insert, the molten alloy and the forging. This bond is free from any oxides which would embrittle the bond or otherwise cause weakening in the areas of the weld joint.
It has also been noted that better hot-hard characteristics are obtained in the areas of the fusion welded pistons if the inside of the forged piston is cooled during or preferably after the flowing of the molten alloy into the mold. A preferred alloy for flowing to form the fusion weld is ASTM CN42A.
It is preferred, according to this invention, to provide the iron ring insert with an Alfin alloy coating. The Aflin alloys are useful for providing molecular bondings of light metals such as aluminum and magnesium and alloys thereof, to dissimilar metals such as ferrous metals and alloys, titanium, nickel, cobalt etc. It enables the formation of bi-metallic joints combining the desirable properties of both metals being joined. The bonded construction provides structures combining the strength hardness and fatigue resistance of the ferrous type metals with the light-weight, high heat-conductivity, bearing properties, oxidation resistance and other properties of aluminum and magnesium. The process essentially consists of diffusing the light metal unto the ferrous metal to form a thin layer of a combined alloy. In the present case it consists of diffusing aluminum unto steel or cast iron to form a thin layer of ferro-aluminum alloy over the areas of the steel or cast iron insert to be bonded and then pouring an aluminum alloy to join the diffused ferro-aluminum alloy layer to the aluminum forging. The ferro-aluminum alloy consists of the intermetallic compound of iron and aluminum designated by the formula: Al y Fe x . The atomic ratios will vary with the alloy constituents of the specific ferrous alloy and the specific aluminum alloys. However, the primary constituent is Al 5 Fe 2 (Eta-phase). The bond can be considered to include four graded zones: unchanged iron, a thin layer of a solid solution of aluminum in iron, the Eta-phase inter-metallic compound Al 5 Fe 2 ; and the aluminum layer permeated with Al 5 Fe 2 .
The basic procedure for forming the Alfin bonding layer on ferrous metals is well known and for insertion of the ring inserts used in this invention is modified to comprise degreasing and cleaning the iron insert until free of oxides, immersing the ring insert into the bath of molten Alfin alloy to form an inter-metallic alloy coating thereon, positioning the coated ring on the piston in the mold, starting the rotation of the mold with heating, pouring the deoxidizing aluminum alloy to form the fusion weld, cooling the mold, unmolding the assembly, and machinging the excess metal and oxides from the forged piston integrally joined to the ring insert by fusion welding.
The process of this invention includes the aspects of joining the piston body to another alloy material of suitable characteristics. In such cases one may bond one material having desirable properties such as thermal resistance on the head of the piston exposed to the combustion gases. By flowing the second alloy properly over the first alloy it is possible to obtain perfect fusion weld joints between a hypereutectic aluminum alloy containing 18% Si(AFNOR-AS20U) and a hypoeutectic 4% Cu alloy (ASTM CN42A).
While the invention has been illustrated with respect to particular constructions, it is apparent that variations and modifications of the invention can be made. | A method of manufacture of novel light-weight pistons of aluminum forgings with an integral iron insert ring by fusion welding is described. The aluminum piston forging is provided with a configuration adapted to receive the iron insert ring which may be coated to provide an inter-metallic joining alloy. The configured piston forging is placed in a mold, the ring is positioned in the configuration. The mold is rotated and molten alloy is introduced at an angle to deoxidize the forging and the ring, sweep the oxides to non-critical areas of the mold and to join the forging to the ring upon cooling to form a fusion weld. | 5 |
This application is a divisional application of U.S. patent application Ser. No. 08/316,941, filed Oct. 3, 1994 and of application Ser. No. 07/903,904 filed Jun. 25, 1992, now U.S. Pat. No. 5,382,609.
FIELD OF THE INVENTION
The present invention relates to sheets of fibrous material, especially comprising cellulosic fibers, which are absorbent for aqueous liquids.
DESCRIPTION OF THE PRIOR ART
There is great demand for materials which are capable of absorbing quantities of liquid, while remaining substantially solid, and which, before use, are compact. Examples of uses for such materials include kitchen rolls, sanitary pads, nappies, plasters and wound dressings in general.
Suitable materials are generally available, but which do not necessarily fulfil all of the requirements. For example, sanitary pads may be too bulky or too solid, and surgical dressings do not absorb a sufficient quantity of exudate from the wounds. An added complication is that, for applications involving contact with the human or animal body, especially a wound, it is highly desirable that there be no toxic compounds present in the dressing which may affect the body in any way. This is a particular disadvantage of many plastics.
Various materials are known which can be used for the above applications. Such materials include foamed plastics, absorbent paper and, more recently, sheets of cross-linked cellulosic fibers.
One advantage of the cross-linked cellulosic fibers is their non-toxicity, provided that the cross-linker is a suitable non-toxic compound, such as carboxymethyl cellulose. These materials also have the advantage of being able to absorb up to about one hundred times their own weight in water.
A primary disadvantage of the cross-linked cellulosic materials arises through the various methods of production available for them. This is essentially because of the difficulties involved in evenly distributing the cross-linker precursor throughout the fibers before effecting cross-linking. Two basic methods are known, the first of which is a dry process, and the second is a wet slurry process.
In the dry process, a layer of suitable cellulosic fibers is generated, such as by the air-felt process, followed by dredging a suitable powdered cross-linker onto the sheet and then compressing the whole, optionally after agitation, together with heating. It is generally necessary to use great pressure in order to effect any kind of satisfactory permeation of the cross-linker through the sheet, and the result is a very densely compressed sheet with variable concentrations of cross-linker throughout. These sheets tend to be least absorbent.
The alternative, wet process involves making a slurry of the cellulosic fibers and the cross-linker. This slurry is dried out and formed into a sheet, and then compressed and heated as before. This results in a more even distribution of the cross-linker throughout the material, but still does not form an optimal material with a particularly even density of cross-linker throughout, and also suffers from the drawback of being time consuming. The main problem is clumping with materials prepared from slurries, even where relatively low quantities of cross-linker are used.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved process for the production of cross-linked cellulosic fibrous materials, which process will ensure that the materials have an even and consistent density of cross-linker throughout, and which process will also not necessarily be limited to bibulous fibers, whether they be cellulosic or other.
It is also an object of the invention to provide absorbent materials of cross-linked fibers, preferably cellulosic fibers, which display superior absorption properties to the known materials.
It has now been discovered that the objects of the invention are readily achievable by mixing of an aerated suspension of statically charged fibers with the cross-linker before heating and compressing, the resulting materials having a capacity for fluid absorption considerably greater than has been heretofore known for such materials.
Thus, the present invention provides, in a first aspect, a process for the production of absorbent materials, comprising preparing a layer of fibers and a cross-linker therefor, and heating and compressing, in either order or together, the layer thereby prepared so as to effect cross-linking of the fibers, characterized in that, before preparation of the layer, the fibers and the cross-linker, both of which are essentially dry, and the cross-linker being in the form of a fine powder, are blended after either or both of the cross-linker and fibers has been electrically charged.
BRIEF DESCRIPTION OF THE DRAWING
The accompanying FIGURE shows apparatus suitable for the production of an absorbent layer of the invention.
DETAILED DESCRIPTION OF THE INVENTION
This process gives rise to an extremely even coating of cross-linker on the fibers, and the composite layer of fibers and cross-linker can then easily be compressed and heated to yield a superior end product. Furthermore, the process is extremely easy to use and effect, and is also cheap and quick, not requiring heavy compression rollers, or time consuming drying of a slurry.
A further advantage lies in the hygienic method of preparation of the product, as the constituents and process are essentially dry, thereby limiting the possibility of contamination.
In the process of the invention, it is generally preferred that the preparations are brought into admixture in a gaseous medium, preferably air.
Before compression, it is desirable to allow the mixture to settle into a layer after first bringing the preparations into admixture in a drum with agitation.
It is generally preferred that the fibers be suspended in air in a suitable container, such as a polyethylene or polypropylene drum, and charged. It is sufficient, for example, to merely provide a quantity of fibers in a polyethylene bag, to inflate the bag, and then to shake or agitate the bag so as to charge the fibers. Once this has occurred, the powdered cross-linker can be introduced to the bag and shaken again, after which the bag can be emptied onto a suitable surface, and the resulting layer heated and compressed.
On a larger scale, the fibers could be provided in a drum which, in turn, could be rotated until such time as the fibers therein were sufficiently charged. The cross-linker could then be introduced, with the drum rotated further, and then the mixture allowed to settle into the composite layer.
In a further aspect, the present invention provides apparatus for the production of absorbent materials from an essentially dry preparation of fibers and an essentially dry preparation of a powdered, heat activatable cross-linker for the fibers, the apparatus comprising a drum 10 having a top, a bottom and walls defining a cavity of the drum and having baffles 120, 160, as shown;
the top of the drum 10 having a first at least one opening 20 through which the fibers 25 can be introduced;
the top of the drum 10 having a second at least one opening 30 through which the cross-linker 70 can be introduced;
dividing means 40 being located between the first and the second openings, as shown, the dividing means 40 extending toward the bottom of the drum, and preferably forming a funnel;
electrical charging means 90 being provided on the wall of the drum 10 at a position below the first at least one opening 20 and above the lowest extent of the dividing means 40;
means 100, 110 for introducing gas under pressure being provided on the wall of the drum 10 at a position below the first at least one opening 20 and above the lowest extent of the dividing means;
means, such as a propellor or fan blade 50 driven by motor 60, as shown, to disperse the cross-linker and the fibers to form a dispersion when the cross-linker falls below the lowest extent of the dividing means 70;
the bottom 130 of the drum 10 defining an opening through which the dispersion can pass;
a fine mesh conveyor 145 being located beneath the bottom of the drum 10 to collect the dispersion conveyor 140 having drive and guide rollers 180, 200 and having nip rollers 170, 190, as shown;
collecting means 147 being disposed beneath the conveyor 140 to collect any excess cross-linker falling 195 through the conveyor;
means 150 to heat the dispersion after collection on the conveyor; and
means 170 to compress the dispersion after collection on the conveyor, the heating and compressing means optionally being provided together in one or more rollers 170, for example.
The fibers may also be charged by other suitable means, such as providing charging plates directly linked to an electrical source, or by using ionizing radiation. It is also not necessary to suspend the fibers in air, especially if either of these latter two methods is used, and the powdered cross-linker can be introduced to the layer of fibers which then need only be agitated sufficiently to allow an even distribution of the cross-linker throughout the fibers, the electrical charge on the fibers serving to attract the cross-linker.
It is also not necessary for the fibers to be charged. It is possible for the powdered cross-linker to be charged instead, and then introduced to a suitable preparation of the fibers. Again, this may be a suspension in air, or may be a layer of fibers which are then agitated after the introduction of the cross-linker.
It is also possible to charge both the cross-linker and the fibers, but this is not required, and may possibly result in clumping of the cross-linker on the fibers if too much cross-linker is introduced.
It is also preferred to allow excess cross-linker to be separated from the composite layer before heating and compression. This may be effected by depositing the layer on a fine mesh, thereby allowing excess powder to fall through, and be collected for further processing if desired. The mesh itself may be agitated to assist loose powder to fall through, if desired. Owing to the charged nature of the layer and the powder, it may also be desirable to earth any container into which the powder falls. It is not so desirable for the mesh, as it may serve to prematurely discharge the composite layer, and allow the cross-linker to fall away from the fibers. In such an instance, an inferior product may be formed. However, it is generally the case that the charged condition of the composite layer exists for several minutes, allowing unhurried preparation of the layer for heating and compression before the charge wears off.
In some cases, it may be desirable to align the fibers in the material, and this may be achieved by any suitable means. One such means is by combing the material, such that the fibers must pass through a suitable array of slots, for example.
Other treatments of the composite layer may comprise spraying or immersion of the layer with water or any other, suitably aqueous, liquid, followed by drying which my be effected at the same time as the heating and compression. Such a treatment affects the end product, but is not usually desirable, unless, for example, the spray includes a dye, antiseptic or antibiotic. Even so, such substances may be added after cross-linking.
Before cross-linking, it may also be desirable to run the layer through a series of rollers, such as wet and dry heated rollers. Again, this affects the end product in a known manner.
Returning to the blending process, it is preferred to keep both cross-linker and the fibers as dry as possible, in order to maximize the effect of the electrical charge. To this extent, it may also be preferable to introduce a stream of warm dry air to displace humid air, or to dry the fibers and/or cross-linker. Further, it is not necessary that air is used, although if any other medium, such as an inert gas, or nitrogen, is used, then this will tend to raise the cost of production, and involve more expensive containment facilities. Nevertheless, use of such alternative media is envisaged by the present invention.
The present invention is particularly applicable to cellulosic fibers, but is not limited thereto. Any fibers may be used, provided that they are capable of being electrically charged. In particular, it is preferred that the fibers comprise polyhydric polymers, useful examples of which are naturally occurring structural polymers, particularly polysaccharides. Suitable examples include lignin, and especially cellulose.
It is not necessary that the fibers be bibulous, as it is generally envisaged that the majority of the absorption of the end product will be effected by the cross-linker matrix. However, it is preferred that the fibers be as fine as possible. This is for two reasons, the first being in order to avoid irritation where the material might come into contact with the human or animal body, and the second being to enhance the ability of the fibers to hold an electric charge. Nevertheless, it is envisaged that, provided that the fibers can hold an electric charge, then any gauge fibers may be used.
It is envisaged that, during the blending process, the powder of the cross-linker will evenly coat each individual fiber, subject to the amount of cross-linker present. Accordingly, it is preferred to prepare the cross-linker in such a manner that it forms a very fine dry powder. It is generally preferred that the mesh size of the powder be such that the powder will appear to float if a pinch of the powder is sprinkled in the air. In general, the cross-linking compounds available tend to be somewhat coarse, and it is preferred that they should be milled further before use.
There is no particular restriction on the nature of the cross-linker, provided that it can form a suitably fine powder for use in accordance with the process of the invention. Suitable cross-linkers may be those that form a gel with water, and examples include such compounds as gum arabic, starch, cellulose, hydroxypropyl cellulose, but especially carboxymethyl cellulose. This last is especially preferred where the end product is to comprise cellulose fibers.
It will be appreciated that the nature of the cross-linker will affect the properties of the end product. Such properties include the quantity of liquid which can be absorbed, as well as the rate at which the liquid is absorbed.
The materials produced in accordance with the present invention tend to have considerably superior absorptive qualities and, for example, a material which comprises essentially cellulose fibers and carboxymethyl cellulose (CMC) as cross-linker can absorb up to about 2,000 times its dry weight.
In the example given above, the rate of absorption tends to be extremely rapid (as little as a few seconds), and this may not always be desirable. If the material is to be used for a burn, for example, where the exudate only emerges slowly, then it may be desirable to tailor the material such that, while the overall capacity for absorbing liquid is substantially unchanged, the rate at which it will absorb the liquid is considerably reduced. Again, in the above example, this is suitably achieved with the addition of hydroxypropyl cellulose to the CMC. A proportion of about 10% hydroxypropyl cellulose to 90% CMC is generally suitable to slow the rate of absorption down such that capacity is only reached after about 24 to 48 hours.
It may also be desirable to provide a blend of substances to form the cross-linker for other reasons. In particular, while CMC is a particularly good absorptive agent, its cross-linking strength is not necessarily particularly high. A material comprising solely CMC and cellulose will hold together, even at full water capacity, but can fairly readily be broken up.
Thus, if required, a further substance can be introduced into the cross-linker powder, or pulve, to enhance the strength of the material. Again, the substance should be finely milled, and does not need to be able to provide an absorbent matrix in its own right. Suitable substances include low density thermoplastics, such as polyethylenes. These may be used in any suitable quantity, but the higher the proportion of the strengthening cross-linker, the lower the final absorptive capacity of the end product will be. A suitable range of strengthening cross-linker in the powder is between about 10% and 30%, with about 20% being preferred. When the layer is heated and compressed, the cross-linking will occur.
After the absorbent material has been prepared, it may be packaged in any suitable manner, or prepared as a dressing or nappy etc. It may be useful, for example, to provide back and front layers on the resulting sheet material, where the back layer is essentially a barrier to the passage of any liquid absorbed by the material, while the front layer is porous to allow liquid to be taken up. This is a particularly preferred embodiment, and is broadly applicable to most applications in which the materials of the invention can be used.
If the materials of the invention are to be applied as a dressing for a wound, for example, then adhesive may be applied to one face of the material, or to the porous layer which would separate the wound from the absorbent material.
It will also usually be preferable to seal the edges of the material to prevent any leakage of liquid out of the side of the product, and this may be achieved in any known manner, such as by the use of a binder or sealant. One method may involve stitching along the edge followed by sealing the stitching, if required, by a suitable sealant.
Suitable non-limiting examples of uses to which the materials of the invention may be put include: surgical sponges; incontinence pads; pledgers; eye pads; plasters; adhesive surgical dressings; impregnated wound dressings; ischaemic ulcer dressings; decubitus ulcer dressings; burn dressings; emergency accident packs; haemostatic dressings and, generally, human or animal applications.
It will also be appreciated that the absorbent materials of the invention may be employed in industrial situations, and may also useful provide insulation.
The materials of the invention may be defined as follows: an absorbent material comprising fibers cross-linked by a suitable cross-linker, characterized in that the cross-linker is associated with substantially the entire surface of each fiber.
More preferably, the materials of the invention comprise fibers cross-linked by a polyhydric cellulose derivative, and preferred cross-linkers comprise at least 50% carboxymethyl cellulose. It is most preferred that the fibers comprise natural structural polymers, the most preferred being cellulose.
The accompanying example is intended for illustration only.
EXAMPLE
ABSORBENT MATRIX
The components of the absorbent matrix are:
1. Cellulose fibers (CF), staple length 0.3 to 0.5 mm;
2. Carboxymethyl cellulose (CMC) milled to pulve; and
3. LDPE Granules milled to pulve.
The constituents are:
100 g CF;
250 g Blanose CMC (BL); and
150 g LDPE granules milled to pulve.
Ten grammes of fine cellulosic fibers, staple length 0.3 mm, are placed in a hexagonal chamber, preferably made from polypropylene, polyethylene or nylon. The chamber is rotated on a long axis mechanically at speeds between 25 and 45 revolutions per minute, depending on the size of the chamber. In this example the chamber is 20 inches high, 10 inches in diameter and bottle shaped (Bench technique). The rotation agitates the fibers and creates an electrostatic charge to the fibers. The charged fibers are tested at intervals by stopping the rotation and placing a 20 inch plastic rod in the container, to see if the fibers are attracted to it. If they are attracted en masse, a few more minutes of agitation is required before the second phase is employed. The procedure usually takes between 10 and 15 minutes, but is very dependent on the surrounding environment and it may be necessary to introduce warm dry air into the chamber to speed the process.
When the fibers are judged to be correct in terms of the charge they are holding, 25-30 g of very finely ground carboxymethylcellulose (pulve) is introduced into the chamber, preferably through a very fine sieve, so as to form clouds of pulve in the chamber. The rotation is then started again between 5 and 10 revolutions per minute. The CMC pulve is attracted to the charged fibers after approx. 5 minutes, depending on thickness of coating required (different thicknesses of coating are used for different product requirements).
When the fibers are sufficiently coated for the product required, the agitation is stopped and the coated fibers are allowed to settle on a Teflon (Trade Mark) coated fine wire mesh positioned 0.5 inch (13 mm) above a metal alloy tray inserted through an aperture at the bottom of the chamber. The coated fibers are collected on the wire mesh and the unused pulve is allowed to pass through and is collected on the tray beneath. The chamber may need to be earthed to prevent the fibers from clinging to the interior.
The wire mesh is then removed with the fibers from the chamber and gently agitated so that the fibers lie flat on the mesh. A duplicate fine wire mesh is then gently laid on the exposed fibers, to sandwich them. The sandwich is then passed through a pair of preheated Teflon (Trade Mark) coated rollers, to effect cross-linking. The fine wire mesh is then removed from the fibers to leave a pad of material.
Thickness may be gauged by the weight of the fibers and CMC pulve introduced into the chamber. The rollers may be heated electronically to produce variable heat for different thicknesses. The temperatures required are usually between 300° F. and 400° F. (149° and 204° C.). Roller pressures are between 10 and 20 lb per square inch, speed of rollers is between 45 seconds and 60 seconds per square yard.
If necessary, the cellulose fibers may be positively charged and CMC negatively charged, thereby speeding the process and producing a better base material. | The present invention relates to an apparatus for the production of absorbent materials comprising fibers cross-linked by a suitable cross-linker therefor, and wherein said cross-linker is associated with substantially the entire surface of each fiber, said materials being preparable by mixing of an aerated suspension of the charged fibers with the cross-linker before heating and compressing, such fibers having a capacity for fluid absorption considerably greater than has been heretofore known for such materials. | 3 |
BACKGROUND
[0001] The present invention, in some embodiments thereof, relates to managing a medical order related to a treatment provided to a patient, and, more specifically, but not exclusively, to managing a medical order through an automated closed loop and real time system that assures correct workflow of a medical order, associates the medical order activities with relevant care providers, tracks progress of the workflow of the medical order, notifies and alerts the relevant care providers and logs the workflow of the medical order.
[0002] Patient care in a controlled environment in which a series of events is initiated, managed and monitored by attending care providers. As patient care services and institutes are becoming more distributed and complex, many care provider entities, for example physicians, nurses, medical institutes, laboratories and/or imaging facilities are involved in the workflow of medical orders relating to a treatment provided to a single patient. This distributed environment requires the workflow of the medical order to be controlled, efficient and near real time in order to avoid lack of synchronization between a plurality of care providers, avoid redundancies, enable remote monitoring of the patient's condition, keep track of the medical order progress and medical activities status, associate a relevant care provider with the medical activities, alert the relevant care provider of a breach in the workflow of the medical order or other predefined events and maintain a log for the medical order workflow. A breach in the workflow of the medical order may be for example, failure to perform tasks in a predefined order failure to perform one or more tasks and/or cancellation of one or more of the tasks by a care provider.
[0003] Reference is now made to FIG. 1 , which is a schematic illustration of a workflow of an exemplary medical order. One or more care of the providers may initiate a medical order that relates to a treatment provided to the patient. The medical order may include a plurality of medical activities that are required by the medical order. Each of the plurality of medical activities is not a workflow by itself but rather a specific contained activity that needs to be performed as part of the workflow of the medical order. The plurality of medical activities may each include a plurality of tasks that are part of the medical activity. Each of the plurality of tasks may be assigned to one or more of the medical care providers. The plurality of tasks that are associated with each of the one or more medical activities are performed with respect to the patient. The results of the plurality of tasks may be reported back to the one or more of the care providers.
[0004] Traditionally, the medical order is initiated manually by the one or more of the care providers after examining the patient and generating a hard copy medical record that includes the medical activities that need to be performed. Other care providers may be involved with the medical activities associated with the medical order. The medical order and its related medical activities are managed and monitored through the patient's medical record which is also used for logging the medical order. The medical order may be modified by an accountable care provider attending to the patient in person. As technology advances, the medical record may be available in electronic format, electronic medical record (EMR) replacing the hard copy record.
[0005] The patient medical record both in hard copy and in electronic form fails to provide an efficient controlled, closed loop system due to the complex and distributed patient care environment. The patient medical record is susceptible to various flaws, for example, different care providers issuing conflicting and/or redundant orders, inability to provide real time information on the medical activities status and/or on the patient's condition, inability to alert a relevant care provider in the event of an emergency or a failure to perform the medical order, etc.
SUMMARY
[0006] According to some embodiments of the present invention, there are provided systems and methods for managing a plurality of medical orders associated with treatments provided to a plurality of patients. Managing the plurality of medical orders enables a tightly controlled, patient centric, closed loop and near real time workflow for a plurality of medical orders that are part of a treatment provided to a plurality of patients. One or more of a plurality of care providers may issue the medical order relating to a treatment provided to one of the plurality of patients. The medical order is received and a list of one or more medical activities is automatically generated according to a pre-defined template that details the medical activities that are required with respect to the medical order. Each of the plurality of medical activities is not a workflow by itself but rather a specific contained activity that needs to be performed as part of the workflow of the medical order. Each of the required medical activities is further divided to a plurality of singular tasks and a tasks list is automatically generated according to a pre-defined template that details the tasks that are required with respect to each medical activity. Each of the plurality of tasks is assigned with a tracking status and each of the plurality of tasks is associated with one or more of the care providers. The tracking status may include a plurality of condition rules that may be used for alerting one or more of the care providers. A notification message containing the tasks(s) information is transmitted to the one or more of the care providers using a plurality of client terminals for example desktop, laptop, tablet, phone and/or beeper. The notification message may be sent using one or more networks, for example, wireless, cellular and/or internet. During the period from issuing the medical order and to the completion of the medical order, input messages are received indicating the status of each of the plurality of tasks. Each of the plurality of tasks is tracked and the tracking status of each of the plurality of tasks is updated according to the received input messages. Alerts may be generated and transmitted to the one or more of the care providers using the plurality of client terminals, according to the progress of the plurality of tasks. The workflow of the medical order is recorded and a log is generated to reflect the plurality of tasks progress.
[0007] Optionally, monitoring information is collected from one or more of a plurality of medical monitoring instruments capable of transmitting data over the one or more networks.
[0008] More optionally, monitoring information is collected over the one or more networks from one or more care providers using the plurality of client terminals.
[0009] More optionally, monitoring information is collected over the one or more networks from the patient using the plurality of client terminals.
[0010] More optionally, monitoring information is available to one or of the care providers using the plurality of client terminals.
[0011] More optionally, monitoring information is recorded in the log of the medical order.
[0012] More optionally an alert message is transmitted to one or more of the plurality of care providers in case a condition rule is fulfilled.
[0013] More optionally, one or more of a plurality of medical records databases is accessed to retrieve medical history of the patient to be used during the period of the medical order. The plurality of medical records databases may be available in a plurality of different formats and/or storage systems. Retrieved data from one or more medical records databases may be synchronized to provide a comprehensive, detailed and up to date description of the patient medical history.
[0014] More optionally, the medical history of the patient is available to one or more of the care providers using the plurality of client terminals.
[0015] More optionally, the status of the plurality of tasks is available to one or more of the care providers using the plurality of client terminals.
[0016] More optionally, the monitoring information of the patient is available to one or more of the care providers using the plurality of client terminals.
[0017] More optionally, one or more of a plurality of resource management system of the care providers is accessed to retrieve availability information of one or more of the care providers. Availability information may include for example, expertise, care provider ranking and/or, location of treatment.
[0018] More optionally, the availability information is used to identify an accountable care provider that is available and suitable for performing a certain task of the plurality of tasks and the accountable care provider is notified of the task information.
[0019] More optionally, the availability information is used to identify and alert an accountable care provider that is available to receive a certain alert of a plurality of alerts that includes alert condition information.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.
[0021] In the drawings:
[0022] FIG. 1 is a schematic illustration of a workflow of an exemplary medical order;
[0023] FIG. 2 is a schematic illustration of an exemplary management system for a medical order and entities the system is interacting with, according to some embodiments of the present invention;
[0024] FIG. 3 is a flowchart of an exemplary process for managing a medical order, according to some embodiments of the present invention;
[0025] FIG. 4 is a schematic illustration presenting notifications and alerts associated with an exemplary medical order work flow, according to some embodiment of the present invention;
[0026] FIG. 5 is a schematic illustration of modules contained in an exemplary system for managing a medical order, according to some embodiment of the present invention; and
[0027] FIG. 6 is a schematic illustration of a workflow of a medical order in an exemplary medical environment implementing a system for managing a medical order, according to some embodiment of the present invention.
DETAILED DESCRIPTION
[0028] According to some embodiments of the present invention, there are provided systems and methods for managing a plurality of medical orders associated with treatments and/or procedures provided to a plurality of patients. A medical order is received from one or more of a plurality of care providers, and a list of one or more medical activities is automatically generated. The medical activities list is generated using a pre-defined template that describes medical activities that are associated with the medical order. Each of the one or more medical activities is not a workflow by itself but rather a specific contained activity that needs to be performed as part of the workflow of the medical order. A tasks list is generated for each of the one or more of the medical activities, where the tasks list includes a plurality of singular tasks required for the medical activity. The tasks list is automatically generated according to a pre-defined template. A tracking status is assigned to each of the plurality of tasks and each task of the plurality of tasks is associated with one or more of the care providers. A notification message is transmitted to the associated one or more of the care providers using a plurality of client terminals for example desktop, laptop, tablet, phone and/or beeper. The notification message includes the associated task(s) information. The notification message may be sent using one or more networks, for example, wireless, cellular and/or internet. Input messages are received during the period from issuing the medical order to the completion of the medical order, where the input messages indicate the status of each of the plurality of tasks. Completion of the medical order may be for example, completion of all tasks, cancellation of medical order, postponement of the medical order, cancellation of remaining unperformed one or more of the plurality of tasks associated with the medical order and/or postponement of remaining unperformed one or more of the plurality of tasks associated with the medical order. The tracking status of each of the plurality of tasks is updated according to the received input messages. Alert may be generated and alert message may be transmitted to an accountable one or more of the care providers according to the progress of the plurality of tasks. The workflow of the medical order is recorded and a log is generated to reflect the plurality of tasks progress.
[0029] Reference is now made, once again, to FIG. 1 . Managing the medical order 103 involves interaction with a plurality of entities. A plurality of care providers 101 may be responsible for performing the required actions to complete the medical order 103 , for example, medical personnel, medical facilities and/or other medical and non-medical resources. As a plurality of patients are provided with treatment at any given time, managing and monitoring of the medical orders is crucial.
[0030] Reference is now made to FIG. 2 which is a schematic illustration of an exemplary management system for a plurality of medical orders 103 and entities the system is interacting with, according to some embodiment of the present invention. A system 200 includes a processing unit that executes one or more software modules for managing and monitoring a plurality of medical orders 103 , for example, personal computer, server, and/or a distributed processing system that includes a plurality of processing nodes. The system 200 interacts with one or more of the plurality of care providers 101 using the plurality of client terminals for receiving the medical order 103 which is a part of a treatment provided to the patient 102 . The system 200 transmits notification and alert messages to one or more of the care providers 101 using the plurality of client terminals over the one or more networks. The notification and alert messages are transmitted according to a plurality of rules, for example, availability of the care providers 101 , contact method of the care providers 101 , patient condition and/or progress of the medical order 103 .
[0031] Optionally, the system 200 receives monitoring information of the condition of the patient 102 from a plurality of medical monitoring instruments 230 that are monitoring the patient 102 and are capable of transmitting monitoring information using the one or more networks.
[0032] More optionally, the system 200 receives monitoring information of the condition of the patient 102 from a plurality of the care providers 101 using the plurality of client terminals over the one or more networks.
[0033] More optionally, the system 200 receives monitoring information of the condition of the patient 102 from the patient 102 using the plurality of client terminals over the one or more networks.
[0034] More optionally, the system 200 accesses one or more resources records 210 of the care providers 101 to retrieve information on one or more service providers 101 .
[0035] More optionally, the system 200 accesses one or more patient history records 220 of the patient 102 to retrieve information on medical history of the patient 102 . The plurality of medical records databases 220 may be available in a plurality of different formats and/or storage systems. Retrieved data from one or more medical records databases may be synchronized to provide a comprehensive, detailed and up to date description of the patient medical history.
[0036] More optionally, the patient medical records 220 include a plurality of EMR systems.
[0037] Reference is now made to FIG. 3 which is a flowchart of an exemplary process for managing a medical order, according to some embodiment of the present invention. As shown at 301 , a process 300 for managing the medical order 103 is started by receiving the medical order 103 issued by one or more of the care providers 101 using the plurality of client terminals.
[0038] As shown at 302 , the received medical order 103 is processed and a monitor list may be generated that includes required monitoring information of the patient 102 and/or a plurality of monitor rules. The monitor list is generated automatically according to a pre-defined template that includes the monitoring parameters required for the medical order 103 , for example, blood pressure, blood count and/or heart beat. The monitor rules may describe the required monitoring information with respect to the patient 102 , for example, blood pressure range, blood count range and/or heart beat range that in case of deviation from the specified range, an alert message is transmitted.
[0039] Optionally, the monitor list is modified by one or more of the care providers 101 according to the condition of the patient 102 .
[0040] More optionally, the monitor list is automatically modified according to the medical history of the patient 102 that is retrieved from the patient history records 220 .
[0041] More optionally, the each one of the plurality of monitor rules has an escalation field to handle escalation in the condition of the patient 102 . The escalation field specifies two or more of the care providers 101 , each of the two or more of the care providers 101 is associated with a different level of criticality of the monitoring information. This is done to assure raising the attention of the accountable one or more of the care providers 101 of an escalation in the condition of the patient 102 and to verify a proper and timely action is taken with respect to the patient 102 .
[0042] As shown at 303 , the received medical order 103 is processed and an activities list is generated which describes the medical activities 104 that need to be performed in order to carry out the medical order 103 . The activities list is generated automatically according to a pre-defined template that includes the medical activities 104 that are required for the medical order 103 .
[0043] Optionally, the activities list is modified by one or more of the care providers 101 according to the condition of the patient 102 .
[0044] More optionally, the activities list is automatically modified according to the medical history of the patient 102 that is retrieved from the patient history records 220 .
[0045] As shown at 304 , the activities list is further divided to one or more tasks lists comprising a plurality of singular tasks 105 required by each activity 104 . The tasks lists are generated automatically according to a pre-defined template that includes the tasks 105 that are required for the corresponding activity 104 . Each of the tasks 105 is assigned with a tracking status to allow the system 200 to track the task's progress.
[0046] Optionally, the tracking status for each task 105 includes a plurality of condition rules which include conditions for alerting one or more of the care providers 101 with regard to the task 105 .
[0047] More optionally, the tracking status for each task 105 has an escalation filed in which at least two of the care providers 101 may be specified, each associated with a different level of criticality and/or urgency of the status of the task 105 with respect to the patient 102 . This is done to assure raising the attention of a higher ranking accountable one or more of the care providers 101 to the progress of the plurality of tasks 105 associated with the medical order 103 . An escalation situation may be preconfigured in the plurality of task condition rules and may include for example, failure to complete one or more tasks within a predefined time period, failure to report on the progress of one or more tasks and/or failure to perform tasks in predefined order.
[0048] As shown at 305 , each task 105 is associated with one or more of the care providers 101 . Association of each of the plurality of tasks 105 to the one or more of the care providers 101 is done according to a pre-defined list of the care providers 101 .
[0049] Optionally, association of the task 105 to the one or more of the care providers 101 is done dynamically by accessing the resources records 210 and identifying a one or more of the care providers 101 that are currently available. Availability may constitute of a plurality of parameters, for example, expertise, responsibility and/or location. Contact information for the accountable one or more of the care providers 101 may be retrieved from the resources records 210 , for example, phone number, internet protocol (IP) address and/or email address.
[0050] As shown at 306 , a notification message for every task 105 is sent over the one or more networks to each one or more of the care providers 101 that is associated with the task 105 . The notification message is a push message in nature, meaning the notification message is automatically transmitted to the one or more of the care providers 101 using the plurality of client terminals with no need for the one or more of the care providers 101 to initiate a query on standing notification messages.
[0051] Optionally, the notification message is persistent according to task 105 progress, retransmitting the notification message to the one or more of the care providers 101 according to preconfigured settings, for example, at predefined intervals, at task start, at task completion, cancellation of task by one or more of the care providers 101 , at modification of task by one or more of the care providers 101 , at identification of failure during task execution, at identification of failure to complete task within a predefined time period, according to task progress, and/or at completion of medical activity and/or medical order.
[0052] As shown at 307 , monitoring information of the condition of the patient 102 may be collected and made available to care providers 101 . As aforementioned the monitoring information may be received from a plurality of medical monitoring instruments 230 capable of transmitting monitoring information, from a plurality of care providers 101 using the plurality of client terminals and/or from the patient 102 using the plurality of client terminal. Monitoring information is received using the one or more networks.
[0053] As shown at 308 , each of the tasks 105 relating to each of the medical activities 104 of the medical order 103 is continuously tracked. Care providers 101 using the plurality of client terminal send over the one or more networks, task progress information for the tasks 105 they are assigned with. The task progress information is used for tracking the plurality of tasks 105 .
[0054] Optionally, tasks 105 tracking information and progress status is available to the care providers 101 .
[0055] As shown at 309 , an alert may be transmitted over the one or more networks to one or more of the care providers 101 using the plurality of client terminals to indicate a plurality of events as defined by the task rules. Task rules may include, for example, start of task, completion of a task, incompletion of a task within a predefined time period, incompletion of task by the time the patient 102 is discharged, escalation in tasks execution, etc. The alert message is of push message in nature, meaning the alert message is automatically transmitted to the one or more of the care providers 101 using the plurality of client terminals with no need for the one or more of the care providers 101 to initiate a query on standing alert messages.
[0056] Optionally, an alert is transmitted to one or more of the care providers 101 at the event of a condition of one or more of the plurality of monitor rules is fulfilled for example, escalation in the condition of the patient 102 .
[0057] More optionally, the alert message is persistent according to the progress of the task 105 , retransmitting the alert message to the one or more of the care providers 101 according to preconfigured settings, for example, at predefined intervals, at task start, at task completion, at cancellation of task by one or more of the care providers 101 , at modification of task by one or more of the care providers 101 , at identification of failure during task execution, at identification of failure to complete task within a predefined time period, according to task progress and/or at completion of medical activity and/or medical order.
[0058] The workflow of the medical order 103 is continuously tracked and monitoring information is collected until the medical order completes. Completion of the medical order 103 may be decided by the accountable one or more of the care providers 101 and may be based on several parameters, for example, completion, addition, repetition and/or cancellation of medical activities 104 and their related tasks 105 that are required by the medical order 103 and/or termination and/or postponement of the medical order 103 .
[0059] Reference is now made to FIG. 4 which is a schematic illustration presenting notifications and alerts associated with an exemplary medical order work flow, according to some embodiment of the present invention. The medical order 103 is initiated and split to one or more medical activities 104 . The one or more medical activities 104 are each further divided to a plurality of tasks 105 and each task 105 is associated with one or more of the care providers 101 . For each task 105 the system 200 transmits a notification to the accountable one or more of the care providers 101 . During the execution of the plurality of tasks 105 , the system 200 may transmit a plurality of alerts to the accountable one or more of the care providers according to the task rules defined in the system 200 , for example, start of task execution, completion of task execution and/or incompletion of task execution within a pre-defined time period.
[0060] According to some embodiments of the present invention, there are provided a system 200 that manages and monitors a medical order, the system 200 receives the medical order 103 , automatically generates a list of medical activities 104 required to perform the medical order 103 , associates the medical activities 104 with relevant one or more of the care providers 101 , notifies the relevant one or more of the care providers 101 of the medical activities 104 , tracks the progress of the medical order 103 , alerts the relevant one or more of the care providers 101 of events in the medical order 103 and logs the medical order 103 .
[0061] Reference is now made to FIG. 5 which is a schematic illustration of modules included in an exemplary system for managing a medical order, according to some embodiment of the present invention.
[0062] An input module 500 receives the medical order 103 that is issued by one or more of the care providers 101 using the plurality of client terminals. The received medical order 103 is forwarded to an activities list generation unit 501 and a monitor list generation unit 502 .
[0063] The activities list generation module 501 splits the medical order 103 into one or more medical activities 104 according to a pre-defined template that includes the medical activities 104 that are required for the medical order 103 .
[0064] The monitor list generation module 502 generates a monitor list according to a pre-defined template that includes the monitoring information required for the medical order 103 with respect to the patient 102 . The monitor list may include a plurality of conditional monitor rules that may be used for alerting one or more of the care providers 101 in the event a condition is fulfilled.
[0065] A tasks lists generation module 503 further divides the activities list to a plurality of singular tasks 105 according to a pre-defined template that includes the tasks 105 that are required for each activity 104 . The plurality of tasks 105 are initiated and maintained in the system 200 . The tasks lists generation module 503 associates each of the plurality of tasks 105 with an accountable one or more of the care providers 101 . The tasks lists generation module 503 transfers the information of each of the plurality of tasks 105 and the information of the one or more of the care providers 101 associated with task 105 to a notification module 505 .
[0066] The notification module 505 transmits a notification message over the one or more networks to one or more of the care providers 101 using the plurality of client terminals. The notification message includes the information of the one or more of the care providers 101 that are assigned with the task 105 .
[0067] A monitoring module 507 monitors the monitoring information for the patient 102 as dictated by the monitor list that is generated by the monitor list generation module 502 . The plurality of tasks 105 are continuously tracked by a tracking module 506 . The tracking module 506 holds an accurate status for each of the plurality of tasks 105 . In case a condition is fulfilled for one or more of the monitor rules, the monitoring module 507 transfers the condition information to an alert module 304 . In case a condition is fulfilled for one or more of the task rules, the tracking module 506 transfers the condition information to the alert module 304 .
[0068] The alert module 304 transmits an alert message over the one or more networks to one or more of the care providers 101 using the plurality of client terminals. The alert message is transmitted according to a pre-defined list of care providers 101 and includes the information on the monitor rule and/or task(s) rule conditions that are identified.
[0069] The logging module 508 logs the tracking status information for the plurality of tasks 105 and/or monitoring information that is collected during the workflow of the medical order 103 . The logged information may be available to one or more of the care providers 101 using the plurality of client terminals during and after the time of execution of the medical order 103 .
[0070] Optionally, the tasks lists generation module 503 accesses the resources records 210 to retrieve the accountable one or more of the care providers 101 that are available to perform the task 105 according to a plurality of availability parameters, for example, expertise, responsibility and/or location. The tasks lists generation module 503 may retrieve contact information for the accountable one or more of the care providers 101 .
[0071] More optionally, the monitoring module 507 receives monitoring information of the patient 102 from a plurality of medical monitoring instruments 230 that are capable of transmitting monitoring information using the one or more networks.
[0072] More optionally, the monitoring module 507 receives monitoring information of the patient 102 from one or more of the care providers 101 using the plurality of client terminals using the one or more networks.
[0073] More optionally, the monitoring module 507 receives monitoring information of the patient 102 from the patient 102 using the plurality of client terminal using the one or more networks.
[0074] More optionally, the monitoring module 507 makes the monitoring information of the patient 102 available to one or more of the care providers 101 using the plurality of client terminals using the one or more networks.
[0075] More optionally, the tracking module 506 makes the status information for each one of the plurality of tasks 105 available to one or more of the care providers 101 using the plurality of client terminals using the one or more networks.
[0076] More optionally, the alerting module 304 accesses the resources records 210 to retrieve the accountable one or more of the care providers 101 that are available to receive the alert according to a plurality of availability parameters. The alerting module 304 may retrieve contact information for the accountable one or more of the care providers 101 .
[0077] Some embodiments of the present invention, are presented herein by means of an example, however the use of this example does not limit the scope of the present invention in any way. The example presents a workflow of the medical order 103 in an exemplary medical environment employing a system 200 for managing the medical order 103 .
[0078] Reference is now made to FIG. 6 which is a workflow of a medical order in an exemplary medical environment implementing a system for managing a medical order, according to some embodiment of the present invention. A medical environment 600 employs a system that maintains closed loop control with feedback for performing medical activities, for example, treatments and/or procedures provided to the patient 102 . The medical environment 600 includes the plurality of care providers 101 , a healthcare organizational structure 601 , the plurality of medical monitoring instruments 230 , the plurality of patient medical records 220 , a monitoring unit 605 , a medical messaging unit 603 , a tracking unit 604 and a medical documentation system 602 all focused on the patient 102 .
[0079] The monitoring unit 605 which may employ the monitoring module 507 and/or the monitor list generation unit 502 of the system 100 collects monitoring information with respect to the patient 102 . The monitoring information may be collected from the plurality of medical monitoring instruments 230 that are monitoring the patient 102 , from one or more of the care providers 102 that are attending the patient 102 and/or from the patient 102 . The plurality of monitoring instruments 230 may be mobile or stationary, and the monitoring information the plurality of monitoring instruments 230 produce may be automatically transmitted by the monitoring instruments 230 using the one or more networks, reported by one or more of the plurality of care providers 101 using the plurality of client terminals and/or be reported by the patient 102 using the plurality of client terminal. The monitoring unit 605 automatically generates a monitor list (watch list) according to a pre-define template that dictates the monitoring information required with respect to the medical order 103 for the patient 102 . The monitor list also includes condition rules for generating an alert message in the event of a medical situation identified through the monitor list condition rules. The monitor list condition rules may include escalation rules to identify an escalation in the condition of the patient 102 and generate an escalation event. The monitor list may be modified by one or more of the care providers 101 to adapt to the condition of the patient 102 . The monitoring unit 605 may access the plurality of patient medical records 220 located at a plurality of locations and present in a plurality of formats for retrieving medical history of the patient 102 and use it for providing a complete medical view of the patient 102 . The patient medical records 220 may further include the plurality of EMR systems. The medical history of the patient 102 may be used to interpret monitoring information and/or manipulate monitoring requirements and monitor list for the patient 102 . The monitoring information may include events identified by the monitor list condition rules, for example, escalation in the condition of the patient 102 . The monitoring unit 605 forwards the collected monitoring information to the medical messaging unit 603 .
[0080] The medical messaging unit 603 may include the task lists generation module 503 , the notification module 505 and/or the alerting module 504 . The medical messaging unit 603 associates the plurality of tasks 105 with one or more of the plurality of care providers 101 , where the plurality of tasks 105 are required by the medical activities 104 which are derived from the medical order 103 . The medical messaging unit 603 informs the accountable one or more of the plurality of the care providers 101 when attention is needed to the patient 102 . The medical messaging unit 603 may handle escalation in the condition of the patient 102 as reported by the monitoring unit 605 . In the event of escalation one or more messages may be transmitted to one or more of the care providers 101 to raise attention to the escalation situation. The medical messaging unit 603 may access the healthcare organizational structure 601 for retrieving availability of the one or more of the care providers 101 from the resources records 210 . The availability information for the plurality of the care providers 101 allows the medical messaging unit 603 to dynamically identify a suitable accountable one or more of the care providers 101 in real time. Availability information parameters may include for example expertise, ranking in the healthcare organization and/or location of treatment.
[0081] The tracking unit 604 which is the final unit in the workflow of the medical order within the medical environment 600 performs tracking on the tasks related to the medical order 103 . The tracking unit 604 may employ the activities list generation module 501 , the tasks lists generation module 503 , the tracking module 506 and/or the alerting module 504 . The tracking unit 604 tracks the progress of the plurality of tasks 105 that are initiated with respect to the medical activities 104 associated with the medical order 103 . The tracking unit 604 may access the healthcare organizational structure 601 for retrieving availability of the one or more of the care providers 101 from the resources records 210 . The availability information for the plurality of the care providers 101 allows the tracking unit 604 to dynamically identify an accountable one or more of the care providers 101 in real time. Availability information parameters may include for example expertise, ranking in the healthcare organization and/or location of treatment. The tracking unit 604 is coupled with the medical messaging unit 603 for transmitting alert messages to the accountable one or more of the care providers 101 with respect to status of the plurality of tasks 105 and/or with respect to the condition of the patient 102 as reported through the monitoring information.
[0082] The documentation unit 602 logs the workflow of the medical order 103 and stores the generated information, for example, status and progression of the plurality of tasks 105 and/or monitoring information of the patient 102 . The documentation unit 602 may employ the logging module 508 . The stored log data may be used for long and short term uses, for example, to be recorded in the medical history record of the patient 102 and/or to be inserted back into the workflow of the medical order 103 to initiate additional medical activities that may be required according to the condition of the patient 102 .
[0083] The terms “client terminal” relates to any device and/or apparatus which may be used for input and/or output of data thorough a human interface, for example desktop computer, laptop, tablet, telephone, mobile phone and/or beeper. The term “human interface” relates to any form of human-machine interface for example, keyboard, touch screen, microphone, speaker and/or motion sensor. | The methods and systems described by the present invention enable managing a medical order provided to a patient, comprising:
a) Receive a medical order provided to a patient that defines a plurality of medical activities to be performed in a predefined order. b) Automatically create a list of a plurality of tasks for each medical activity, each task is assigned with a tracking status. c) Automatically associate each task with at least one of a plurality of care providers. d) Automatically notify the at least one care provider using a client terminal about the respective associated task. e) Aggregate a plurality of input messages each indicative of a status of one of the tasks. f) Automatically update the tracking status according to the input messages during the period of the medical order. g) Outputting a dataset of the medical order which is indicative of the tracking status for each task. | 6 |
BACKGROUND OF THE INVENTION
The invention relates to a push-in coupling for pipes comprising a sleeve and a holding device which contains a clamping ring for joining a pipe end to the sleeve.
European patent application No. EP 587,131 discloses a push-in coupling of this kind, which has a coupling sleeve, a holding means in the form of a clamping device, and an operating device. The coupling sleeve is configured as a dual sleeve, so that with this push-in coupling the ends of two plastic pipes can be joined together with the two clamping devices. The holding means contains a clamping ring which has externally a clamping taper and internally at least one clamping rib which can be brought into engagement with the pipe end. By means of a sleeve nut which can be threaded onto the coupling sleeve the opposite taper can be gripped by the clamping ring. Also, a sealing ring is disposed in the coupling sleeve. When applying the coupling care must be taken that the pipe end is inserted far enough into the coupling sleeve so that the clamping ring and likewise the sealing ring can perform their functions. There is a danger, however, that as a result of incomplete insertion of the pipe end into the push-in coupling, the connection will fail to hold or will be defective.
Published German Patent Application No. DE 3,112,255 discloses a quick coupling for pipes having a holding system which comprises an axially displaceable hold-back means. The hold-back means contains axial slits and is disposed partially within a rigid ring with a circular rib. The hold-back element consists of resilient-elastic material and has a rib directed radially outward, as well as a conical surface at the front end, which corresponds with a taper of an intermediate element. When a pipe is inserted, first the hold-back means and the surrounding ring with the circular rib are moved in the axial direction until the ring comes into contact with a bottom of the sleeve body. As insertion of the pipe continues, the radial ring of the hold-back means moves past the circular rib, while the resistance to insertion increases and the hold-back means is pressed radially against the outside surface of the pipe. If the rib of the hold-back means is all the way past the circular rib of the ring, the rib enters into an annular groove in the ring, while the given resistance to the insertion movement suddenly ceases. Thereupon the pipe together with the hold-back means and the snapped-in ring is moved forward contrary to the insertion movement until the conical surface of the hold-back means is tightened against the cone of the intermediate element. The specification and the adjustment of the force of resistance requires a not inconsiderable production difficulty involving close tolerances, especially in the hold-back means and of the ring with the circular rib. Close limits must also be observed for the outside diameter of the pipes, since otherwise the teeth of the hold-back means are forced only partially into the pipe and the pipe can be pulled back out of the coupling. The prior-art coupling furthermore permits relative axial movements of the pipe with respect to the coupling, and foreign bodies can come within the reach of a gasket placed between a nut and the intermediate element and there is a danger of leakage of the medium under pressure from the pipe.
Furthermore, German Utility Model No. DE-U 93 08 181 discloses a connection fitting for pipes which has a connecting means that can be fastened to a pipe end and an annular groove for a sealing ring. A pilot ring which can be moved by the pipe end past the sealing ring during assembly is present, which has a surface for contact by an end surface of the pipe end. When the pipe end is inserted, the pilot ring has to be pushed by the sealing ring, with the need to overcome increased resistance to insertion. When the pilot ring has been pushed completely through the sealing ring, the resistance decreases markedly. Damage to the sealing ring by the pipe end is said to be prevented by the pilot ring without the need to chamfer the pipe end.
A push-in coupling for pipes, hoses or similar round bodies also is disclosed in Published German Patent Application No. DE 4,304,241, which comprises a holding means and at least one sealing ring in a receiving sleeve. The holding means contains, radially within it, a slotted or fan-like holding disk whose tongues sloping radially inward toward the sleeve bottom serve for clamping the exterior surface of the inserted pipe end. In this push-in coupling also the danger is that the pipe end will not be inserted far enough and the required connection will not be properly established.
SUMMARY OF THE INVENTION
It is an aim of the invention to provide an improved push-in pipe coupling with which a connection to at least one pipe end can be established with little difficulty and great reliability.
Another aim of the invention is to provide a push-in coupling which permits simple and practical handling during assembly.
A further aim of the invention is to provide a push-in coupling which can be manufactured at low production cost and which assures that when the connection is made, the parts essential to operation, such as especially the seal, the clamping ring or the like, will function properly.
These and other aims have been achieved in accordance with the present invention by providing a push-in pipe coupling for joining a pipe end to a sleeve, said coupling comprising the sleeve, a holding device which includes a clamping ring, and an axially displaceable sliding body which is configured independently of the holding device, the sliding body having a striker which, when the pipe end is inserted, is pushed over an edge and upon reaching a given depth of insertion of the pipe end strikes against a surface thereby producing a detectable signal.
The push-in coupling of the invention is characterized by a functional design and assures a reliably operating and long-lasting connection. A sliding body having a striking means is provided which can be displaced axially by the inserted pipe end. The striking means is preferably in the form of a radially movable tongue, and when the pipe reaches a predetermined specific depth of insertion it collides with an associated strike surface. When it collides a signal is produced which can be called a click, and which is easily perceivable by the installer without additional aid. The signal produced by the collision can be perceived by the installer as an acoustical signal, especially, and/or the signal can be felt by the hand itself as a thump or vibration.
When the pipe end is inserted, the radially acting tongue is caused to pass over an end surface which extends radially inward and is thereby biased radially, and after it passes over an edge and the pipe reaches the predetermined insertion depth, the tongue strikes against the end surface producing the vibratory signal which is heard as a noise or felt by the hand. The tongue and the said end surface are adapted or matched to one another such that no additional devices for amplifying the collision and/or vibratory signal are necessary. The radial biasing of the striking means or tongue requires virtually no additional force, and the insertion movement of the pipe can be performed and completed largely without hindrance. It is not necessary for the striking means to come in contact with the exterior surface of the pipe when it is biased, and after passing over the said edge and after the outward radial flexure of the striking means, the latter is entirely out of contact with the exterior surface of the pipe. After the acoustical or vibratory signal occurs, the installer can end the insertion movement, since he knows with great certainty that the connection is now properly made.
The sliding body is preferably configured as a ring with a surface for contact with an axial end face of the pipe to be inserted. The striking means is preferably an integral component of the sliding body and is a kind of resilient tongue which, when the required depth of insertion is reached, is flexed outwardly, preferably in the radial direction, over a step, a nose or the like, and then snaps back against the associated strike surface to produce the vibratory signal or click. The holding means is independent of the striking means according to the invention, and preferably comprises a clamping ring with a conical exterior surface. The clamping ring is preferably fixed in the required manner with respect to the sleeve body by means of a cap. The clamping ring and the sliding body are separate components independent of one another; the clamping ring retains its axial position in the sleeve body when the pipe end is inserted, while the sliding body is shifted axially with respect to the sleeve body by the end of the pipe. After complete insertion is signaled by the striking means, the cap is installed on the sleeve body by slipping it on axially or screwing it on, so that the clamping ring is clamped against the exterior surface of the pipe end. By means of the clamping ring a sealing ring is also compressed in an advantageous manner relative to the exterior surface of the pipe end and the sleeve body. When the pipe end is inserted, the surface and edge associated with the striking means substantially retain their axial positions in the sleeve body, and only the sliding body is displaced axially by the pipe end. Preferably the sliding body is arranged as a separate component axially spaced away from the holding means, particularly from its clamping ring.
Further forms and special embodiments of the invention are set out in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments depicted in the accompanying drawings in which:
FIG. 1 is a sectional view taken in an axial plane through a push-in pipe coupling according to the invention which is configured as a double push-in pipe coupling;
FIG. 2 is a section through the sliding body still joined to the sleeve;
FIG. 3 is an end view of the sleeve and the sliding body viewed in the direction of arrow III in FIG. 2;
FIG. 4 is an axial section through the cap;
FIG. 5 is a view of the cap seen in the direction of arrow V in FIG. 4;
FIG. 6 is a section taken in an axial plane through an alternate embodiment of a push-in pipe coupling according to the invention;
FIG. 7 is an axial section of a sleeve with a sliding body of the embodiment of FIG. 6;
FIG. 8 is an end view of the sleeve with the sliding body according to FIG. 6;
FIG. 9 is an axial section of the clamping ring of the embodiment of FIG. 6;
FIG. 10 is an elevational view of the clamping ring of the embodiment of FIG. 6;
FIG. 11 is an axial section of the sleeve of the embodiment of FIG. 6; and
FIG. 12 is an elevational view of the sleeve of the embodiment of FIG. 6.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows in longitudinal section a push-in pipe coupling with a sleeve 2 which hereinafter is also called a housing, and in which tube ends 3 and 4 are partially inserted from each end. The push-in pipe coupling or sleeve is configured as a double sleeve which is depicted as being in mirror symmetry about a center plane 5. In the scope of the invention, the push-in coupling can also be designed for only one pipe end, and especially as a component of a fitting or the like. Insofar as explanations are given hereinafter for the left or right portion of the double sleeve, such explanations apply also to the other portion. The individual components of the left or right portion of the double sleeve are of identical configuration and are installed in the push-in pipe coupling with rotation with respect to the center plane, only the sleeve being the same for both portions.
In the housing or sleeve 2 there is a clamping ring 6 which is partially also surrounded by a fastener body 8. The fastener body 8 is configured expediently as a cap or hood which extends over a good part of the sleeve 2. In the case of the double sleeve shown in the drawing, each of the two fastener bodies or caps 8 almost completely overlaps their related portions of the sleeve 2 and of the clamping ring. The clamping ring 6 has a tapered exterior surface 10 against which lies a corresponding tapered internal surface 12 of the fastening body 8. The clamping ring 6 is not entirely inside of the sleeve, but at least its tapered outer surface 10 protrudes from the sleeve into the portion of the fastener body 8 in which the tapered inside surface 12 is provided. The clamping ring 6 contains a preferably axial slit 14 and has on its inside surface teeth 16 which are designed to penetrate into the outside surface of the tubes 3 and 4. The fastener body 8 is configured as a cap partially overlapping the sleeve 2. The fastener body or cap 8 contains at its end facing the center plane 5 catch means 18 which are pointed radially inward toward the axis 20 and engage in a circumferential groove 22 on the sleeve. The cap 8 contains a number of longitudinal slots 24 distributed over the circumference, which extend over a portion of the total length of the cap 8 from the catch means 18. The cap 8 consists of a sufficiently spring-elastic material, especially plastic, and the arms with the catch means 18, formed by the longitudinal slots 24, can be flexed radially outward to a given extent to produce the junction with the sleeve. The sleeve 2 has for this purpose a conical outside surface 26 with its apex pointing away from the central plane 5.
To produce the connection between the sleeve 2 and the cap 8, the latter is pushed axially onto the sleeve 2 in the direction of the arrow 28 until the catch means 18 engage the circumferential groove 22. The wall 30 of the snap-catch groove or circumferential groove 22 does not lie exactly in a radial plane but is tilted or disposed with a radius 32, while the center point of this torus or circular surface faces the free end 34 of the sleeve 2. This assures in an advantageous manner that the cap 8 is drawn onto the sleeve 2 in the axial direction, i.e., in the direction of the arrow 28. Furthermore, after the catch means 18 has been snapped into the circumferential groove 22, escape is prevented.
Although the connection between the fastening body and the cap, which is no longer releasable after it has been made, has proven to be very desirable, other means can be provided for holding the cap on the sleeve 2, such as a releasable screw connection or a non-releasable weld, which are mentioned only by way of example. Furthermore, the holding device with clamping ring and cap constitute no restriction of the invention. Other designs of the holding system, i.e., for the joining of the inserted tube end 3, 4, to the sleeve 2, can be provided.
In the axial direction toward the face 36 of the sleeve, the clamping ring 6 is adjoined inside of the sleeve 2 by a sealing ring 38 in contact with a thrust ring 40. Then follows a sleeve 42, which is arranged between the thrust ring 40 and the sleeve face 36. In the double sleeve here depicted, the sleeve face 36 is formed by an axial surface of a ring 44 disposed in the area of the central plane 5. Of course, if the sleeve design is in one piece the sleeve 42 is in contact with and supported by a surface of the fitting, an armature or the like that is comparable with the sleeve face 36. The explained components are coordinated with one another such that, after the tube end 3, 4, has been inserted into the sleeve 2, the sealing ring 38 is in contact, with the necessary radial bias, with the external surface of the tube end 3, 4, for the purpose of sealing. The sealing ring 38 is disposed axially between clamping ring 6 and sleeve 42 and the thrust ring 40. The striker 52 and/or thrust ring 40 are fixed axially, preferably on the sleeve face 36, such that, when the fastening body 8 is displaced as described, the clamping ring 6 is driven axially toward the supporting ring 40 and/or the sleeve 42, and thus the sealing ring 38 is tightly held. It is expressly stated that, when the tube end is inserted, the thrust ring 40 and/or the sleeve 42 do not perform any axial movement and are axially secured in the sleeve against the insertion movement.
As shown in the drawing, the tube end 3, 4, is not yet fully inserted into the sleeve 2. The axial end face 46 of the tube end 3 is lying against a sliding body 50 which is independent of the holding device and its clamping ring and is at a distance axially therefrom, and it also has at least one striker 52. It is important to note that the sliding body 50 is independent of the holding device which, in the embodiment shown here contains the clamping body 6. The sliding body 50 is able to move separately and independently of the holding device when the tube end is inserted. Preferably, three such striking means are provided, which are distributed over the circumference of the sliding body 50, and which are preferably configured as radially movable tongues. The striking means 52 is disposed and/or guided in an axial groove or recess 54 of sleeve 42. When the tube end 3 is in the position represented, the sliding body 50 has already been shifted axially so far that the outside surface 56 of the striking means 52, which is at an angle to the longitudinal axis 20, is in contact with an end face 56 of the longitudinal groove 54. Due to the resilience of the striking means 52, the latter is forced radially inward as the tube end 2 continues to enter, until its free end has been pushed over an edge 60. Then the striking means 52 snaps over the edge 60 and then strikes against a surface 61 in the interior of the sleeve 42. When the free end of the striking means 52 strikes against this abutment surface 62, a signal is produced according to the invention, which is perceived acoustically and/or as a vibration manually by the operator, and can also be called a click or clunk. The operator is thus informed of the complete and proper insertion of the tube end 3 into the push-in pipe coupling. The inner surface of the edge 60, on the one hand, and the greater inside diameter of the abutment surface 62 on the other, are so adapted to one another that the acoustical signal is clearly perceived by the operator outside of the push-in pipe coupling.
The position of the sliding body 50 before the tube end 3 is inserted is indicated in broken lines. In this position, the sliding body 50, as it will be described below, is joined to the sleeve 42 such that any unintentional escape of the sliding body is thus prevented. The junction between the sliding body 50 and the sleeve 42 is designed such that, when the tube end 3 is inserted, it is released by a comparatively small force, so that then the sliding body 50 can be displaced axially in the direction of arrow 28 in the manner explained.
FIGS. 2 and 3 show the sliding body 50 in the position joined to the sleeve 42. Between the sleeve 42 and the sliding body 50 there is at least one small spur 66. The sleeve 42 and the sliding body 50 are preferably made in one piece together with the at least one spur 66. Three such spurs 66 are expediently provided between the inner surface of the sleeve 42 and the outer surface of the sliding body 50, and are distributed over the circumference. These spurs 66 are of such dimensions that they break off under the effect of a predetermined axial force and thus the sliding body 50 becomes displaceable in the sleeve 42. The spurs 66 are preferably not arranged in the area of the grooves 54 for the striking means or tongues 52, but in the area between grooves 54 adjacent one another in the circumferential direction.
In FIG. 3 the three grooves 54 for the three striking means or tongues 52 can easily be seen. Furthermore, the axial grooves 54 extend over only a part of the total length 68 of the sleeve 42, which is continuous over the circumference at the counter abutment surface 62. The longitudinal groove 54 is followed in the direction toward the counter abutment surface 62 by the end surface 58 which is arranged at a given angle 70 and along which, after the sliding body 50 breaks off, the striking means 52 slides as the tube end is further inserted, until it snaps over the edge 60 and then opens radially outward and thus abuts against the counter abutment surface 62 in the manner described above.
FIGS. 4 and 5 show the fastening body configured as the cap 8 with the already-mentioned arms 72 for the catch means 18. Uniformly distributed over the circumference are a number--in this case twelve--of such arms 72 with the catch means 18 pointing radially inward. The inner abutment surfaces 74 of the catch means 18 are at an angle 76 with respect to the longitudinal axis, or they are provided with a radius. This radius or inclination is coordinated with the radius or slope or inclination of the side wall of the circumferential groove in the sleeve as explained in connection with FIG. 1.
Although the arrangement of the sleeve 42 has proven practical, the sleeve can be eliminated or integrated into the sleeve in another embodiment of the invention. In this embodiment, and thus mainly the groove 54, the edge 60 as well as the counter-abutment surface 62, are integral components of the sleeve 2 within the scope of the invention.
FIG. 6 shows an alternative embodiment of the invention, in which the cap 8 is removably fastened to the sleeve 2. The cap or the fastening body is provided with an internal thread 80 and the sleeve 2 a matching external thread 82. The external thread 82 and likewise the internal thread 80 do not extend over the entire circumference, but are divided into segments with spaces between them such that the cap does not have to be screwed on over the entire length of the threads, but needs only to be rotated through a small angle to create the attachment to the sleeve. Due to the division of the threads 80 and 82 into segments, as will be explained in detail below, a quick connection is created which assures that the cap 8 will be fastened reliably on the sleeve 2 with little loss of time.
The sleeve 2 advantageously has an abutment 84 for the axial face 86 of the cap 8. The abutment 84 contains a detent groove 88 running in the radial direction. The detail represented at the upper right in FIG. 6 shows this radial detent groove 88 in a position rotated 90° out of the plane of drawing. The cap contains in its axial end face 86 a corresponding detent 90 which, when the cap reaches the predetermined rotational position of the cap 8 with respect to the sleeve 2, engages in the detent groove 88. The sleeve 2 contains in the center an annular recess 92 whose bottom contains at least one surface for engagement by a tool and is configured preferably as an octagon for a fork wrench. With the tool or fork wrench, an operator can hold the sleeve easily as the cap is being threaded on.
In this embodiment, the clamping ring 6 contains an abutment 96 which limits the axial movement of the clamping ring 6 as the tube end 3 is inserted, so that during the insertion of the tube end 3 the sealing ring 38 will not be additionally compressed and the insertion force required will remain virtually unchanged. Without the abutment 96, when the tube end 3 is inserted the clamping ring would be driven in the direction of insertion indicated by the arrow 28, until the sealing ring 38 comes in contact with the sleeve 42. Since the clamping ring 6 rests tightly on the external surface of the pipe end 3, the resilient sealing ring 38 would become compressed, resulting in radial pressure on the external surface and an increase in resistance to the insertion. As a result of the abutment 96, the locking action of the clamping ring 6 is performed in an especially practical manner because, when the insertion takes place, there is no increase of the bias of the sealing ring 38 and thus any increase in the required insertion force is avoided. For the abutment 96, which is configured as a radial lug, ring, segment or the like, a free space 98 is provided, the axial length of which is adapted to the allowable movement of the clamping ring 6. The free space 98 is provided expediently between an axial end face 100 of the sleeve 2 and a bead or step 102 inside of the cap 8. The clamping ring 6 with the abutment 96 can thus be installed and used without problems.
In the left half of FIG. 6 the pipe end 3 is shown in the position in which during its insertion it reaches the sliding body 50. As explained in connection with the first embodiment in FIG. 2, in this position the sliding body 50 is still connected to the sleeve 42 by a small spur of material. As insertion of the pipe end 3 continues this connection is broken and the sliding body 50 is driven to the right in the direction of arrow 28. Thus the striking means or tongue 52 arrives at the end face 58 of the sleeve 42, and as insertion continues it is forced radially inward. Then the striking means 52 snaps over the edge 60 and then strikes against the abutment surface 62 which in this special embodiment is a component of the sleeve 2. In accordance with the invention, the surface lies on a greater radius than the edge 60, and as the tongue or striking means 52 snaps back radially outward, the signal is produced which is heard by an operator and/or is felt by the hand as a vibration.
FIGS. 7 and 8 show the sleeve 42, in which the sliding body 50 is still held fast by the spur 66. In comparison with the embodiment explained in FIG. 2, the sleeve 42 has less axial length, since the above-explained abutment surface is not a component of the sleeve, but lies inside of the sleeve.
FIGS. 9 and 10 show the clamping ring 6 with the abutment 96. As it can be seen in FIG. 10, the abutment 96 is divided into a number of segments. The clamping ring 6 furthermore contains the above-mentioned conical exterior surface 10, which is brought into contact with the corresponding conical inside surface of the fastening body or cap. In this embodiment the clamping ring 6 is provided in the area of the conical exterior surface 10 with slots 104 to create at least one radially flexible tongue 106. The at least one tongue 106 has a nosing 108 by which, when the cap is screwed on, the tongue 106 is pressed further inward radially toward the longitudinal axis 20 than are the other areas of the clamping ring 6 provided with the slit 14. The gripping tab 110 of tongue 106 is thus forced more strongly into the exterior surface of the inserted tube end than are the other portions of the tooth 16. This results in a local increase of the surface pressure between the gripping tab 110 and the tube and thereby a considerable improvement of the holding force is assured. The push-in pipe coupling thus configured assures a lasting, reliably acting and positive junction even in the case of very high internal pressures in a conduit system. The nose 108 projects beyond the conical exterior surface 10 of the clamping ring 6 at a given height 112. The height 112 of the nose and the size of the clamping tongue 106 are coordinated with one another such that a secure positive fit between the clamping ring 6 and the inserted tube end is assured. As can be seen in FIG. 10, three radially flexible tongues 106 advantageously are provided, which extend preferably over an angle of 20° to 40°, especially of an order of magnitude of 30° with respect to the longitudinal axis 20.
FIG. 11 shows in an axial section the sleeve 2 of the embodiment according to FIG. 6, and FIG. 12 shows an axial elevation in viewing direction XII of FIG. 11. The three thread segments 114 of the external thread and the gaps 116 are easily seen in FIG. 12. In FIG. 11 the lower threaded segments 114 and the gaps 116 extend in each case over an angle of approximately 60°. Also the associated internal thread of the cap is divided accordingly into threaded segments and gaps. To produce the junction the cap is first slipped axially onto the sleeve 2 such that the threaded segments of the cap engage the gaps in the sleeve 2 and vice-versa. Then the cap is to be rotated only over a given angle, especially only about 60°, such that the thread segments of the cap become engaged in the thread segments of the sleeve 2. By means of the detent explained above, which enters into the detent groove of the sleeve, the defined rotational angular position of the cap is assured for a lasting and reliably operating lock on the sleeve 2.
The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof. | A push-in coupling for pipes contains a sleeve body (2) and a holding means, especially with a clamping body (6), for connecting a pipe end (3, 4) to the sleeve body (2). This push-in coupling permits proper handling with little effort during assembly, and insofar as possible prevents the danger of faulty assembly. A sliding body (50) is disposed within the sleeve body (2), the sliding body (50) being made independently of the holding means. The sliding body (50) contains a striker (52) which upon insertion of the pipe end (3, 4) is pushed over an edge (60), and upon reaching a given depth of insertion of the pipe end (3, 4) strikes against a surface (62) producing a detectable signal such as an acoustical signal and/or a vibration signal. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to Korean Patent Application Number 10-2009-0083934 filed Sep. 7, 2009, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a noise reduction apparatus for a shift cable, in more detail, a technology that can be used to prevent gear whine noise of an automatic transmission vehicle from traveling into the passenger compartment through a shift cable.
2. Description of Related Art
A transmission equipped in vehicles has a basic structure that has a shift lever, which is an internal operator, regardless of whether it is a manual transmission or an automatic transmission, and transmits the operational force of the shift lever to the transmission through a shift cable.
Therefore, gear whine noise generated from the transmission having the structure can travel into the passenger compartment through the shift cable, and accordingly, a method of attaching a mass damper to the shift cable is commonly used in the related art to exclude the noise.
The method of attaching a mass damper to the shift cable described above, however, has a problem that the weight is necessarily increased by the mass damper and the cost is considerable.
The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
Various aspects of the present invention are directed to provide a noise reduction apparatus for a shift cable which can improve silence and ride comfort of the vehicle by effectively absorbing and preventing noise from traveling into the passenger compartment from the transmission through the shift cable, without using an excessive weight, such as a mass damper.
In an aspect, the present invention may provide a noise reduction apparatus for a shift cable having a mounting socket that is fixed to a shift lever mounting bracket, with an inner cable of the shift cable therethrough, a cable connection pipe that has one side connected to a shift lever-sided end of an outer cable of the shift cable, and a housing connection pipe that has one end elastically-coupled to a shift lever-sided end of the cable connection pipe with a predetermined distance therebetween by a first antivibration member in a damper housing and the other end thereof elastically-connected to the shift lever mounting bracket by a second antivibration member in the mounting socket.
The shift lever-sided end of the cable connection pipe may have a flange having an increased diameter, the housing connection pipe has first and second flanges having an increased diameter at both the end one and the other end thereof respectively, the damper housing is formed to cover the flange of the cable connection pipe and the first flange of the housing connection pipe to prevent the flange of the cable connection pipe and the first flange of the housing connection pipe from opening, and the first antivibration member prevents direct contact among the damper housing, the flange of the cable connection pipe and the first flange of the housing connection pipe, and the second antivibration member prevents direct contact between the mounting bracket and the second flange of the housing connection pipe.
The mounting socket may be formed to cover the second flange of the housing connection pipe to restrict relative motion of the second flange in a longitudinal direction of the shift cable with respect to the mounting socket.
The flange of the cable connection pipe and the first flange of the housing connection pipe in the damper housing may be positioned to correspond to each other in the same shape, and the one end and the other end of the housing connection pipe are formed in the same shape in symmetry.
The cable connection pipe may further include a spacer formed along an inner circumference thereof to receive the inner cable therein.
The housing connection pipe may further include a spacer formed along an inner circumference thereof to receive the inner cable therein.
In another aspect of the present invention, the noise reduction apparatus for a shift cable, may include a mounting socket that is fixed to a shift lever mounting bracket, with an inner cable of the shift cable therethrough, a cable connection pipe that has one side connected to a shift lever-sided end of an outer cable of the shift cable, and a damper housing that has one side elastically coupled to a shift lever-sided end of the cable connection pipe by a first antivibration member therein and the other side thereof elastically coupled to the shift lever mounting bracket in the mounting socket by a second antivibration member.
The damper housing may have an integral flange having an increased diameter at the other end thereof which is disposed in the mounting socket while the one side thereof covers a flange formed in the shift lever-sided end of the cable connection pipe and elastically coupled thereto by the first antivibration in the damper housing, wherein the first antivibration member prevents direct contact between the flange of the cable connecting pipe and the damper housing, and the mounting socket is formed to cover the integral flange of the damper housing and elastically coupled thereto by the second antivibration to restrict relative motion of the integral flange in a longitudinal direction of the shift cable with respect to the mounting socket, wherein the second antivibration member prevents direct contact between the integral flange of the damper housing and the mounting socket.
The cable connection pipe may further include a spacer formed along an inner circumference thereof to receive the inner cable therein.
In further another aspect of the present invention, the noise reduction apparatus for a shift cable, may include at least two cable connection pipes that have one side connected to an end of an outer cable of the shift cable and the other side thereof having a flange having an increased diameter respectively, a damper housing that is formed to cover the flanges formed in the other side of the respective cable connection pipe to prevent the flanges from opening, wherein the flanges are spaced with a predetermined distance therebetween in the damper housing, and an antivibration member elastically coupling the flanges in the damper housing to prevent direct contact between the flanges of the respective cable connection pipe and between the flanges and the damper housing.
An inner diameter of the cable connection pipe may be set such that an inner cable of the shift cable passes the cable connection pipe without contacting, wherein the cable connection pipe and the outer cable are connected by swaging.
The respective cable connection pipe may further include a spacer formed along an inner circumference thereof to receive the inner cable therein.
The respective cable connection pipe may have a T-formed cross section with the flange, and the damper housing may have a U-formed cross section that covers the flanges having a T-formed cross section while rotating about the respective cable connection pipe.
The present invention makes it possible to improve silence and ride comfort of a vehicle by effectively absorbing and intercepting noise traveling into the vehicle from the transmission through a shift cable, without using an excessive weight, such as a mass damper.
The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an exemplary noise reduction apparatus for a shift cable according to the present invention;
FIG. 2 is a view showing another exemplary noise reduction apparatus for a shift cable according to the present invention;
FIG. 3 is a view showing another exemplary noise reduction apparatus for a shift cable according to the present invention; and
FIG. 4 is a view illustrating when an exemplary mounting socket according to the present invention is mounted.
It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
Referring to FIGS. 1 and 4 , an exemplary embodiment of the present invention includes, a mounting socket 5 that is fixed to a shift lever mounting bracket 3 , with an inner cable 1 of a shift cable 15 therethrough, a cable connection pipe 7 that has one side connected to the shift lever-sided end of an outer cable 20 of shift cable 15 , a damper housing 11 that is connected to the shift lever-sided end of cable connection pipe 7 by an antivibration member M, and a housing connection pipe 13 that has one end connected to damper housing 11 by an antivibration member M and the other end connected to mounting socket 5 by an antivibration member M.
That is, vibration transmitted through the outer cable 20 of shift cable 15 is intercepted by a double antivibration structure that intercepts the vibration primarily at damper housing 11 and secondarily at mounting socket 5 .
The shift lever-sided end of cable connection pipe 7 has a flange F having an increased diameter, housing connection pipe 13 also has a flange F having an increased diameter at both ends, damper housing 11 is shaped to cover flange F of cable connection pipe 7 and flange F of housing connection pipe 13 and prevents the flanges from opening, and antivibration member M prevents direct contact between damper housing 11 , flange F of cable connection pipe 7 , and flange F of housing connection pipe 13 .
That is, cable connection pipe 7 has a T-shaped cross section with flange F, housing connection pipe 13 also has a T-shaped cross section at one side, similar to flange F of cable connection pipe 7 , while facing flange F of cable connection pipe 7 , and damper housing 11 has a U-shaped cross section that covers two flanges F having a T-shaped cross section while rotating about cable connection pipe 7 .
Mounting socket 5 is shaped to cover flange F of housing connection pipe 13 to restrict relative motion of flange F in the longitudinal direction of shift cable 15 with respect to mounting socket 5 , and antivibration member M prevents direct contact between flange F of housing connection pipe 13 and mounting socket 5 .
Flange F of cable connection pipe 7 and flange F of housing connection pipe 13 in damper housing 11 are positioned to correspond to each other in the same shape, and both ends of housing connection pipe 13 are formed in the same shape in symmetry.
That is, housing connection pipe 13 and cable connection pipe 7 basically have the same shape, but cable connection pipe 7 has only at one side the same shape as housing connection pipe 13 .
Cable connection pipe 7 and the outer cable 20 are connected by swaging and the inner diameter of cable connection pipe 7 is set such that inner cable 1 of shift cable 15 pass the cable connection pipe without contacting.
In an exemplary embodiment of the present invention, the cable connection pipe 7 and the housing connection pipe 13 may include a spacer 25 along inner circumference thereof such that the contact between the inner cable 1 and the cable and housing connection pipes 7 and 13 may be minimized.
Therefore, noise traveling from the transmission to the shift lever through the outer cable 20 of shift cable 15 is primarily absorbed and intercepted by the antivibration member M in damper housing 11 and the secondarily absorbed and intercepted by antivibration member M in mounting socket 5 , such that the noise does not substantially travels into the interior. Accordingly, it is possible to improve silence and ride comfort of the vehicle.
For reference, mounting socket 5 is fixed to shift lever mounting bracket 3 equipped with the rotatable shift lever, as shown in FIG. 4 , such that shift cable 15 is fixed to shift lever mounting bracket 3 .
FIG. 2 shows another exemplary embodiment of the present invention, which includes a mounting socket 5 that is fixed to a shift lever mounting bracket 3 , with an inner cable 1 of a shift cable 15 therethrough, a cable connection pipe 7 that has one side connected to the shift lever-sided end of an outer cable 20 of shift cable 15 .
The present exemplary embodiment may further includes a damper housing 11 - 2 which is formed by integrally fixing the housing connection pipe 13 to the damper housing 11 such that the damper housing 11 - 2 has one side connected to the shift lever-sided end of cable connection pipe 7 by an antivibration member M and the other side connected to mounting socket 5 by an antivibration member M.
The shift lever-sided end of cable connection pipe 7 has a flange F having an increased diameter, damper housing 11 - 2 has an integral flange F having an increased diameter at the end in mounting socket 5 while covering flange F of cable connection pipe 7 , mounting socket 5 is shaped to cover flange F of damper housing 11 - 2 to restrict relative motion of flange F in the longitudinal direction of shift cable 15 with respect to mounting socket 5 , antivibration member M prevents direct contact between flange F of damper housing 11 - 2 and mounting socket 5 , and antivibration member M prevents direct contact between damper housing 11 and flanges F of cable connection pipe 7 .
In an exemplary embodiment of the present invention, the cable connection pipe 7 may include a spacer 25 along inner circumference thereof such that the contact between the inner cable 1 and the cable connection pipe 7 may be minimized.
That is, as compared with the exemplary embodiment of FIG. 1 , the present exemplary embodiment reduces the number of parts, the weight, and the assembly process, by removing housing connection pipe 13 and making damper housing 11 - 2 itself function as housing connection pipe 13 .
FIG. 3 shows another exemplary embodiment of the present invention, which includes a cable connection pipe 7 that has one side connected to the end of an outer cable 20 of a shift cable 15 and the other side with a flange F having an increased diameter, a damper housing 11 that is shaped to cover two opposite flanges F of cable connection pipe 7 to prevent the flanges from opening, and an antivibration member M that prevents direct contact between two flanges F of cable connection pipe 7 and between two flanges F and damper housing 11 .
In the present exemplary embodiment, two cable connection pipe 7 and damper housing 11 are disposed at the middle portion of shift cable 15 , such that this configuration makes it possible to freely select an optimum mounting position because the entire noise-traveling characteristics of shift cable 15 change in accordance with the position of damper housing 11 , and can be used to replace when it is hard to install shift lever mounting bracket 3 , and mounting socket 5 and damper housing 11 around the shift lever mounting bracket.
Cable connection pipe 7 and the outer cable 20 are connected by swaging and the inner diameter of cable connection pipe 7 is set such that inner cable 1 of shift cable 15 pass the cable connection pipe without contacting.
In an exemplary embodiment of the present invention, the cable connection pipe 7 may include a spacer 25 along inner circumference thereof such that the contact between the inner cable 1 and the cable connection pipe 7 may be minimized.
Cable connection pipe 7 has a T-shape cross section with flange F and damper housing 11 has a U-shaped cross section that covers two T-shaped flanges F while rotating about cable connection pipe 7 .
Antivibration members M may be made of rubber in the exemplary embodiments, and any other materials may be used as long as they can effectively absorb and intercept vibration and maintain mechanical stable positional relationships among damper housing 11 , cable connection pipe 7 , and housing connection pipe 13 .
For convenience in explanation and accurate definition in the appended claims, the terms “inner” or “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A noise reduction apparatus for a shift cable, may include a mounting socket that is fixed to a shift lever mounting bracket, with an inner cable of the shift cable therethrough, a cable connection pipe that has one side connected to a shift lever-sided end of an outer cable of the shift cable, and a housing connection pipe that has one end elastically-coupled to a shift lever-sided end of the cable connection pipe with a predetermined distance therebetween by a first antivibration member in a damper housing and the other end thereof elastically-connected to the shift lever mounting bracket by a second antivibration member in the mounting socket. | 5 |
GOVERNMENT INTEREST
The government has rights to this invention pursuant to Contract No. F33615-77-C-2034 awarded by U.S. Airforce.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hydraulic ram type actuators. More particularly, it relates to the provision of a hydraulic ram type actuator system which is capable of accepting a digital command and which exhibits certain advantages in efficient use of hydraulic power and an invulnerability to hardover failure of its output element when compared with a valved ram or a valved rotary hydraulic motor driven servo.
2. Description of the Prior Art
The actuator system of this invention is suitable for, but not limited to, use for positioning control surfaces of an aircraft, e.g. a flap.
Conventional systems for positioning control surfaces of an aircraft normally utilize a valved ram or valved rotary hydraulic motor type actuator. A disadvantage of these systems is that the valved hydraulic ram or motor cannot adapt its power consumption to load demands and must dissipate large amounts of hydraulic power across the orifices of its control valve whenever a high rate with less than maximum output force or torque is demanded. A second disadvantage of such systems is that they require a feedback to insure adequate dynamic response and as a result are susceptible to a hardover reaction of the output in the event of a loss of the feedback signal continuity.
There are some flight control surface actuators in existence which have power conserving properties when used on dynamically active surfaces. However, under static output conditions, these systems waste power by keeping a variable displacement pump in constant rotation at a high rotational speed.
Present trends of aircraft actuation systems are toward electrically controlled hydraulic actuators. Centrally located on-board digital computers or dispersed individual microprocessors are foreseen to provide the command signals to these actuators. Present state-of-the-art actuators and controls are analog type devices that require digital to analog conversion components to be compatible with the digital electric control signals.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, an electric stepping motor, operable by an incremental command signal, is used to operate a rotary distributor valve which serves to control the flow of hydraulic fluid to and from a hydraulic power transfer unit. The power transfer unit comprises a plurality of piston-cylinder units and means operable in response to sequenced pressurization of cylinders, and attendant piston movement, to drive a wobble plate which sequences an output valve. These pistons, being double ended, serve also to displace fluid to or from the output ports of the power transfer unit. The output shaft of the stepping motor is connected to a rotary port control member which, when rotated, opens and closes ports to control the distribution of hydraulic fluid to and from the output cylinders. During operation, a group of the cylinders which are pressurized in series are in communication with hydraulic pressure and the rest are vented to a return line. Stepping motor rotation of the rotary control member sequences pressurization by progressively adding a cylinder to the forward edge of the pressurized group and removing a cylinder from the trailing edge of the pressurized group, to in that manner deliver driving pulses of hydraulic pressure to the pistons of the hydraulic power transfer unit. Each group of pressurized cylinders functions to drive the wobble plate output of the hydraulic transfer unit into a new position of equilibrium and then hold it in such position until another change is made in the makeup of the pressurized group. Owing to this arrangement, an increment of wobble displacement of the wobble plate output member occurs in direct response to each command pulse that is received by the stepping motor.
An increment of wobble plate motion in one direction results in an increment of fluid transfer from one side of the piston in a hydraulic ram to the other side and an increment of wobble plate motion in the opposite direction results in a reversal in the direction of fluid transfer and ram movement.
Accordingly a principal object of the present invention is to provide an electrohydraulic mechanism which will provide an incremental displacement or movement of a hydraulic ram for each electric pulse transmitted from a computer or microprocessor.
An advantage of this type of system is that the hydraulic power transfer unit demands hydraulic flow and demands power only in proportion to the magnitude of the output load or force of the ram.
Another object of the present invention is to provide an incrementally driven linear hydraulic motor or ram with a source of make-up hydraulic fluid or quiescent pressure for substantially maintaining a predetermined average pressure level between the two sides of the piston, in order to maintain output stiffness of the ram. One system for performing this function includes a regulating valve which meters flow of make-up fluid in response to fluctuations in the average of the two pressures on the opposite sides of the ram piston. A hydraulic ram incremental actuator equipped with a make-up system of this type, may be provided with a monitor feedback circuit which senses the position of the driven member and sends a signal based on such position to apparatus for changing the command signal to the stepping motor, if necessary, in order to bring the input and output functions into synchronization.
In another embodiment of the invention, the apparatus used for providing quiescent pressure for the ram includes a four-way flow control valve of low capacity or gain adapted to drive the ram in parallel with the output of the positive displacement hydraulic transfer unit. This form provides an absolute correspondence between the electric stepper motor input and the ram output. No monitor feedback is required in this case because all fine position is accomplished by the control valve and its positioning mechanism.
According to an aspect of the invention, the linear hydraulic motor or ram actuator is used aboard an aircraft for actuating a flight control flap or the like and command signals for the stepping motor are provided by an onboard digital computor or microprocessor.
These and other objects, advantages and features of the present invention are evident from the embodiments of the invention which are illustrated by the drawings and described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings like element designations refer to like parts, and,
FIG. 1 is a schematic diagram of a first embodiment of the invention, in which the linear hydraulic motor or ram is used aboard an aircraft for moving a control surface, and is provided with a feedback monitor for the stepping motor controller and a make-up valve controlled by an average of the two pressures on the opposite sides of the ram piston;
FIG. 2 is an enlarged scale view of the make-up valve shown in FIG. 1;
FIG. 3 is a schematic view of a second embodiment of the invention, in which a four-way flow control valve of low capacity or gain is used to drive the ram in parallel with outputs of the power transfer unit;
FIG. 4 is an enlarged scale view of the four-way flow control valve shown in FIG. 3;
FIG. 5 is an isometric diagrammatical view of the stepping motor, the distributor valve and an end portion of the hydraulic motoring section for the fluid power transfer unit; and
FIG. 6 is an axial sectional view of an embodiment of the hydraulic power transfer unit.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, an electrical stepping motor 12 is shown to include an output shaft 14 which is coupled to a rotary port control member 16 of a rotary hydraulic pressure distributor valve 18.
Valve 18, which will be hereinafter described in detail, may be housed within an end portion of hydraulic power transfer unit 20. Such unit, which will also be hereinafter described in detail, comprises a piston type hydraulic motoring section, controlled by the valve 18, which drives a positive displacement apparatus for transferring hydraulic fluid between the two sides of a piston in a linear hydraulic motor or ram 22.
Ram 22 is shown to comprise a cylinder 24, an end 26 of which is suitably connected to a support member. A balanced piston 28 within cylinder 24 divides the interior of the cylinder into first and second expansible chambers 30, 32, located at opposite sides of the piston 28. A first piston rod 34 extends from one side of piston 28, through chamber 30, and then through a sealed opening 36 formed in the end wall at the fixed end of the cylinder 24. Piston rod 34 terminates in a free end outside of the cylinder 24. A second piston rod 38 extends in the opposite direction from the piston 28, through chamber 32, and then out through a sealed opening 40 in the opposite end wall of cylinder 24. The outer end of piston rod 38 is attached to a load, e.g., an end of a crank arm 42 which extends radially outwardly from a live shaft 44 on a control surface 46.
The electric stepper motor 12 is reversible and is controlled by a command signal from a controller 48. In the embodiment shown by FIG. 1, the control surface shaft 44 is connected to and drives a pair of shaft encoders or position transducers 50, 52, which are a part of a monitor feedback system.
In operation of the monitor feedback circuit, an error is generated at summing junction #1 between the input command and a signal from a position transducer 50, 52, indicating the position of the control surface 46. This error is compared to several fixed magnitude values. When the first gate value is exceeded a train of corrective pulses or steps, whose sum is equal to the magnitude of the first gate error threshold, is added to the system command at summing junction #2. This train of corrective pulses is input at a limited rate and serves to bring input and output functions into synchronization at the time of system start up and correct errors or missed steps which occur for any reason. Comparison of error with a second and larger gate threshold at gate 2 is used to switch the monitor feedback function from a primary output encoder 50 to a secondary or standby unit 52. A third and still higher error threshold level at gate 3 is used to disable the error correcting function altogether, causing the unit to revert to operation as an open-loop stepping motor feedback correction.
Know feedback systems are "high gain" closed-loop systems. In the event of a failure of the feedback continuity the flight control surface or other driven element that is being actuated by the conventional actuator would slam hard over to a stop position. If the monitor system of the present invention were to fail, the driven element would not slam hard over. It would move over but slowly, causing the monitor system to disconnect the error corrective feedback function. The pilot would have sufficient time to detect if something was wrong and correct it by manually trimming out whatever positional error was present at the control surface.
In a manner to be hereinafter described in detail, operation of the hydraulic power transfer unit 20 results in an incremental transfer of hydraulic fluid from one of the ram chambers 30, 32 to the other. In a system of this type it is necessary to provide a source of makeup hydraulic fluid to maintain a predetermined desired average pressure level between the two sides of the control ram or actuator 22 in order to maintain sufficient output stiffness of the ram 22. The make-up circuit shown by FIG. 1 includes a pressure regulating valve 54 which includes a port control member 56 located within a housing 58. As best shown by FIG. 2, port control member 56 may be in the form of a spool comprising a plurality of axially spaced apart lands 60, 62, 64, 66 separated by reduced diameter portions 68, 70, 72. Annular chambers 74, 76, 78 are formed within the housing 58 axially between each adjacent pair of lands and circumferentially about the reduced diameter portions of the spool 56. In conventional fashion, the housing 58 is constructed to include a plurality of ports 80, 82, 84, constituting inlets to passageways which communicate with the return pressure line 86 of a hydraulic fluid circuit. Housing 58 also includes ports 88, 90, constituting outlets for passageways leading from the system pressure line 92. Housing 58 further includes a port 94 at the valve end of a passageway 96 which communicates with expansible chamber 30 and a port 98 at the valve end of a passageway 100 which communicates with expansible chamber 32.
A first end of port control member 56 is in contact with a compression spring 102 which functions to bias spool 56 to the right, as pictured. The opposite end of spool 56 includes a reduced diameter portion 104 extending endwise outwardly from land 56. An annular chamber 106 is formed around end portion 104, between an end surface 108 of land 66 and an opposing radial surface of a fixed wall 110. End portion 104 is snuggly received in a central opening in wall 110. A seal is provided between the two so that when leakage does not occur between chamber 106 and another fluid chamber 112 located on the opposite side of wall 110.
One of the passageways 96, 100 communicates with chamber 106 and the other communicates with chamber 112. As a result, the pressure within one of the chambers 30, 32 is subjected to the end surface 108 on land 66 and the pressure in the other chamber 30, 32 is subjected to an end surface 114 at the end of spool 56 opposite the spring 102. This arrangement will result in an average of the pressures in the two chambers 30, 32 acting to produce a force on member 56 in opposition to the force of the spring 102 action on the opposite end of member 56. As long as the average pressure does not vary from a predetermined desired value, the system is in equalibrium and there is no movement of valve member 56. However, any change in the average pressure of the two chambers 30, 32 will be sensed at the pressurized end of member 56, and will result in endwise movement of member 56. As is evident from FIGS. 1 and 2, a decrease in the pressure created force at the pressurized end of member 56 would result in a movement of member 56 to the right (as illustrated). Movement of lands 62, 60 out from positions in which they block ports 88, 90, results in system pressure being communicated to both chambers 30, 32, via supply avenues 92, 88, 74, 94, 96 and 92, 90, 78, 98, 100. When the pressure in chamers 30, 32 is increased to the desired level the pressure created force at the pressurized end of member 56 will increase enough to move member 56 back to the left (as pictured) in opposition to the force of spring 102, until lands 62, 64 again close the ports 88, 90. Any excess pressure force will move member 56 an additional amount to the left (as pictured) until lands 60, 64 are moved out from positions in which then block the ports 80, 84. This results in a momentary venting of the chambers 30, 32 to the pressure return 96, via avenues 96, 94, 74, 80 and 100, 98, 78, 84. Such venting will continue until the over pressure condition is relieved, the pressure created force at the pressurized end of member 56 is reduced, and the spring 102 has returned the member 56 to the position shown by FIG. 2.
A second method of providing quiescent pressure for a ram actuator constructed according to the present invention employs a four-way flow control valve 116 of low capacity or gain to drive the ram 118 in parallel with outputs of the power transfer unit 20. This type of valve action provides an absolute correspondance between the electric stepper motor input and the hydraulic ram output. No monitor feedback is required in this type of system because all fine positioning is accomplished by the four-way valve 116 and the hydraulic servo repeater circuit. The power transfer unit 20 handles the major portion of any command response. The parallel valve system acts as an integrating trim and also provides for regulation of the quiescent ram pressures.
Referring to FIG. 3, the second embodiment of the invention comprises a cylinder 120 having end walls 122, 124. A piston 126 divides the interior of the cylinder 120 into first and second expansible chambers 128, 130. A first piston rod 132 projects from piston 126, through chamber 128, and then through a sealed opening in end wall 122. Piston rod 132 includes a suitable connector 134 at its outer end for connecting it to a fixed support 136. A second piston rod 138 projects from piston 126 in the opposite direction, through chamber 130, and then through a sealed opening in end wall 124, and terminates in a free end 140. Piston rod 138 is provided to balance the areas of the pressure faces of the piston 126.
In this embodiment the piston assembly 126, 132, 140 is fixed and the cylinder 120 moves relative to it as hydraulic fluid is exchanged between the two chambers 128, 130. The end of cylinder 120 opposite the piston connection 134 is connected to a load, shown in the form of a crank are 144 which projects radially from a live shaft of a control surface 146. As is evident, axial movement of cylinder 120 will cause the control surface 140 to pivot about the axis of such shaft.
In this embodiment the housing 148 of trim valve 116 is carried by and may be an integral a part of the housing of cylinder 120. Housing 148 includes an elongated chamber for receiving a sliding port control member 150 which may be of the spool type. In a manner conventional to four-way spool type valves, the housing 148 is formed to include a pair of ports 152, 154 connectable with the system return line 155 and a pair of ports 156, 158 connectable with the system pressure line 159.
The electric stepping motor 12 includes an output shaft at its end opposite the rotary distributor valve 18 which is connected to and drives a gear reduction 160 having a rotary output connected to a crank arm 162. Thus, the stepping motor 12 rotates both the distributor valve port control member and the crank arm 162, about coinciding axes. The outer end of crank arm 162 is connected via a short link 164 having a pivot joint at each of its ends to a guided connector rod 166 which in turn is connected to the valve spool member 150.
As best shown by FIG. 4, valve spool member 150 comprises lands 168, 170, 172, and reduced diameter portions 174, 176, between adjacent lands. Annular fluid chambers 178, 180 are defined axially between the lands 168, 170, 172 and about the reduced diameter portions 174, 176. The cylinder housing is formed to include ports 182, 184, communicating with the chambers 178, 184, respectively. Port 182 also communicates with a passageway 186 leading into chamber 128 and port 184 communicates with a passageway 188 leading into chamber 130.
As previously explained, operation of hydraulic power unit 20 in one direction transfers hydraulic fluid from chamber 128 to chamber 130 and operation in the opposite direction reverses the direction of fluid transfer. Hydraulic power transfer unit 20 is driven in increments and hence it transfers fluid in increments and the ram 118 is driven in increments. The gear ratio of gear reducer 160 is chosen such that ideally the valve port control member 150 will move axially in increments which are equal to the increments of movement of cylinder housing 120 for any given incremental rotation of the stepping motor 12. In other words, the system design is that the trim valve housing 148, which is a part of or is carried by the housing of cylinder 120, and the valve port control member 150 will move together in equal increments or bits. When this happens the trim valve 116 will not function as neither trim nor fluid make-up are necessary. However, if the electric stepper motor input and the hydraulic ram output get out of synchronization for any reason, a differential movement of housing 148 and port control member 150 will occur, causing valve 116 to function by supplying fluid for driving the ram 118 in a position-correcting direction.
For example, a differential movement of the port control member 150 to the right, as illustrated in FIG. 4, will result in movement of lands 170, 172 to uncover ports 152, 158. This results in chamber 130 being brought into communication with the system pressure via port 150, chamber 180, port 184 and passageway 188. It also results in chamber 120 being brought into communication with the system return pressure via passageway 186, port 182, chamber 178 and port 152. Since the piston 128 is fixed and the cylinder 120 is allowed to move, this addition of fluid into chamber 130 and removal of a like amount of fluid from chamber 120, will cause the cylinder 120, and hence the ram output, and the valve housing 148, to be shifted to the right (as pictured).
Although the system of FIG. 3 is illustrated to employ a mechanical connection between an output of the electric stepping motor 12 and the port controller four-way valve 116, it is to be understood that the same result could be obtained by using a digital-to-analog converter driving an analog electrohydraulic valve with either digital or analog feedback of the ram output position.
FIG. 5 is a diagram of a porting sequence for a six cylinder hydraulic motoring device of a type which may be used in the power transfer unit 20. In this figure the valve ports in both the pressure and return sections of the valve have been given the same numbers as the associated cylinders of the hydraulic motor. The sequence of pressurization can be determined from FIG. 5 by visualizing a step-by-step rotation of the valve port control member 16. Such sequence of pressurization may be diagrammed as follows:
______________________________________Six Cylinder Sequence of Pressurization______________________________________1 21 2 3 2 3 2 3 4 3 4 3 4 5 4 5 4 5 6 5 6 5 6 1 6 1 6 1 2Diagram I______________________________________
The number of cylinders is a variable. By way of example, another installation may involve a nine cylinder motor and a sequence of pressurization as follows:
______________________________________Nine Cylinder Sequence of Pressurization______________________________________ 1 2 3 1 2 3 4 2 3 4 2 3 4 5 3 4 5 etc.Diagram II______________________________________
The sequence of pressurization that is illustrated by these diagrams is of a type which progresses first by adding a cylinder to the forward edge of the pressurized group of cylinders and then removing from the trailing edge of the pressurized group.
Referring now to FIG. 6, the distributor valve 18, the hydraulic motoring section 190 and the transfer or pumping section 192 of the power transfer unit 20 may share a common housing 194.
Unit 20 includes an input shaft 196 which is coupled to and is driven by the stepper motor shaft 14 (FIG. 1) and is journaled for rotation at one end of the housing 194 in a central portion of an end member 198, by means of a bearing 200. Shaft 196 is connected to and rotates the rotary port control member 16 of the distributor valve 18. Port control member 16 is rotatably received within a stationary valve sleeve 202.
End plate 198 is formed to include an inlet port 204 that is connected with the system pressure line 206 and a second port 208 which is connected with the system return line 210. Port 204 is a port of a passageway 212 which is shown to extend from the inner end of port 204, first axially through both end member 198 and an end portion of cylinder block 190, and then radially inwardly through cylinder block 190 to communicate with an annular groove 214 formed in the peripheral portion of sleeve 202. In similar fashion, another passageway extends from the inner end of port 208, first axially through both end member 198 and such end portion of cylinder block 190, then radially through cylinder block 190 to communicate with a second annular groove 218 formed in the periphery of sleeve 202, at a location spaced axially from groove 214. Ports and passageways formed in sleeve 202, port control member 16 and cylinder block 190 function to sequence pressurization as member 16 is rotated in accordance with a sequence plan such as shown in diagram I above.
The motoring cylinders 220 may constitute bores formed in the cylinder block 190.
By way of typical and therefore nonlimitive example, block 190 at its end opposite end member 198 of the motoring cylinder, may be telescopically received in, and connected to, an end of a tubular housing 222. A cylinder block 224 of the pumping or outlet section of the unit 20 may be housed within the opposite end portion of housing 222, and may be spline connected to the housing 222 at location 223 as illustrated. Cylinder block 224 is constructed to include the same number of cylinders 226 as motoring cylinder block 190. The motoring cylinders 220 and the pumping cylinders 226 are axially aligned and a double ended piston member 228 is associated with each aligned pair of cylinders 220, 226. The motoring pistons 230 and the pumping pistons 232 are separated by a spherical wobble plate coupling 234.
The ends of motoring cylinders 220 adjacent the end member 198 may be closed by plugs 236. The closed ends of pumping cylinders 226 are closed by a ported end wall portion 238 of the cylinder block 224 and a rotating disc valve member 242. A port 240 extends from each cylinder 226 through the end wall 238. The outer ends of ports 240 are open and closed by the rotating disc valve member 242 which is housed within unit 20, axially between end wall 238 of cylinder block 242 and an end member 244. End member 244 includes a first port 246 which connects to a line leading to ram chamber 30, 128 and a second port 248 which is connected to a line which leads to ram chamber 32, 130. Port 246 includes an axial portion 240 having an inner end which is adjacent to the rotating disc valve 242. In similar fashion, port 248 includes an axial portion 252 having an end which is also adjacent to the rotating disc valve 242. Disc valve 242 includes passageways in it which are separated by closed sections. The spacing and arrangement of the passageways in the disc valve 242 is such that each pumping cylinder 226 is in communication with one of the ports 246, 248 while the piston 232 therein is retracting and is in communication with one of the ports 246, 248 while the piston 232 therein is advancing.
Disc valve 242 is spline connected or otherwise attached to an end of the crank shaft 254 which may be journaled for rotation with cylinder block 224 by means of bearings 256, 260. A crank element 262 at the opposite end of shaft 254 engages a bearing 276 secured to a central portion of a wobble plate 266. The central portion of wobble plate 266, on the side thereof opposite bearing 276, is formed to provide a spherical socket or cup 268 having a flared entrance.
The socket 268 provides a seat for the spherical head 270 of a wobble plate preload pin 272.
At its periphery, wobble plate 266 carries a plurality of ball end couplers 274 which are equal in number and circumferentially spacing to the bearing cups 232. The couplings provided by the balls 274 and the cups 234 serve to tie the operation of the motoring piston-cylinder units 230, 220 together, so that increments of axial movement of the pistons 230 will be converted into increments of wobble movement of the wobble plate 226. Since the pumping and motoring pistons are connected, each such increment of axial movement of the motoring pistons 230 directly results in an equal amount of axial movement of the particular pumping piston 232 to which it is connected. As wobble plate 266 orbits about the center line of the unit 20, it applies a rotating torque to the crank 262. The wobble plate 266 wobbles in increments and the crank shaft 254 rotates in increments.
As illustrated, wobble plate 266 carries a bearing 276 which journels an end portion 278 of the crank 262 for rotation.
The subject invention is similar to, but yet is significantly different than, the invention of our co-pending application Ser. No. 117,388, filed Feb. 1, 1980, and entitled Rotary Digital Electrohydraulic Actuator. In the present invention, the hydraulic motoring section is used to power a pumping section, rather than to generate a rotary output for supplying torque to a shaft mounted element. In other words, in systems of the present invention the hydraulic motoring section is used to provide hydraulic flow and power reduction rather than a rotary output. Systems of the present invention may use a hydraulic ram output rather than a power hinge output, to provide a more efficient conversion of hydraulic input power to mechanical output.
It is estimated that a hydraulic ram actuator system embodying the present invention will provide a considerable reduction in hydraulic peak power demand and hydraulic system weight when compared with alternative actuator systems.
The hydraulic power transfer unit 20 may be a modified version of a hydraulic power transfer unit that is manufactured by Aero Hydraulics, Inc. of Ft. Lauderdale, Florida, a subsidiary of The Garrett Corporation. The modification of the Aero Hydraulics unit that is necessary in order to adapt it for use in practicing the present invention involves the removal of an internally commutated input plate valve from the hydraulic motoring section and the substitution therefore of an electric stepper motor driven valve of the type described herein.
The terms "motoring means" (or "motoring section") and "pumping means" (or "pumping section") are used herein to denote the two sections of the power transfer unit. These terms are used because the power transfer device is a unitary mechanism and not a motor driving a pump. However, in other installations it may be desirable to employ a hydraulic motor driving a pump in place of the power transfer unit. For that reason it is intended that the terms "motoring means", "motoring section", "pumping means", and "pumping section" be considered broad enough to also mean a true motor and a true pump in any combination of the two which performs the basic function of the power transfer unit in an installation which is covered by a claim herein. | An electric stepping motor, operated by command signals from a computer or a microprocessor, rotates a rotary control member of a distributor valve, for sequencing hydraulic pressure and hence flow to the cylinders of an axial piston hydraulic machine. A group of the cylinders are subjected to pressure and flow and the remaining cylinders are vented to a return line. Rotation of the rotary control valve member sequences pressurization by progressively adding a cylinder to the forward edge to the pressurized group and removing a cylinder from the trailing edge of the pressurized group. The double ended pistons of each new pressurized group function to drive a wobble plate into a new position of equilibrium and then hold it in such position until another change in the makeup of the pressurized group. These pistons also displace hydraulic fluid from the opposite cylinder head which serves as the output of a pumping element. An increment of displacement of the wobble plate occurs in direct response to each command pulse that is received by the stepping motor. Wobble plate displacement drives the rotary valve of the hydraulic power transfer unit, causing it to transfer hydraulic fluid from a first expansible chamber on one side of a piston in a hydraulic ram to a second expansible chamber on the opposite side of the piston. Reverse drive of the hydraulic power transfer unit reverses the direction of transfer of hydraulic fluid between the two expansible chambers. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 2004-78096, filed on Sep. 30, 2004 and Korean Patent Application No. 2005-83474, filed on Sep. 8, 2005 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a refrigerator and a method of making shaved ice, and, more particularly, to a refrigerator and a method of making shaved ice that is capable of controlling a feeding rate of ice, whereby the ice is fed in the optimum quantity necessary to make shaved ice.
[0004] 2. Description of the Related Art
[0005] Generally, a refrigerator includes a refrigerating compartment and a freezing compartment, which are operated at different temperatures. Some of the cool air generated from an evaporator of the freezing compartment is supplied to the refrigerating compartment, or an additional evaporator is disposed in the refrigerating compartment to lower the temperature in the refrigerating compartment. Therefore, foods are maintained in a fresh state in the refrigerator.
[0006] Recently, there has been increasingly used a refrigerator with an ice/water dispenser that allows cold water or ice to be taken out of the refrigerator without opening a door of the refrigerator, as a quality and a capacity of the refrigerator is increased. There has also been proposed another refrigerator with an ice shaver to shave cubed ice made in the freezing compartment into shaved ice, and then discharge the shaved ice out of the freezing compartment, which eliminates the necessity of an additional ice-shaving unit to make ice water.
[0007] The ice shaver of the refrigerator is disposed under the discharge port of an ice bucket to store cubed ice made by an ice shaver, and the cubed ice discharged from the ice bucket is shaved into shaved ice by the ice shaver. The ice bucket has a spiral feeding unit to feed the stored ice to the discharge port. The feeding unit is connected to an ice-feeding motor, which is disposed at the rear of the ice bucket. In the ice shaver is defined an ice-shaving compartment. The ice-shaving compartment has an ice shaving cutter and a discharge port. Cubed ice discharged from the ice bucket is shaved into shaved ice by the ice-shaving cutter, and the shaved ice is discharged through the discharge port. To the ice shaver is connected to a shaved ice-making motor to drive the ice shaver. In FIG. 1 , a method of making shaved ice includes in operation 10 , using a control unit to determine whether a shaved ice-making signal is input when a user pushes a shaved ice-making button to make ice water. When it is determined in operation 10 , that the shaved ice-making signal is input, the process moves to operations 20 and 30 , where the control unit outputs a control signal to a shaved ice-making motor and an ice-feeding motor to drive the shaved ice-making motor and the ice-feeding motor.
[0008] The ice-feeding motor feeds cubed ice in the ice bucket to an ice-shaving compartment, where the cutter disposed in the ice-shaving compartment is operated by means of the shaved ice-making motor to shave the fed cubed ice into shaved ice. The shaved ice is discharged out of the ice-shaving compartment through the discharge port.
[0009] From operation 30 , the process moves to operation 40 , where the control unit determines whether a predetermined amount of shaved ice has been made. When it is determined in operation 40 , that the predetermined amount of shaved ice has been made, the process moves to operation 50 , where the control unit outputs a stop signal to the shaved ice-making motor and the ice-feeding motor, and the shaved ice-making motor and the ice-feeding motor are stopped.
[0010] As shown in FIG. 2 , in the conventional method of making shaved ice, the shaved ice-making motor and the ice-feeding motor are operated at the same time when the shaved ice-making signal is input to the shaved ice-making motor and the ice-feeding motor, and the shaved ice-making motor and the ice-feeding motor are stopped at the same time when the predetermined amount of shaved ice has been made.
[0011] Other ice shavers for refrigerators are disclosed in detail in Korean Unexamined Patent Publication No. 1999-40637 and Korean Registered Patent Publication No. 10-360863.
[0012] In the conventional method of making shaved ice, however, the ice-feeding motor is operated simultaneously when the shaved ice-making motor is operated. As a result, ice is continuously fed to the ice-shaving compartment, and therefore, the amount of the ice is excessively increased. The excessive amount of ice may overflow the ice-shaving compartment, or may even break the ice shaver.
[0013] Furthermore, a large amount of ice is left in the ice shaver after the shaved ice has been made, since the ice is continuously fed until the making of the shaved ice is completed. As a result, the ice left in the ice shaver may mass into a lump, or the ice left in the ice shaver may thaw into water, which may drop out of the refrigerator.
SUMMARY OF THE INVENTION
[0014] Accordingly, it is an aspect of the present invention to provide a refrigerator and a method of making shaved ice that is capable of controlling a feeding period during which ice is fed into an ice shaver, thereby preventing ice from overflowing the ice shaver and preventing the ice shaver from being broken due to an excessive amount of ice.
[0015] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0016] The foregoing and/or other aspects of the present invention are achieved by providing a refrigerator and a method of making shaved ice, capable of minimizing an amount of ice left in the ice shaver after shaved ice has been made, thereby preventing the ice left in the ice shaver from massing into a lump, or preventing the ice left in the ice shaver from thawing into water, which may drop out of the refrigerator.
[0017] It is an aspect of the present invention to provide a method of making shaved ice including feeding cubed ice stored in an ice-storing unit mounted in a freezing compartment to a shaved ice-making unit mounted at a discharge port side of the ice-storing unit though an ice-feeding unit to make shaved ice, the method further including setting a driving time for the shaved ice-making unit, and setting a driving time for the ice-feeding unit, wherein the driving time for the shaved ice-making unit is longer than the driving time for the ice-feeding unit.
[0018] The method further includes performing a controlling operation such that the ice-feeding unit is stopped earlier than the shaved ice-making unit.
[0019] The method further includes further driving the shaved ice-making unit for a predetermined period after the ice-feeding unit is stopped.
[0020] The method further includes repeatedly driving and stopping the ice-feeding unit while driving the shaved ice-making unit continuously.
[0021] The method further includes driving the ice-feeding unit for a predetermined first period, and then stopping for a predetermined second period, while driving the shaved ice-making unit continuously, thereby repeatedly driving and stopping the ice-feeding unit.
[0022] The method further includes further driving the shaved ice-making unit for a predetermined third period after the predetermined period elapses to make cubed ice.
[0023] The method further includes stopping the ice-feeding unit after the ice-feeding unit is driven for a predetermined number of times.
[0024] The method further includes further driving the shaved ice-making unit for a predetermined third period after the predetermined period elapses to make cubed ice.
[0025] It is another aspect of the present invention to provide a method of making shaved ice including feeding cubed ice stored in an ice-storing unit mounted in a freezing compartment to a shaved ice-making unit mounted at a discharge port side of the ice-storing unit though an ice-feeding unit to make shaved ice, the method further including driving the shaved ice-making unit for a predetermined period, and controlling the ice-feeding unit such that the ice-feeding unit is repeatedly driven and stopped for the predetermined period.
[0026] The method further includes driving the ice-feeding unit for a predetermined first period, and then stopping for a predetermined second period, while driving the shaved ice-making unit, thereby repeatedly driving and stopping the ice-feeding unit for the predetermined period.
[0027] The method further includes immediately stopping the ice-feeding unit, without stopping the ice-feeding unit for the predetermined second period, after the ice-feeding unit is driven for a predetermined number of times.
[0028] It is another aspect of the present invention to provide a refrigerator including an ice shaver mounted in a freezing compartment to make ice, an ice-storing unit to store the ice made by the ice shaver, an ice-feeding unit to feed the ice stored in the ice-storing unit to the outside of the ice-storing unit, a shaved ice-making unit to receive the ice from the ice-feeding unit and to make the ice into shaved ice, and a control unit to perform a controlling operation such that the shaved ice-making unit is driven for a longer period than the ice-feeding unit.
[0029] The control unit performs a controlling operation such that the ice-feeding unit is stopped earlier than the shaved ice-making unit.
[0030] The control unit performs a controlling operation such that the ice-feeding unit is driven for a predetermined first period, and is then stopped for a predetermined second period, while the shaved ice-making unit is driven, the ice-feeding unit being repeatedly driven and stopped.
[0031] The control unit drives the shaved ice-making unit for a predetermined period, drives the ice-feeding unit for a predetermined first period, and then stops the ice-feeding unit for a predetermined second period, the ice-feeding unit being repeatedly driven and stopped for the predetermined period, and further drives the shaved ice-making unit for a predetermined third period after the predetermined period elapses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, of which:
[0033] FIG. 1 is a flow chart illustrating a conventional method of making shaved ice;
[0034] FIG. 2 is a graph respectively illustrating driving time for a shaved ice-making motor and an ice-feeding motor according to the conventional art;
[0035] FIG. 3 is a sectional view schematically illustrating an inner structure of a refrigerator according to an embodiment of the present invention;
[0036] FIG. 4 is a block diagram illustrating components of the refrigerator shown in FIG. 3 ;
[0037] FIG. 5 is a graph respectively illustrating a driving time for a shaved ice-making motor and an ice-feeding motor according to an embodiment of the present invention; and
[0038] FIG. 6 is a flow chart illustrating a method of making shaved ice in the refrigerator shown in FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures.
[0040] In FIGS. 3 and 4 , a refrigerator according to the present invention comprises a housing 1 having an open front part, a freezing compartment door 2 and a refrigerating compartment door (not shown) hinged to the open front part of the housing 1 . The housing 1 , the freezing compartment door 2 , and the refrigerating compartment door together form the external appearance of the refrigerator. In the housing 1 are partitioned a freezing compartment 4 and a refrigerating compartment (not shown), which are opened/closed by means of the freezing compartment door 2 and the refrigerating compartment door.
[0041] To the rear wall of the housing 1 is mounted an evaporator 5 to generate cool air. At the lower rear part of the housing 1 is disposed a compressor 6 to compress refrigerant. At the upper part of the freezing compartment 4 is disposed an automatic ice shaver 10 to automatically make and feed cubed ice of a predetermined size.
[0042] The automatically ice shaver 10 comprises an ice-making container 11 to make ice with water supplied to the ice-making container 11 , an ice-storing container 20 disposed below the ice-making container 11 to store cubed ice made at the ice-making container 11 , and a water-supplying pipe 12 connected to an external water-supplying source (not shown) and extending above the ice-making container 11 to supply water necessary to make ice to the ice-making container 11 .
[0043] To the freezing compartment door 2 is mounted a shaved ice-making unit 30 to make the cubed ice fed from the ice-storing container 20 into shaved ice and supply the shaved ice. At the freezing compartment door 2 are formed a recess 17 where the shaved ice-making unit 30 is disposed, and a shaved ice-discharging port 13 . At the ice-storing container 20 is disposed a cubed ice-feeding unit 50 to feed the cubed ice to the shaved ice-making unit 30 . At the rear of the cubed ice-feeding unit 50 is mounted an ice-feeding motor 51 to drive the cubed ice-feeding unit 50 .
[0044] When a predetermined time period elapses after water is filled in the ice-making container 11 through the water-supplying pipe 12 , the water in the ice-making container 11 is frozen into cubed ice by means of cool air circulating in the freezing compartment 4 . The cubed ice is automatically fed to the ice-storing container 20 .
[0045] When a user inputs a shaved ice-making signal, the ice-feeding unit 50 and the shaved ice-making unit 30 are operated such that shaved ice is discharged out of the freezing compartment door through the shaved ice-discharging port 13 .
[0046] The ice-feeding unit 50 is connected to the ice-feeding motor 51 , which is mounted at one end of the ice-storing container 20 , to feed the cubed ice stored in the ice-storing container 20 to the shaved ice-making unit 30 disposed at the freezing compartment door.
[0047] Specifically, the shaved ice-making unit 30 is disposed inside the freezing compartment door. The shaved ice-making unit 30 comprises a shaved ice-making motor 32 fixed to the recess 17 , which communicates with the shaved ice-discharging port 13 , while being disposed at the outside inner space of the freezing compartment door a reduction gear assembly 33 disposed above the shaved ice-making motor 32 , a case 34 fixedly fitted in the inner space of the freezing compartment door, and a rotary tub 35 rotatably disposed in the case 34 .
[0048] The reduction gear assembly 33 , which is connected to the shaved ice-making motor 32 via a shaft, comprises a plurality of reduction gears (not shown), which are engaged with each other for properly reducing the rotation speed of the shaved ice-making motor 32 .
[0049] The rotary tub 35 , which has open upper and lower ends, is provided at the inner circumference thereof with a spiral wing 37 . To the bottom of the case 34 , in which the rotary tube 35 is rotatably fitted, is fixed a cutting blade 41 , which cooperates with the spiral wing 37 such that the spiral wing 37 is rotated to make shaved ice.
[0050] As shown in FIG. 4 , the refrigerator according to the present invention further comprises a key input unit 61 to allow the user to select the amount of shaved ice to be made or a predetermined time period for which the shaved ice is to be made and a control unit 60 to control various units of the refrigerator.
[0051] When a shaved ice-making signal is input to the control unit 60 , the control unit 60 outputs a driving signal to the shaved ice-making motor 32 and the ice-feeding motor 51 such that the shaved ice-making motor 32 and the ice-feeding motor 51 are operated to make shaved ice. As the ice-feeding motor 51 is operated, cubed ice stored in the ice-storing container 20 is fed to the shaved ice-making unit 30 by means of the ice-feeding unit 50 . When the cubed ice is introduced into the shaved ice-making unit 30 , the cubed ice is shaved into shaved ice by means of the cutting blade 41 disposed at the bottom of the case 34 while being rotated in the rotary tube 35 by means of the spiral wing 37 formed at the rotary tube 35 as the shaved ice-making motor 32 is operated.
[0052] In this way, cubed ice fed by means of the ice-feeding motor 51 is made into shaved ice by means of the shaved ice-making motor 32 . If the cubed ice is continuously fed to the shaved ice-making unit 30 , the cubed ice in the shaved ice-making unit 30 is unnecessarily increased. As a result, the cubed ice may overflow the shaved ice-making unit 30 , or the shaved ice-making unit 30 may be broken by the cubed ice. For this reason, driving time for the shaved ice-making motor 32 and the ice-feeding motor 51 is controlled as is shown in FIG. 5 .
[0053] While the shaved ice-making motor 32 is operated for a predetermined period TM 1 after the shaved ice-making signal is input, the ice-feeding motor 51 is driven for a predetermined first reference period T 1 such that cubed ice is fed to the shaved ice-making unit 30 , and then the ice-feeding motor 51 is stopped for a predetermined second reference period T 2 such that an appropriate amount of ice is fed to the shaved ice-making unit 30 . Although the feed of the ice is interrupted for the second reference period, shaved ice is continuously made for the first reference period T 1 and the second reference period T 2 . After the second period T 2 elapses, the ice-feeding motor 51 is driven for the first period T 1 such that cubed ice is fed to the shaved ice-making unit 30 , and then the ice-feeding motor 51 is stopped for the second period T 2 such that the cubed ice fed to the shaved ice-making unit 30 for the first period T 1 is made into shaved ice. The above procedure is repeatedly carried out.
[0054] After the ice-feeding motor 51 is driven by a predetermined number of times N, the ice-feeding motor 51 is completely stopped. In this case, the shaved ice-making motor 32 is further operated for a predetermined third reference period T 3 such that the cubed ice remaining in the shaved ice-making unit 30 is discharged out of the shaved ice-making unit 30 .
[0055] The first reference period, the second reference period, the third reference period, and the number of times may vary depending on which mode the shaved ice is made in. The values are previously calculated on the basis of the corresponding mode, and stored in the control unit 60 . For example, when a user pushes a one-serving selection button to make the shaved ice corresponding to one serving of ice water with red bean, the shaved ice-making motor 32 is driven for 52 seconds. At this time, the ice-feeding motor 51 is driven for 3 seconds (T 1 ) and then stopped for 4 seconds (T 2 ). This procedure is repeatedly carried out. Specifically, the ice-feeding motor 51 is repeatedly driven for 3 seconds (T 1 ) by 8 times N, and is then repeatedly stopped for 4 seconds (T 2 ) by 7 times. In this way, the ice-feeding motor 51 is repeatedly driven and stopped for 52 seconds. The shaved ice-making motor 32 is further operated for 4 seconds (T 3 ) to made shaved ice.
[0056] Now, a method of making shaved ice in the refrigerator shown in FIG. 4 will be described with reference to FIGS. 5 and 6 .
[0057] In FIG. 5 , in operation 100 , when a user selects a shaved ice-making mode using the key input unit 61 , and then inputs a shaved ice-making signal, the control unit 60 determines whether the shaved ice-making signal is input through the key input unit 61 .
[0058] When the shaved ice-making signal is input in operation 100 , the process moves to operation 110 where the user sets the third reference period T 3 , for which the shaved ice-making motor 32 will be further operated, on the basis of the shaved ice-making mode. The set third period is transmitted to the shaved ice-making motor 32 . From operation 110 , the process moves to operation 120 , where the first period T 1 , for which the ice-feeding motor 51 is driven, the second period T 2 , for which the ice-feeding motor 51 is stopped, and the number of times N, for which the ice-feeding motor 51 is driven, are set. The set first period, the set second period, and the set number of times are transmitted to the ice-feeding motor 51 .
[0059] After the mode of controlling the shaved ice-making motor 32 and the ice-feeding motor 51 has been set in operations 110 and 120 , the process moves to operation 130 , where the shaved ice-making motor 32 is driven. At the same time, in operation 140 , the ice-feeding motor 51 is also driven. As the shaved ice-making motor 32 and the ice-feeding motor 51 are driven, shaved ice is made according to the above shaved ice-making mode. From operation 140 , the process moves to operation 150 , where the control unit 60 determines whether the first period T 1 has elapsed after the ice-feeding motor 51 is driven. When it is determined in operation 150 , that the first period T 1 has elapsed, the process moves to operation 160 , where the ice-feeding motor 51 is stopped.
[0060] From operation 160 , the process moves to operation 170 , where the control unit 60 determines whether the ice-feeding motor 51 has been repeatedly driven by the predetermined number of times N. Since the ice-feeding motor 51 has been driven once, in operation 180 , the microcomputer determines whether the second period T 2 has elapsed after the ice-feeding motor 51 is stopped. After the ice-feeding motor 51 has been stopped for the second period T 2 , the ice-feeding motor 51 is driven again for first period T 1 . This procedure is repeatedly carried out.
[0061] After the ice-feeding motor 51 has been driven for the predetermined number of times N, the ice-feeding motor 51 is completely stopped, and from operation 170 , the process moves to operation 190 , where the shaved ice-making motor 32 is further driven for the third period T 3 such that the cubed ice remaining in the shaved ice-making unit 30 is made into shaved ice and then the shaved ice is discharged out of the shaved ice-making unit 30 .
[0062] As apparent from the above description, the ice-feeding unit is repeatedly driven and stopped to prevent ice from being excessively fed into the shaved ice-making unit. Consequently, the present invention has the effect of preventing ice from overflowing the shaved ice-making unit and preventing the shaved ice-making unit from being broken.
[0063] Furthermore, the shaved ice-making motor is further driven after the cubed ice-feeding unit is stopped to minimize the amount of ice left in the shaved ice-making unit. Consequently, the present invention has the effect of preventing the ice left in the shaved ice-making unit from massing into a lump, or preventing the ice left in the shaved ice-making unit from thawing into water, which may drop out of the refrigerator.
[0064] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A refrigerator and a method of making shaved ice by controlling a period during which ice is fed into an ice-shaving compartment, thereby preventing ice from overflowing the ice-shaving compartment and preventing the ice-shaving compartment from being broken due to an excessive amount of ice. The method of making shaved ice comprises feeding cubed ice stored in an ice-storing unit mounted in a freezing compartment to a shaved ice-making unit mounted at a discharge port side of the ice-storing unit though an ice-feeding unit to make shaved ice, setting a driving time for the shaved ice-making unit, and setting a driving time for the ice-feeding unit. The driving time for the shaved ice-making unit is longer than the driving time for the ice-feeding unit. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US National Stage of International Application No. PCT/DE2003/002431, filed Jul. 18, 2003 and claims the benefit thereof. The International Application claims the benefits of German application No. 10232947.8 filed Jul. 19, 2002, both applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to an enclosure having a first enclosure base body and a second enclosure base body. In particular, the invention relates to an enclosure which constitutes a housing for a mobile telecommunication device. The invention also relates to a method for producing a housing part for a mobile telecommunication device.
BACKGROUND OF THE INVENTION
The British patent application GB 2 345 818 describes a portable telecommunication component, a hand-held mobile radio device. This consists of a plurality of components, in particular a keypad, a display field, an upper housing and a lower housing, and a battery part. The individual components are assembled by inserting the keypad into the upper housing, then inserting the component containing the display into the upper housing and subsequently screwing together the lower housing and the upper housing. The lower housing contains a recess into which the battery part is introduced. Patent application GB 2 345 818 A specifies different possible ways of screwing together the upper housing and the lower housing or inserting one into other.
The international patent application WO 01/083381 A1 relates to a mobile telecommunication device having an upper housing shell comprising an integrated keypad and display. To this end, a transparent plastic housing is produced in an injection molding process by injecting a plastic into a mold and makes a connection with a film in such a way that an upper housing shell is produced. In this situation, the plastic housing has a first area which serves as a display window, and also a second area having at least one cutout with means for transmitting a key depression. The film covers at least the second area and implements a key, located above the cutout, which in particular is identified by a character printed on the film and whereby a key depression is transmitted by way of the means.
The German patent specification DE 196 18 453 C1 relates to a 2-component plastic housing, in particular for a key with remote operation facility for a motor vehicle. The housing is produced such that an elastic material which is used as a mounting support for a printed circuit board is injected in an upper housing part. Furthermore, the elastic material also serves as a seal between this upper part and a lower part of the housing, whereby this seal is located inside the lower part.
The German published patent specification DE 196 30 966 A1 relates to a method for producing a housing part having a shielding effect for radio devices, in particular a handset for a radio device. In this situation, a conductive seal is arranged on a lower shell, which seal is used for making contact with a printed circuit board. The seal simply makes a seal between the lower shell and the printed circuit board.
The German published patent specification DE 44 28 335 A1 relates to a plastic housing for an electrical module having a housing body and a base plate. A seal, which can also be produced using a method such as the two-color injection molding process, is used in order to seal an opening in the housing body as well as in one of the embodiments shown as a seal between the housing part and the base plate.
The German utility model DE 298 19 434 U1 describes a housing with a shielding seal for the electromagnetically shielded accommodation of electronic components, particularly of a mobile telecommunication device device. A sealing profile, which in its initial state has a pasty consistency or is foamed in a liquid form and becomes an elastically hardened plastic, is applied to a first housing part. In this situation, the hardened sealing material does not adhere to the upper part. The German utility model 93 11 554 U1 describes a sealing strip for sealing a slot in a slide control, whereby a seal is cast onto the sealing strip. The material comprising the strip is harder than the material comprising the seal which can be a soft, rubber-elastic material having a Shore hardness of 50.
The international patent application WO 00/08722 A1 relates to a mobile radio telephone having a moisture-resistant electrical contact. The mobile radio telephone has a housing with an upper housing part and a lower housing part which together form a shell that surrounds the components contained therein. The moisture-resistant electrical contact is located outside the housing and penetrates the lower housing part, whereby it is connected by means of a spring arm to the electrical circuits of the mobile radio telephone. By melting the electrical contact into the lower housing parts a moisture-resistant connection is produced between the material comprising the lower housing part and the electrical contact.
More rigorous demands can be made of the housings or enclosures for electrical devices or enclosures and also of storage containers, for example for the storage of perishable foodstuffs or weather-sensitive objects, in respect of their capability to seal against moisture, dust or other detrimental influences. With regard to a mobile telecommunication device, for example a cordless telephone or a mobile radio telephone, the first enclosure base body can be a so-called upper shell and the second enclosure body base can be a so-called lower shell, or vice versa.
SUMMARY OF THE INVENTION
The object of the present invention is to specify an enclosure comprising at least two enclosure base bodies, whereby a sealing function is implemented between the two enclosure base bodies.
This object is achieved according to the invention by an enclosure, particularly a housing for a mobile telecommunication device, having a first enclosure base body made of a first base material comprising a first edge and having a second enclosure base body made of a second base material comprising a second edge. The two enclosure base bodies butt against one another along the first edge and the second edge and have a seal there made of a sealing material which is permanently fixed to the first enclosure base body and which makes a seal resting against the second edge, whereby the sealing material consists of an elastically deformable material.
The enclosure can preferably be a housing for accommodating electrical devices or mechanical elements, components or equipment. In particular, in this situation this can be a mobile radio telephone, in other words a mobile radio terminal device, a cordless telephone also for use in an industrial environment, such as for example in repair and production workshops, paint shops right through to a potentially explosive environment such as for example in the petrochemical industry. Other possible enclosures can be provided for pocket calculators, electronic appointment planners, sensor housings, clocks and other items. In this situation, a corresponding housing can have a length of just a few up to several tens of centimeters, a width of likewise just a few up to several tens of centimeters and accordingly a height of just a few up to likewise several tens of centimeters. Typical dimensions for mobile radio terminal devices and cordless telephones lie in the order of a length of 5 to 20 centimeters, a width of 2 to 5 centimeters and a height of 1 to 3 centimeters. In this situation the actual seal can run along the edge or circumference of a corresponding housing and have a width of less than one millimeter up to several millimeters and a height of below one millimeter up to several millimeters. With regard to a housing for a mobile telecommunication device, for example a cordless telephone or a mobile radio telephone, the first enclosure base body can be a so-called upper shell and the second enclosure base body can be a so-called lower shell, or vice versa.
A seal which is permanently fixed to the first edge, and in particular is linked conclusively and in integrated fashion to first base body itself actually implements a sealing effect in respect of the first enclosure base body. The seal is an integral part of the first edge. A sealing effect in respect of the second enclosure base body is achieved by means of the elastic deformability of the material comprising the seal in that when the first edge and the second edge are pushed together the sealing material deforms elastically against the second edge and thus largely implements a sealing effect against the penetration of moisture, dust or similar.
Such an enclosure is therefore suitable for accommodating sensitive objects such as electronic devices or mechanical equipment and also foodstuffs which require protection against ambient influences such as moisture, water, chemicals, dust or also mechanical influences for example. Having a fixed joint between the seal and the first enclosure base body reduces the number of loose elements or elements which can be displaced with respect to one another in order to produce a sealing connection between the first enclosure base body and the second enclosure base body on these two enclosure base bodies. It is therefore not necessary to provide a separate seal, for example in the form of a sealing ring and to provide corresponding holding devices, grooves or other mounting facilities for this purpose with their associated production resource requirement. The number of enclosure parts to be provided is thus also reduced, which simplifies both the storage and also the handling of the enclosure parts. By preference, the seal is located on the outside of the first enclosure base body which for example can be an upper shell of a housing for a mobile telephone. By this means, a penetration of dust, moisture etc is largely inhibited actually on the outside of the first enclosure base body and thus also at the edge of the second enclosure base body, with the result that no dust, moisture or similar is able to collect between first enclosure base body and second enclosure base body. The seal preferably projects beyond the first enclosure base body on the outside in the direction of the second enclosure base body. Furthermore, by preference, a labyrinth seal can be formed from the first enclosure base body, the seal and the second enclosure base body. This can be implemented in a plurality of ways, whereby for example the second enclosure base body is undercut in the manner of a step and the first enclosure base body projects into this step such that the first enclosure base body and the second enclosure base body overlap. In addition, it is possible for the second enclosure base body, when viewed from the outside in, to have a prominence behind the seal in the direction of the first enclosure base body, as a result of which a narrow channel can be formed between first enclosure base body and second enclosure base body in the interior of the housing behind the seal.
By preference, the second edge against which the seal rests is produced from a harder material than the seal itself. In this situation, the second enclosure base body can preferably be produced from a single material which is simultaneously also used as the material for the second edge. It is likewise also possible to produce the second edge from a different material than is used for the remainder of the second enclosure body. The first enclosure body can likewise preferably be produced from a harder material than is used for the seal.
In this situation, the first enclosure base body is preferably produced from a hard plastic and the seal from a soft plastic.
By preference, the first enclosure base body is produced together with the seal using the so-called two-color injection molding method. In two-color injection molding, also known as two-component injection molding, plastic materials for individual components and functional elements also employing different materials and hardness (hard/soft combinations) are produced in a single processing cycle, which can result in considerable savings in assembly costs. Depending on the choice of materials, components or elements produced in this way are resistant to external influences and are characterized by a high adhesive strength. An adhesion achieved in the boundary surface area can in this situation brought about by means of a chemical bond or mechanical anchoring. With regard to chemically compatible plastics, a permanent molecular bond is generally achieved by means of melting or welding. The two-component injection molding method is based on the friction-locked and/or form-locked connection of two plastic components having generally different properties to form an integrated shaped part. The two-component injection molding method is particularly suitable for components which are intended to have both rigid and elastic area, as a result of which different functions can be implemented simultaneously.
The material for the seal is preferably a thermoplastic elastomer. Elastomers are understood to include synthetic or natural polymers with rubber-elastic properties, as described for example in Römpps Chemielexikon 8th Edition, p. 1082, Franksche Verlagshandlung Stuttgart, 1981. Thermoplastic elastomers can be obtained for example from Kraiburg TBE GmbH, Teplitzer Strasse 20, D-84478 Waldkraiburg, Germany. With regard to thermoplastic elastomers, these can be such as are based on SEBS and SEPS (filtered styrol block copolymers).
A thermoplastic material is preferably used for the first base material of the first enclosure base body. The second base material for the second enclosure base body likewise preferably consists of a thermoplastic material. According to the above Römpps Chemielexikon, thermoplastic materials are at normal temperature, particularly room temperature, hard or even brittle plastics which soften reversibly on the application of heat and become mechanically easily deformable. Furthermore, thermoplastic materials are defined in Deutsche Industrienorm 7724 (DIN, German Industrial Standard).
The sealing material comprising the seal preferably exhibits a Shore hardness of between 50 and 60. In accordance with the above Römpps Chemielexikon, the Shore hardness is defined according to Deutsche Industrienorm (DIN) 53505 by way of the resistance of elastomers, rubber and natural rubber to the penetration of a truncated cone.
By preference, a housing for a mobile telecommunication device, which can be a handset for a cordless telephone or for a mobile radio telephone, has a third enclosure base body which serves to accommodate an exchangeable electrical power source, in particular a battery or a rechargeable accumulator. In this situation, the third enclosure base body butts either against the first enclosure base body or against the second enclosure base body and is sealed with respect to the corresponding enclosure base body by means of a further elastic seal. The further seal is preferably located either on the third enclosure base body itself or on the enclosure base body butting against the latter, in other words the first or the second enclosure base body. In this situation the seal can be of the same type as the seal between the second and the first enclosure base body, in particular it can in a two-color injection molding method form an integral part with the third enclosure base body or the first or second enclosure base body associated with the latter.
By applying the seal to one of the enclosure base bodies it is possible, as already described above, to establish a sealing effect between the enclosure base bodies butting against one another, in particular against moisture and dust, in a simple manner with a small number of individual components.
According to the invention, the object directed towards a method for producing a housing part, in particular for a mobile telecommunication device, is achieved by a method in which an elastic seal is applied using the two-color injection molding method. In a first production step, a hard component is injected onto a fixed tool and the hard component is shaped by means of a first countertool which moves in a mold release direction. In a second production step, a soft component forming the seal is injected onto the hard component and is shaped by means of a second countertool which is moved in the same mold release direction as the first countertool in order to release the mold. Releasing the mold both for the hard component and also for the soft component in the same direction provides a simple and fast but also cost-effective production method for a housing part having a sealing function, as a result of which the danger of backspraying is excluded or at least considerably reduced. If slight backspraying should occur, then this would occur firstly at non-visible locations and secondly at non-load locations in the circular slot and would therefore be unproblematic. By using only two countertools, also referred to pressing dies, only a minimum effort with low costs is required in order to produce the tools. Compared with a production method using four pressing dies, the production method can be accelerated and implemented more cost-effectively.
By preference, the method employs a rotary platen mold on which at least two housing parts of the same type are processed. By rotating the rotary platen mold, a housing part currently undergoing processing is passed from a first processing operation, the application of the hard component, to a second processing operation, the application of the soft component. By using a rotary platen mold, the production time for a large number of housing parts of the same type can therefore be reduced. At one point in time during processing, the hard component is produced at one position on the rotary platen mold while at the same time at another position on the rotary platen mold the soft component is being applied to an already produced hard component of the housing part. After the rotary platen mold has rotated, the housing part with a hard component and a soft component is removed and the housing part with the hard component is rotated into the position in which the soft component is applied at the next point in time during processing.
By preference, the soft component is applied to the hard component while the hard component is still warm. In this context, warm means that the hard component still has a temperature at which a bonding of the soft component to the hard component takes place, in particular a chemical molecular bonding, which is stronger than would be the case at normal room temperature.
The enclosure, particularly a housing for a mobile telecommunication device, and also the method for producing a housing part will be described in detail by way of example with reference to the drawing. Other embodiments are naturally also possible, which are also covered by the invention. In this situation the figures show a representation, not necessarily to scale and partly schematized, of a mobile telecommunication device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a housing of a mobile telecommunication device,
FIG. 2 shows an enclosure base body, an upper shell, of a mobile telecommunication device,
FIG. 3 shows a top view of a lower enclosure base body, a lower shell,
FIG. 4 shows a top view of the interior of an upper shell according to FIG. 2 ,
FIG. 5 shows a schematic top view of a rotary platen mold with two mounting positions for a housing part,
FIG. 6 shows a section of a longitudinal section through the rotary platen mold with a hard component of a housing part and one pressing die,
FIG. 7 shows a section by analogy with FIG. 6 with a soft component applied to the hard component and a pressing die corresponding to this,
FIG. 8 shows a section through a longitudinal section of an enclosure with a first enclosure base body, having a seal, and a second enclosure base body, and
FIG. 9 shows a section through a further enclosure with a first enclosure base body and seal and also a second enclosure base body.
The reference numerals have the same meaning in all the figures.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view of an enclosure 1 , here a housing 1 for a mobile telecommunication device. The housing 1 has a first enclosure base body 2 which is produced from a hard component 8 , onto which is applied an elastically deformable soft component 4 on a first edge 3 , essentially corresponding to the outer circumference of the first enclosure base body 2 . In the first enclosure base body 2 , which represents an upper shell 2 , openings are provided for keys 5 , a display 6 and a loudspeaker 7 . The hard component 8 is produced from a first base material, in particular a thermoplastic material. The housing 1 has a second enclosure base body 9 , a lower shell. This lower shell 9 has a second edge 10 which butts against the first edge 3 of the upper shell 2 . In this situation, the second edge 10 comes into direct contact with the soft component 4 , the seal 4 , such that the housing 1 is sealed to prevent the penetration of dust and moisture. On the side facing away from the upper shell 2 , a further soft component 11 is applied onto the lower shell 9 at least in an area for accommodating a third enclosure base body 12 , a battery or accumulator part. A send and receive antenna 13 additionally projects from the housing 1 .
FIG. 2 shows an alternative embodiment of a first enclosure base body 2 , an upper shell of a cordless mobile telecommunication device in a top view of the outside. The upper shell 2 likewise has openings for keys 5 , a display 6 , a loudspeaker 7 and also a microphone 14 . Around the outer circumference, a first edge 3 of the first enclosure base body 2 , a soft material is applied on the outside which, as represented schematically in FIG. 4 , is directed in the form of a flange away from the outside beyond a first base material forming a hard component 8 towards to a second enclosure base body 9 (see FIG. 3 ). The soft component 4 is also applied to the outside of the upper shell 2 in the form of a broad band where it has no sealing function. In this situation it can serve as an additional visual element.
FIG. 4 shows a top view of the interior of an upper shell 2 according to FIG. 2 . On the inside of the upper shell 2 the hard component 8 has running around its outer circumference an outer flange 14 which is directed inwards. Further out still, the soft component 4 runs around this outer flange 14 , thereby forming a sealing flange 27 . The outer flange 14 and also the seal 4 projecting inwards are spaced apart from one another, for example by less than 1 mm or up to several mm. The sealing flange 27 and the outer flange 14 , which are spaced apart from one another by a corresponding recess, are formed by the hard component recess 24 and the soft component recess 25 . In this situation, it is both possible that the sealing flange 27 projects beyond the outer flange 14 or vice versa or both terminate at the same level. Within the area of the hard component 8 enclosed by the outer flange 14 the former has locking flanges 15 and also guide cylinders 16 . These serve to engage in corresponding counterflanges and cylinders situated on the lower shell 9 for fixing purposes and for holding together the upper shell 2 and the lower shell 9 to form a housing 1 .
By means of the sealing flange 27 and the outer flange 14 which preferably extends into the lower shell 9 , a channel of a labyrinth seal 30 is formed between the sealing flange 14 and the second edge 10 (see FIG. 8 ). In the embodiment according to FIG. 9 with the additional sealing flange 28 which extends into the recess between the sealing flange 27 and the outer flange 14 , an even narrower channel is formed between upper shell 2 and lower shell 9 of a labyrinth seal 30 .
FIG. 3 shows a top view, onto the outside, of a lower shell 9 , matching the upper shell 2 , according to FIG. 2 . The lower shell 9 has receiving area 17 for an accumulator part which is not shown. The receiving area 17 is edged by a further soft component 11 which is applied to the hard component 18 (second base material) of the lower shell 9 . In this situation, the further soft component 11 forms the seal between the lower shell 9 and the accumulator part which is not shown. The hard components 8 and 18 are preferably produced from the same base material, in particular a thermoplastic material. Soft components 4 , 11 are likewise preferably produced from an identical sealing material, in particular a thermoplastic elastomer.
FIG. 5 shows a schematic top view of a rotary platen mold 19 which can rotate around an axis of rotation 20 . The rotary platen mold 19 has two tool structures of the same type for the production of identical housing parts (see FIG. 6 , FIG. 7 ). The rotary platen mold 19 shown schematically in FIG. 5 is used for producing a first enclosure base body 2 , an upper shell of a housing for a mobile telecommunication device. By analogy with the upper shells 2 shown in FIGS. 1 and 2 , such a first enclosure base body 2 has openings for keys 5 , display 6 and loudspeaker 7 . A moving countertool (not shown) which can move in the direction of the axis of rotation 20 is assigned to the rotary platen mold 19 for producing the upper shell 2 . The rotary platen mold 19 is the fixed half of the tool, the countertool which is not shown is the moving half of the tool. Production of the upper shell 2 takes place in two steps, whereby in a first method step after bringing together the rotary platen mold 19 and the moveable countertool 22 (see FIG. 6 ) a hard component is injected using the injection molding method between the rotary platen mold 19 and the first moveable countertool 22 . The tool structure 21 of the rotary platen mold 19 has a hard component recess 24 and also the housing contour structure 26 joining up with it. The hard component 8 injected into the space between the rotary platen mold 19 and the first moveable countertool 22 assumes the shape of the upper shell 2 in accordance with the housing contour structure 26 , whereby the hard component 8 which has penetrated into the hard component recess 24 forms a corresponding flange, for example an outer flange 14 by analogy with FIG. 4 . After injection of the hard component 8 , the first moveable countertool 22 is driven in the direction of the axis of rotation 20 , as a result of which a deformation of the hard component 8 takes place in the vertical direction. After this first production step the rotary platen mold 19 is rotated through 180° such that the hard component 8 can now be surrounded by a second moveable countertool 23 (see FIG. 7 ). The cavity resulting between the hard component 8 and the second moveable tool 23 has a soft component 4 injected into it. This soft component 4 flows right into a soft component recess 25 in the rotary platen mold 19 and receives its contour through the hard component 8 . In this situation, the soft component is injected onto an outside 29 of the hard component. The soft component 4 , which can be a thermoplastic elastomer, is preferably then actually injected onto the hard component 8 , which can be a thermoplastic material, when the hard component 8 still has a temperature which is elevated such that a good chemical bond occurs between the hard component 8 and the soft component 4 . The second moveable countertool 23 is likewise raised in the direction of the axis of rotation 20 such that a deformation of the soft component 4 likewise takes place in the vertical direction (see FIG. 7 ). Through the soft component recess 25 , the soft component 4 likewise forms a type of flange which is suited by virtue of the elastic deformability of the soft component 4 for making a seal with respect to a lower shell of the housing for a mobile telecommunication device. (Sealing flange 27 by analogy with FIGS. 8 and 9 ).
The sealing flange 27 and the outer flange 14 , which are spaced apart from one another by a corresponding recess, are formed by the hard component recess 24 and the soft component recess 25 . In this situation, it is both possible that the sealing flange 27 projects beyond the outer flange 14 or vice versa or both terminate at the same level.
FIGS. 8 and 9 show two different embodiments of a first enclosure base body 2 and a second enclosure base body 9 butting against it in a section of a longitudinal section. The first enclosure base body 2 has in each case a hard component 8 with an outer flange 14 . A soft component 4 serving as a seal is applied in each case to the first enclosure base body 2 on the outside, which forms a sealing flange 27 that is adjacent to the outer flange 14 and as a result of the material property of the soft component 4 is elastically deformable. The soft component 4 makes a seal with the sealing flange 27 against the edge 10 of the second enclosure base body 9 . In FIG. 9 the second enclosure base body 9 has an additional sealing flange 28 which extends into the space or recess 31 between the sealing flange 27 and the outer flange 14 . Through the sealing flange 27 and the outer flange 14 which preferably extends into the lower shell 9 , a channel of a labyrinth seal 30 is formed between the sealing flange 14 and the second edge 10 (see FIG. 8 ). In the embodiment according to FIG. 9 with the additional sealing flange 28 which extends into the recess 31 between the sealing flange 27 and the outer flange 14 , an even narrower channel is formed between upper shell 2 and lower shell 9 of a labyrinth seal 30 . By this means the sealing function of the housing 1 formed from first enclosure base body 2 and second enclosure base body 9 protecting against dust and moisture is further improved. By using the two-color injection molding method, as described above, different embodiments can be implemented between sealing flange 27 of the soft component 4 and of the hard component 8 , in particular the outer flange 14 , in respect of their mutual position, length etc. | The invention relates to an enclosure, particularly a housing for a mobile telephone, comprised of a first enclosure base body and of a second enclosure base body with a seal made of a sealing material. This seal is joined in a fixed manner to the first enclosure base body and sealingly rests against a second edge of the second enclosure base body. The seal is made of an elastically deformable sealing material. The invention also relates to a method for producing a housing part for a mobile telephone provided with an elastic seal according to the two-color injection molding method. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to International Application Ser. No. PCT/CH2008/000466 filed Nov. 4, 2008, which claims priority to Swiss Patent Application No. 01755/07 filed Nov. 13, 2007, the contents of which are incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a wound drainage dressing.
PRIOR ART
[0003] It is known to treat large or poorly healing wounds using a vacuum drainage device. A cover, for example a film or a stiff cap, covers the wound, such that a wound space is obtained. A drainage hose is inserted into the wound space from outside and is connected to a vacuum pump in order to suck wound secretions out of the wound. In order to fill the wound space, and in particular to distribute the vacuum uniformly across the wound surface, a wound drainage dressing is placed on the wound. This wound drainage dressing is usually a foam insert with suitably configured pores. The foam insert usually also serves as an absorption body for the wound secretions and therefore has to be frequently changed. Corresponding wound drainage dressings are known, for example, from WO 2006/056294, U.S. Pat. No. 7,070,584, EP 1 284 777 and EP 0 620 720. A wound drainage dressing with a foam insert outside the airtight top sheet is described in WO 2006/052839.
[0004] However, these foam inserts have the disadvantage that, when a vacuum is applied, they collapse, or their pores at least block. As a result, a constant transport of fluid cannot be maintained. In the worst case, the transport of the wound secretions is even blocked.
[0005] WO 03/086232 further discloses a wound drainage dressing for placing on a wound that is to be treated by vacuum, with a layer which is placed on the surface of the wound and which has through-holes and channels for distribution of the vacuum, and with a top sheet which is arranged over the layer and which has an access opening for the vacuum hose. The wound dressing is stiff and incompressible. It is also transparent, such that the wound healing can be monitored. The wound drainage dressing can be impregnated with silver ions.
[0006] US 2002/0065494 discloses a similar wound drainage dressing, where a gauze is arranged over the top sheet and fills the wound cavity up to the height of the healthy skin. A film is arranged over this gauze and allows water vapor to escape from the cavity.
[0007] EP 0 099 758 discloses a wound dressing for use without drainage, in particular for use with electrical stimulation. This wound dressing is multilayered and has a semipermeable membrane, a permeable reinforcing layer made of a textile material, and a biodegradable, non-adhesive contact layer. The membrane controls the transfer of water vapor away from the wound. In U.S. Pat. No. 5,653,699 too, a wound dressing without drainage is described that is able to control the transfer of water vapor for the purpose of keeping the wound moist. Wound dressings with layers that transport a fluid into a next higher layer are also described, for example in U.S. Pat. No. 6,077,526 and WO 2004/060412.
[0008] U.S. Pat. No. 5,989,478 discloses a woven fabric, which is proposed as a top sheet for sanitary towels, diapers or wound dressings. The woven fabric is permeable to liquid and actively transports the liquid from one surface to the opposite surface, where the liquid can be delivered to a suction layer.
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to create a wound drainage dressing that ensures optimal transport of wound secretions while being of simple construction.
[0010] The wound drainage dressing according to the invention, for placing on a wound that is to be treated by vacuum, has at least two layers arranged one on top of the other, wherein a first layer facing the wound is a functional textile material, and a second layer, arranged over the first layer, is dimensionally stable and permeable to liquid.
[0011] The functional textile material is preferably permeable to liquid at least in one direction and preferably has an anisotropic configuration.
[0012] This wound drainage dressing is suitable for use as an inlay in a wound, to which a vacuum is applied. Such wound drainage arrangements are suitable for the healing of wounds in humans and animals.
[0013] The first layer and the second layer can be single-ply and be designed uniformly across the entire volume, or they can each be made from a composite material. The second layer is preferably wide-meshed or designed with large openings otherwise distributed across its surface or the entire volume, such that the applied vacuum can be distributed uniformly and the suction channels of the second layer cannot be blocked by wound secretions being sucked out.
[0014] Other advantageous embodiments are set forth in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The subject matter of the invention is explained below on the basis of a preferred illustrative embodiment and with reference to the attached drawings, in which:
[0016] FIG. 1 shows a schematic representation of a wound drainage dressing according to the invention, and
[0017] FIG. 2 shows the wound drainage dressing according to FIG. 1 in use in a wound.
DETAILED DESCRIPTION
[0018] FIG. 1 shows a preferred illustrative embodiment of the wound drainage dressing according to the invention or the filler according to the invention. As can be seen from FIG. 2 , it is used for placing on a wound W and for inserting into a wound cavity K, wherein the wound drainage dressing is covered completely with an airtight cover 5 , and the wound cavity K is thus sealed in an airtight manner. The cover 5 can be a rigid cap, a flexible film, or another cover means known from the prior art. The cover 5 is preferably self-adhesive, at least at the edges thereof, such that it can be affixed in an airtight manner to the healthy skin surrounding the patient's wound. However, it is also possible for the cover 5 not to be self-adhesive and for it to be secured by additional securing means, in particular adhesive strips.
[0019] A drainage hose 4 leads outward from the wound drainage dressing. This drainage hose 4 is connected to a vacuum pump, such that a vacuum can be generated in the cavity K, and the liquid present in the cavity K, in particular the wound secretions, can be sucked out. A vacuum of 50 mmHg to 220 mmHg is typically generated. In addition to the drainage hose 4 , one or more supply lines can be routed through the cover 5 into the cavity K. Cleaning solutions, such as sodium chloride, or medicaments, for example zinc oxide, can be introduced into the wound cavity K through these supply lines.
[0020] As can be seen in FIG. 1 , the wound drainage dressing according to the invention is foamless. It is composed of at least two layers or plies arranged one on top of the other, namely a first layer 1 facing the wound and made from a functional material, and a second layer 2 , which is arranged over the first layer 1 and which is dimensionally stable or stiff and is permeable to liquid. As is shown in FIG. 1 , a third layer 3 can additionally be present, which covers the second layer 2 and is designed as a liquid-impermeable top layer. It can be airtight but does not have to be.
[0021] The first layer 1 is made from a functional textile material. A textile material is understood here as a material that can be in the form of a woven fabric or knitted fabric, for example. A functional material is understood here as a material that is able to perform an active function, for example transporting liquid or dispensing medicaments. The materials known from the sports clothing industry are suitable in particular as the functional textile material.
[0022] The first layer is preferably flexible, in particular a flexible woven fabric. This first layer 1 can be configured as a single ply. However, it preferably has several plies with different functions. This first layer 1 preferably has a thickness of 0.1 mm to 5 mm. This first layer 1 is preferably self-supporting. It can be connected to the second layer 2 , in which case it does not necessarily have to be self-supporting.
[0023] The functionality of the material can be of various types. In a preferred embodiment, this first layer 1 is configured in such a way that it can perform an active or automatic transport of liquid. That is to say, the wound liquid is transported away from the wound into the next higher layer, here the second layer 2 , even without application of a vacuum. For this purpose, the first layer 1 preferably has capillaries. Materials of this kind are known from the prior art, for example for sports clothing, or, as was mentioned at the outset, for sanitary towels, diapers and bandages without drainage.
[0024] In another preferred embodiment, the first layer 1 is designed for delayed and/or precisely metered dispensing of active substances. It can, for example, dispense medicaments and/or be coated with silver ions. This functionality can be combined with the functionality of the automatic transport of liquid. Other functionalities of the kind known from the field of nanotechnology are likewise possible.
[0025] The second ply or layer 2 is relatively stiff or at least dimensionally stable. However, adaptation to irregularities in the wound is preferably possible. Dimensionally stable in this context is intended to signify that, when a vacuum is applied, this second layer 2 does not collapse, and its inner cavities or channels are not compressed, or they are compressed only to an insignificant extent. It is also permeable to liquid and is designed with sufficiently large inner openings to allow the wound secretions to be sucked out through this second layer 2 , without this second layer 2 becoming blocked. These inner openings are preferably distributed uniformly across the entire surface of the second layer 2 , such that the applied vacuum can be distributed uniformly on the surface of the first layer 1 and thus of the wound. The second layer 2 is preferably designed uniformly across the entire volume, i.e. the inner openings are distributed uniformly across the entire volume. However, it is also possible for the size, number and distribution of the openings in the area of the second layer 2 near the wound to be different than in the area of the second layer 2 directed away from the wound. This second layer is preferably composed of a single ply. However, it can also be configured with several plies, and the individual plies can be identical to or different than one another. Thus, for example, a ply of the second layer 2 near the wound can have larger openings or a greater number of openings than a ply directed away from the wound. The second layer 2 is preferably a wide-meshed woven fabric, a loose knitted fabric or a wire braid. It can, for example, be made from a plastic or from a metal. The thickness of the second layer 2 depends on the configuration and depth of the wound. The second layer 2 has in particular a thickness many times greater than the first layer 1 .
[0026] The third layer 3 is impermeable to liquid and is preferably airtight. It is, for example, a simple woven fabric, a film or a coating, which is applied to the second layer 2 , in particular affixed or welded thereto. This third layer 3 is preferably transparent, such that the flow of wound secretions or the flow of medicament in the second layer 2 can be monitored. The abovementioned cover 5 is preferably also transparent.
[0027] In this example, the drainage hose 4 is inserted laterally into the second layer 2 directly, i.e. without passing through the third layer 3 . However, it can also pass through the third layer 3 . Within the second layer, the drainage hose 4 merges into one or more distributor tubes 40 , which have suction openings distributed about their circumference. The distributor tubes 40 can be formed integrally on the hose 4 or can be plugged to the latter. These distributor tubes 40 preferably extend approximately across the entire width and length of the second layer. It is also possible, however, to insert the drainage hose 4 approximately centrally into the second layer 2 or to have the latter end only in an edge area and continue no further into the second layer 2 . The applied vacuum is distributed uniformly thanks to the presence of the large openings in the second layer 2 .
[0028] The wound drainage dressing according to the invention is of simple construction, has a good mode of action thanks to the functional first layer, and ensures optimal transport of wound secretions thanks to the dimensionally stable second layer. | The invention relates to a wound drainage covering for covering, by means of low pressure, a wound that is to be treated. The covering comprises at least two layers that are superimposed. A first layer that is applied on the side of the wound is made of a functional textile material and second layer that is arranged thereon is dimensionally stable and permeable to liquid. The wound drainage covering has a simple design and due to the functional first layer, is effective and ensures, due to the dimensionally stable second layer, an optimal removal of wound secretion. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority under 35 USC 120 from U.S. Provisional Application No. 61/775,009, filed 8 Mar. 2013.
FIELD OF THE INVENTION
[0002] The present invention relates to a fluid coking process and more particularly to a fluid coking process in which the coking zone can be run at a lower temperature than the stripping zone.
BACKGROUND OF THE INVENTION
[0003] Much work has been done over the years to convert heavy hydrocarbonaceous materials to more valuable lighter boiling products by various thermal processes including visbreaking, delayed coking and fluid coking.
[0004] In fluid coking, a heavy oil chargestock, such as a vacuum residuum, is fed to a coking zone containing a fluidized bed of hot solid particles, usually coke particles, sometimes referred to as seed coke. The heavy oil undergoes thermal cracking at the high temperatures in the coking zone resulting in conversion products which include a cracked vapor fraction and coke. The coke is deposited on the surface of the seed coke particles and a portion of the coked-seed particles is sent from the coking zone to a heating zone which is maintained at a temperature higher than that of the coking zone. Some of the coke is burned off in the heating zone and hot seed particles from the heating zone are returned to the coking zone as regenerated seed particles, serving as the primary heat source for the coking zone. In the variant of the fluid coking process developed by Exxon Research and Engineering known as Flexicoking™, a portion of hot coke from the heating zone is circulated back and forth to a gasification zone which is maintained at a temperature greater than that of the heating zone. In the gasifier, substantially all of the remaining coke on the coked seed particles is burned, or gasified, in the presence of oxygen (air) and steam to generate low heating value fuel gas which can be partly passed to the burner/heater to increase temperature in that zone and/or used as refinery fuel. Fluid coking processes, with or without an integrated gasification zone, are described, for instance in U.S. Pat. Nos. 3,726,791; 4,203,759; 4,213,848; and 4,269,696.
[0005] Modifications have been made over the years in an attempt to achieve higher liquid yields. For example, U.S. Pat. No. 4,378,288 discloses a method for increasing coker distillate yield in a coking process by adding small amounts of a free radical inhibitor. Nootwithstanding these improvements, however, there remains a need for process and equipment modifications which can increase liquid yields and in fluid coking, a reduction of the temperature in the coking zone is the most effective solution. While there are economic incentives to increase the feed capacity, reducing the temperature of the coking zone and increasing unit capacity will tend to increase the amounts of liquid hydrocarbon passing from the coking zone to the stripping zone with consequent increase in the fouling in the stripping zone. Various techniques for alleviating the fouling problem have been proposed: US 2011/114468, for example, describes the use of perforated sheds in the stripping zone while U.S. 2011/0206563 describes the use of downwardly slopping frusto-conical baffles in the coking zone to the same end. Nevertheless, the objective of increasing the yield of the desired liquid products remains with the desirability of reducing reactor temperature even in the face of the fouling problem which is created by reductions in reactor temperature.
[0006] By increasing the temperature of the stripping zone the liquid yield may be increased by enabling the temperature of the coking zone to be reduced. U.S. Pat. No. 5,176,819 describes a process to run the stripping zone at a higher temperature than the coking zone by feeding a portion of the heated solids from the burner/heater (and gasifier if applicable) to the stripping zone. Significant liquid yield increases of 1% are reported while the increased temperature of the stripping zone also tends to reduce the amount of hydrocarbon carryunder out of the stripping zone. We have now found that the flow in the fluid bed coking unit, especially in the coking zone, is dominated by large scale recirculation patterns that are much faster (˜50×) than the external circulation rate between the coking zone and the burner/heater/gasifier. This suggests that the hot solids from burner/heater/gasifier fed to the stripping zone in the manner described in U.S. Pat. No. 5,876,819 could be recirculating in both the stripping zone and the coking zone: the hot coke fed to the top of the stripper becomes distributed in both the coking zone and the stripping zone and the mass fraction of the hot coke in the coking zone and in the stripping zone is similar. This indicates that the coking zone and the stripping zone are not effectively decoupled and that the coking zone is not being operated at the desired relatively lower temperature with a consequent loss in liquid yield and, conversely, that the stripping zone is not being operated at the higher temperature appropriate to reduce fouling.
SUMMARY OF THE INVENTION
[0007] We have now found that the stripping zone and the coking zone may be more effectively decoupled by means of an annular baffle at the top of the stripping zone. With the annular baffle, the recirculation between the coking zone and the stripping zone is reduced and hot coke solids fed to the stripping zone are confined in the stripping zone. The operating temperatures in the coking zone and the stripping zone can then be controlled separately by adjusting the coke circulation rates to the coking zone and the stripping zone. This allows the coking zone to be run at a lower temperature, which can increase either the liquid yields or the capacity of the coking process. In accordance with the present invention, therefore, the fluid coking unit for converting a heavy oil feed to lower boiling products by thermal cracking under coking conditions in a fluid bed, comprises: (i) a coking zone to contain a fluidized bed of hot solid particles into which the heavy oil feed is introduced to convert feed to lower boiling products in the form of vaporous cracking products with deposition of coke on the solid particles in the coking zone; (ii) a scrubbing zone into which the vaporous products from the coking zone are passed; (iii) a stripping zone, at the bottom of the coking zone, for stripping hydrocarbons which adhere to the solid particles passing into the stripping zone from the coking zone; (iv) a heater communicating with the stripping zone to receive solid particles from the stripping zone; (v) a return conduit for passing hot solid particles from the heater to the coking zone; (vi) a recycle conduit for recycling hot solid particles from the heater to the stripping zone; and (vii) a centrally-apertured annular baffle at the top of the stripping zone to inhibit recirculation of solid particles from the stripping zone to the coking zone.
[0008] The unit may optionally include a gasifier which is connected by a transfer conduit to the heater to receive a portion of the fluidized solid particles from the heater; in the gasifier, the coke on the particles is converted by reaction with steam and oxygen (typically supplied as air) in an oxygen-limited atmosphere at a temperature higher than that of the heater, suitably from 870 to 1100° C., to a fuel gas at least a part of which can be fed to the heater to support the temperatures required in the heater, the rest being used as fuel gas elsewhere. A slipstream of hot solid particles from the gasifier may be recycled to the coking zone and/or the stripping zone depending on the temperature requirements in the respective zones.
[0009] The process for running the unit essentially comprises the following operations: (i) introducing a heavy oil feed into a coking zone containing a fluidized bed of solid particles and subjecting the feed to thermal coking conditions in the coking zone in the presence of the solid particles to produce hydrocarbon vapors and coke which is deposited on the solid particles with hydrocarbons adhering to the particles; (ii) passing solid particles from the coking zone to the stripping zone through a central aperture in the baffle at the top of the stripping zone and stripping at hydrocarbons which adhere to the solid particles passing into the stripping zone while inhibiting recirculation of solid particles from the stripping zone to the coking zone; (iii) passing solid particles from the stripping zone to the heater where the coke on the particles is combusted in a fluidized at a temperature greater than that of the coking zone to generate heat; (iv) recycling a portion of heated solids from the heating zone to the coking zone; and (v) recovering the hydrocarbon vapors from the coking zone.
[0010] With the use of the annular baffle at the top of the stripping zone to reduce the extent of recirculation from the stripping zone, the coking zone will operated at a lower temperature than the stripping zone.
DRAWINGS
[0011] In the accompanying drawings:
[0012] FIG. 1 is a simplified schematic of a fluid coking unit of the type described in U.S. Pat. No. 5,176,819;
[0013] FIG. 2A is a simplified section of the reactor section of a fluid coking unit with recycle of hot coke from the heater to the stripping zone and an annular baffle to inhibit recirculation of coke from the stripping zone into the reactor;
[0014] FIG. 2B is an enlarged portion of FIG. 2A in the region of the baffle, showing the configuration including the optional, upturned lip at the circumference of the aperture; and
[0015] FIG. 3 is a graphical representation showing the effect of stripping coke rate and reactor temperature reduction.
DETAILED DESCRIPTION
[0016] Any heavy hydrocarbonaceous oil which is typically fed to a coking process can be used in the present fluid cokers. Generally, the heavy oil will have a Conradson Carbon Residue (ASTM D189-06e2) of about 5 to 40 wt. % and be comprised of fractions, the majority of which boil above about 500° C. and more usually above 540° C. or even higher, e.g. 590° C. Suitable heavy oils include heavy petroleum crudes, reduced petroleum crudes, petroleum atmospheric distillation bottoms, petroleum vacuum distillation bottoms, pitch, asphalt, bitumen, liquid products derived from coal liquefaction processes, including coal liquefaction bottoms, and mixtures of these materials.
[0017] A typical petroleum chargestock suitable for coking in a fluid coking unit will have, for example, a composition and properties within the following ranges:
[0000]
Conradson Carbon
5 to 40 wt. %
Sulfur
1.5 to 8 wt. %
Hydrogen
9 to 11 wt. %
Nitrogen
0.2 to 2 wt. %
Carbon
80 to 86 wt. %
Metals
1 to 2000 wppm
Boiling Point
340° C.+-650° C.+
API Gravity
−10 to 35°
[0018] FIG. 1 shows an integrated coking/gasification unit where most of the coke is gasified with a mixture of steam and air in a gasification zone, as shown in U.S. Pat. No. 5,176,819. A heavy oil feed stream is passed via line 10 to the reaction or coking zone 12 of coker reactor 1 , which contains a fluidized bed of hot seed particles having an upper level indicated at 14 . Although the seed material will normally be coke particles, they may also be other refractory materials selected from the group consisting of silica, alumina, zirconia, magnesia, alumina or mullite. They may also be synthetically prepared, or naturally occurring materials, such as pumice, clay, kieselguhr, diatomaceous earth, bauxite. The seed particles preferably have an average particle size of about 40 to 1000 microns, preferably from about 40 to 400 microns.
[0019] The lower portion of the coking reactor constituting stripping zone 13 has the purpose of removing occluded hydrocarbons from the coke. A fluidizing gas e.g. steam, is admitted at the base of coker reactor 1 , through line 16 , into stripping zone 13 of the reactor to produce a superficial fluidizing gas velocity in the seed particles. The velocity is typically in the range from 0.15 to 1.5 m/sec. A major portion of the feed, undergoes thermal cracking reactions in the reactor in the presence of the hot seed particles to form cracked hydrocarbon vapors and a fresh coke layer containing occluded hydrocarbons on the fluidized seed particles. Vaporous conversion (cracking) products pass through reactor cyclone 20 to remove entrained solids which are returned to the coking zone through cyclone dipleg 22 . The vapors leave the cyclone through line 24 , and pass into a scrubbing zone 25 mounted on the top of the coking reactor. A stream of heavy materials condensed in the scrubbing zone may be recycled to the coking reactor via line 26 . The coker conversion products are removed from the scrubber 25 via line 28 for fractionation and product recovery in the conventional manner.
[0020] The coke is partially stripped of occluded hydrocarbons in the stripping zone 13 by use of the steam and carried via line 18 to the heating zone 2 , also referred to here as the burner or heater where it is introduced into the fluidized bed of hot seed/coke particles in the heater up to an upper level indicated at 30 . In the heater, combustion of the coked particles takes place to generate heat required for the endothermic cracking reactions taking place in the reactor. The portion of the hot coke that is not burned in order to provide the heat requirements of the coking zone is recycled from heater 2 to coking zone 12 through recirculation conduit 42 to supply the heat required to support the endothermic cracking reactions. The heater is maintained at a temperature above the temperature maintained in the coking zone, for example, at a temperature from 40 to 200° C., preferably from 65 to 175° C., and more preferably 65 to 125° C. in excess of the operating temperature of the coking zone. The heated solids are sent to the coking zone in an amount sufficient to maintain the coking temperature in the range of 450 to 650° C. The pressure in the coking zone is typically maintained in the range of 0 to 10 barg, preferably in the range of 0.3 to 3 barg.
[0021] A portion of the hot seed/coke from the heating zone is passed via line 19 to the top of the stripping zone 13 . This allows the temperature of the stripping zone to be controlled independently of the temperature of the coking zone so as to raise the temperature of the stripping zone above the temperature of the coking zone to achieve higher liquid yields. In the past, higher temperatures than needed for maximum liquid yields had been maintained in the coking zone to prevent defluidization of the seed particles in that zone as well as in the stripping zone which is more susceptible to defluidization. Besides improving fluidization in the stripping zone, the increase in the stripping zone temperature also improves stripping of the occluded hydrocarbons to increase liquid yield and reduces fouling although the increase in the temperature of the stripping zone has, in the past, resulted in increases in the temperature of the reaction or coking zone which tend to reduce liquid yield as a result of overcracking. The interposition of the annular baffle above the stripping zone, however, reduces the recirculation of hot coke from the heater into the reaction zone via the stripping zone, thus decoupling the stripping zone from the reaction zone. If desired, a portion of hot seed/coke particles can also be passed from the gasifier to the top of the stripping zone in addition to, or instead of, the particles from the heater.
[0022] The gaseous effluent of the heater, including entrained solids, passes through a cyclone system comprising a primary cyclone 36 and a secondary cyclone 38 in which the separation of the larger entrained solids occur. The separated larger solids are returned to the heater bed via the respective cyclone diplegs 37 and 39 . The heated gaseous effluent which contains entrained solids is removed from the heater via line 40 .
[0023] The portion of the stripped coke that is not burned in order to satisfy the heat requirements of the coking zone is recycled from the heater to the coking zone through recirculation conduit 42 to supply heat to support the endothermic cracking reactions. Normally, the recycled coke passes out of a return line from the heater to enter the reactor near the top of the coking zone, as shown in US 2011/0206563, with an inverted cap over the top of the return line to direct the recycled coke particles downwards into the coking zone. The cap on the top of the coke return line conveniently comprises an annular ring supported over the open top of the return line with a flat circular cap plate axially centered over the line and the annular ring, supported by a spider structure supporting the annular ring. A preferred variation allows a smaller flow of hot coke from the heater to be admitted from a second return line higher up in reactor 1 at a point in the dilute phase where it is entrained into the cyclone inlet(s) as scouring coke to minimize coking of the reactor cyclones and the associated increase in the pressure drop. Reference is made to US 2011/0206563 for a description of these options.
[0024] Another portion of coke is removed from heater 2 and passed by line 44 to the gasification zone 46 in gasifier 3 in which is maintained a bed of fluidized coke particles having a level indicated at 48 where the hot coke is converted to a fuel gas by partial combustion in the presence of steam in an oxygen-deficient atmosphere. Any remaining portion of excess coke may be removed from heater 2 by line 50 as fluid coke by-product. The temperature in the fluidized bed in heater 2 is partly maintained by passing fuel gas from gasifier 3 into the heater by way of line 32 . Supplementary heat may be supplied to the heater by hot coke recirculating from the gasifier 3 through return conduit 34 .
[0025] The gasification zone is suitably maintained at a temperature ranging from about 870° to 1100° C. and at a pressure ranging from about 0 to 10 barg, preferably at a pressure ranging from about 1.5 to about 3 barg. Steam by line 52 , and a molecular oxygen-containing gas, such as air, commercial oxygen, or air enriched with oxygen by line 54 , pass via line 56 into gasifier 3 . The reaction of the coke particles in the gasification zone with the steam and the oxygen-containing gas produces a hydrogen and carbon monoxide-containing fuel gas of low heating value, typically from 3 to 7 MJ/kg. The product gas from the gasifier, which may further contain some entrained solids, is removed overhead from gasifier 3 by line 32 and introduced into heater 2 to provide a portion of the required heat as previously described or sent to the refinery fuel gas system for use elsewhere.
[0026] FIG. 2A , which uses the same references are FIG. 1 where applicable, shows the form of the annular baffle 51 at the top of stripping zone 13 . Briefly, it comprises the frustum of a downwardly pointed cone with a central aperture 52 to allow the seed/coke particles to pass from the coking zone 12 into stripping zone 13 . The frusto-conical baffle is fixed at its upper, outer circumference to the inner wall of the reactor and may have an upturned lip around the circumference of the aperture as shown in FIG. 2B to direct the downward flowing solids more to the center of the bed and it so provide a longer residence time for the downward flowing solids before reaching the stripper. This will have the effect of reducing the fouling in the stripper and, in the case of the Flexicoker, reducing the fouling in the heater overhead with fewer hydrocarbons carried over into the heater.
[0027] The configuration of the baffle, together with the downward flux of particles from the coking zone through the aperture, inhibits or precludes recirculation of the particles from the stripping zone back into the coking zone so that the particles in the stripping zone are effectively confined in that zone. In this way, temperatures of the stripping zone and the coking zone are more effectively decoupled making it feasible to maintain a relatively lower temperature in the coking zone to improve the yield of liquid cracking products and/or increase the capacity of the unit. Typically, the annular baffle will have open area from 30 to 70% of its total area (as seen on a horizontal (plan) projection), normally between 40 to 60%, with about 50% being generally useful. The angle is typically from 30 to 60°, most usually about 45° from the vertical.
[0028] FIG. 2A has multiple feed injection nozzles 10 a , 10 b , 10 c , 10 d , 10 e , 10 f located at vertically spaced levels in the reactor with the nozzles arranged in rings around the circumference of the coking zone to inject the feed inwardly into the coking zone The hot coke return line from heater 2 (not shown in FIG. 2A ) is made through line 42 which introduces the hot coke near the top of coking zone 12 allowing the hot coke to descend in the body of the coking zone, contacting the heavy oil feed injected through the successive rings of injection nozzles 10 a . . . 10 f , as it falls through the ascending cracked vapors and injected oil streams in the coking zone before passing through central aperture 52 in downwardly directed frusto-conical baffle 51 into stripping zone 13 . As described above for FIG. 1 , the cracked vapors leave the coking zone by way of cyclones 20 to pass into the scrubbing zone above the reactor. Hot scouring coke may also be introduced from heater 2 at a higher level into the coking zone through line 60 in the region of the cyclone vapor inlet in order to minimize the pressure drop associated increase with coking in the reactor cyclones.
[0029] Introduction of the recycled hot coke from line 19 through the side of the stripper as shown is feasible. and is preferred for mechanical simplicity although it relies on the staging baffle to facilitate the distribution of the hot coke into the coke entering the stripper from the coking zone to increase increasing its temperature. Alternative mechanical configurations are, however, conceivable, as site and unit locations permit, for example, with the recycled hot coke entering the stripping zone from the heater by way of a vertical conduit extending upwards along the central axis of the stripper. Tangential injection of the recycled hot coke, although promoting vigorous mixing with the coke from the reaction zone is not generally favored in view of its effect on downward flow in the stripper.
[0030] Stripping zone 13 has steam spargers 14 arranged below stripper sheds 53 which are preferably in the form of apertured sheds as shown in U.S. Patent Publication No. 2011/0114468 to which reference is made for details of these sheds. The aperture sheds improve stripping of the occluded hydrocarbons and reduce shed fouling (formation of “shark fins”) in the stripping zone. Disposition of the sheds in the cross hatch arrangement with sheds in successive tiers rotated angularly from one another in the horizontal plane, usually at 90°, as described in U.S. 2011/0114468. The hot coke from heater 2 which enters the stripping zone through conduit 19 has its outlet 55 located at the top of stripping zone 13 above the stripper sheds on the central vertical axis off the stripping zone which itself coincides with the central vertical axis of the reactor. Although the flow of coke from the heater into the stripper through conduit 19 is typically sufficient to maintain the desired hot coke recycle flow rate into the stripping zone, cap 56 may be provided over the outlet to maintain the desired flow rate and distribution around the stripper. Although discharge of the recycled hot coke from heater 2 into stripping zone 13 is preferably made on the central axis of the stripper, different off-center locations may be selected if flow patterns at the bottom of the coking zone and in the stripper favor. While hot coke may also be recirculated from the gasifier (if present as in a Flexicoking unit), this will generally not be favored as the gasifier coke is at a lower temperature than heater coke as a result of the fuel gas conversion reactions taking place in the gasifier.
[0031] The characteristic annular baffle is located immediately at the top of the stripping zone above the stripper sheds and the outlet for the recycle hot coke from the heater. Annular staging baffles with solids flow downcomers (flux tubes) as described in US 2011/0206563 to promote downward flow of solids and upward flow of gases may also be provided in the coking zone at multiple levels above the present characteristic annular baffle but in one embodiment, the annular baffle immediately at the top of the stripping zone is the only downwardly angled frusto-conical baffle in the reactor. In contrast to the configuration of the baffles shown in US 2011/0206563, however, the present annular baffle used to confine the recycled hot coke to the stripping zone has only a central aperture, i.e. is imperforate apart from the central aperture, so as to direct the coke flow into the stripping zone and inhibit recirculation of recycled hot coke from the stripping zone to the coking zone: flux tubes at the periphery of the baffle are absent. A space is allowed below the baffle and above the stripper sheds in order to create a mixing zone in which the coke from the coking zone becomes well mixed with the recycled hot coke so as the promote, as far as practically feasible, a uniform coke composition (albeit on a gross scale) in the stripping zone. Normally the baffle will located from 0.5 to 1.5 bed diameters (stripping zone bed diameter) and in most cases about one bed diameter above the uppermost stripper shed and below the lowermost feed ring in the reactor.
[0032] Computational fluid dynamics (CFD) studies have shown that the annular baffle is capable of making a significant difference to the hot coke distribution. In a typical CFD study, the mass fraction of hot coke fed to the top of the striper and recirculated from the stripper to the coking zone was reduced from values in the range of approximately 4 to 20 percent practically to zero indicating that almost all the hot solids fed to the top of the stripping zone would be confined in the stripping zone and the transition zone below the annular baffle. A higher mass fraction of hot coke in the transition zone between the annular baffle and the stripping zone was observed suggesting that a higher temperature zone exists in the transition zone below the annular baffle, which could be helpful to mitigate fouling in the stripping zone. With the annular baffle and the hot coke fed to the top of the stripper, the operating temperatures at the coking zone and the stripping zone can then be controlled separately by adjusting the coke circulation rates to the coking zone and the stripping zone so that the coking zone and the stripping zone are effectively decoupled. This allows the coking zone to be run at a lower temperature, which can increase either the liquid yield or the capacity of the coking process. In general terms, significantly less than 20 percent by weight of the mass flow of hot coke entering the stripper below the baffle will re-enter the coking zone and typically less than 10 or even less, e.g. 2 or 1 percent by weight.
[0033] FIG. 3 illustrates the results of a predictive model showing the effect of stripping hot coke rate on hydrocarbon carryunder from the stripper (hydrocarbon transferred from the stripper to the heater) at varying reactor temperatures. The model is based on the use of plain (non-perforated) sheds. The larger the amount of the hydrocarbon carryunder from the stripper, the higher the potential of the fouling problem in the downstream equipment as well as the loss of potential liquid yield by combustion in the heater. The temperature shown in different lines is the reactor operating temperature (° F.). The base line is 985° F. reactor operating temperature without hot coke circulation to the stripping zone. By adding the stripping hot coke to the stripper under the annular baffle to increase the stripper severity, the reactor operating temperature can be reduced while maintaining the same hydrocarbon carryunder from the stripper as the base case. As shown in FIG. 3 , for a stripper with parallel plain sheds, the reactor temperature could be reduced by approximately 12° F./7° C. by adding 10.5 TPM (tons per minute) stripping hot coke to the stripper while keeping the same hydrocarbon carryunder as the base case. For a stripper with cross-hatched sheds with lips and apertures as shown in US 2011/0114468, the reactor temperature could be reduced by 17° F./9° C. by adding 10.5 TPM stripping hot coke to the stripper while keeping the same hydrocarbon carryunder as the base case. Temperature differentials of 5 to 15° C. between the coking zone and the stripping zone are therefore realistic given the normal coke recycle rate to the stripper and favorable flow patterns at the top of the stripper induced the downward flow of coke from the coking zone and the entry of the recycle coke. | A fluid coking unit for converting a heavy oil feed to lower boiling products by thermal has a centrally-apertured annular baffle at the top of the stripping zone below the coking zone to inhibit recirculation of solid particles from the stripping zone to the coking zone. By inhibiting recirculation of the particles from the stripping zone to the coking zone, the temperatures of the two zones are effectively decoupled, enabling the coking zone to be run at a lower temperature than the stripping zone to increase the yield of liquid products. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/867,827, filed on Aug. 20, 2013; U.S. Provisional Patent Application No. 61/869,886, filed on Aug. 26, 2013; and U.S. Provisional Patent Application No. 61/870,470, filed on Aug. 27, 2013, all of which are incorporated herein by reference in their entirety.
FIELD OF INVENTION
[0002] Embodiments of the present invention are generally related to communication connectors, and more specifically, to communication connectors such as jacks which are compatible with more than one style of a plug.
BACKGROUND
[0003] The fastest communication data rate currently specified by the Institute of Electrical and Electronics Engineers (IEEE) over structured copper cabling is 10 gigabit/second (Gbps) per the IEEE802.3ba standard. The structured cabling infrastructure called out in this standard is based on twisted pair cabling and RJ45 connectivity which calls for plugs and jacks having four pairs of corresponding contacts arranged in a generally parallel 1-8 in-line fashion with one of the pairs split around the center pair. This type of structured copper cabling specified by the IEEE includes four balanced differential pairs over which Ethernet communication takes place. Compliant channels will also meet the TIA568 Category 6A (CAT6A) specifications for cable, connectors, and channels. These CAT6A components and channels provide 500 MHz of bandwidth for data communication across 100 meter links.
[0004] In 2010, the IEEE ratified a new standard, IEEE802.3an, for high speed Ethernet communication at speeds of 40 Gbps and 100 Gbps. While this new standard called for both fiber and copper media, the only supported copper media was a short (7m) twin-ax based copper cable assembly. No provisions were made for twisted pair structured copper links. Additionally, the proposed standard includes a specification that has Medium Dependent Interface (MDI) components such as magnetics and printed circuit board (PCB) traces. This PHY (Physical Layer Transceiver) to PHY specification creates a challenging task for designers.
[0005] Traditionally, copper connectivity has been associated with a number of benefits including lower cost, ease of field terminability, and ease of mateability between corresponding connectors. This has prompted the investigation of the feasibility of transmitting 40 Gbps over a structured copper channel. One approach to this is detailed in the International Electrotechnical Commission (IEC) 60603-7-71 standard, which incorporates two “modes” of operation to allow for backward compatibility with RJ45 style plugs and a higher bandwidth style plug, sometimes referred to as “ARJ45”, with 4 pairs of contacts isolated in “quadrants.” When mated with an RJ45 plug, the connector must provide the necessary electrical crosstalk compensation to comply with the RJ45 rated standard such as CAT6A. When mated with an IEC 60603-7-71 plug, the connector must provide the corresponding isolated contact locations.
[0006] This dual-mode functionality is achieved by sharing the two outermost pairs of RJ45 contacts, while also grounding the middle two pairs of RJ45 contacts and providing two new pairs of isolated contacts in case of mating with an IEC 60603-7-71 plug. In total there are six pairs of contacts in the connector, of which only four are used depending on which style plug the connector is mated with.
[0007] The presence of the extra pairs and the mechanical operation of the connector results in a challenging electrical design due to the potential parasitic coupling between unused contacts and/or unwanted compensation circuitry. Thus, there exists a continued need for further development and advancement of communication connectors, including PCB-mounted versions, which may allow for increased transfer rates while retaining backward compatibility with the RJ45 standard. Furthermore, since communication connectors are often used in systems which incorporate adjacent connector configurations, there is a continuing need for improved system designs which improve system performance, increase the ease of manufacturability, and provide robust electrical mating points.
SUMMARY
[0008] Accordingly, at least some embodiments of the present invention are directed towards communication jacks which are compatible with more than one type of a plug.
[0009] Furthermore, at least some other embodiments of the present invention are directed towards communication systems which incorporate multiple communication jacks, methods of use of said systems, and components thereof.
[0010] In an embodiment, a jack according to the present invention is a PCB-mounted jack.
[0011] In another embodiment, the electrical and mechanical design of a jack in accordance with the present invention may extend the usable bandwidth beyond the IEC 60603-7-71 requirement of 1000 MHz to support potential future applications such as, but not limited to, 40GBASE-T. In addition, the jack may be backwards compatible with lower speed BASE-T applications (e.g., 10GBASE-T and/or below) when an RJ45 plug is mated to the jack.
[0012] In yet another embodiment, the present invention is a communication jack capable of mating with either one of a first type of a communication plug and a second type of a communication plug, the first type and second type of a communication plug being different. The communication jack includes a housing having a front portion, the front portion including an aperture for receiving the either one of the first type of a communication plug and the second type of a communication plug. The communication jack also includes a first set of plug interface contacts (PICs) configured to interface the first type of a communication plug, and a second set of PICs configured to interface the second type of a communication plug. The communication jack also includes jack contacts, the jack contacts being one of insulation displacement contacts (IDCs) and connector pin contacts. And the communication jack also includes a printed circuit board (PCB), the PCB being movable between a first position and a second position along a longitudinal plane relative to the communication jack, the first position providing a first electrical path from the first set of PICs to the jack contacts, and the second position providing a second electrical path from the second set of PICs to the jack contacts, the PCB being positioned at the first position when mated with the first type of a communication plug, and the PCB being positioned at the second position when mated with the second type of a communication plug.
[0013] In still yet another embodiment, the present invention is a communication jack capable of mating with either one of a first type of a communication plug and a second type of a communication plug, the first type and second type of a communication plug being different. The communication jack includes a housing having a front portion, the front portion including an aperture for receiving the either one of the first type of a communication plug and the second type of a communication plug. The communication jack also includes a first set of PICs configured to interface the first type of a communication plug, and a second set of PICs configured to interface the second type of a communication plug. The communication jack also includes IDCs. And the communication jack also includes a PCB having a top surface and a bottom surface, some of the IDCs interfacing the PCB on the top surface and some of the IDCs interfacing the PCB on the bottom surface, the PCB being movable between a first position and a second position, the first position providing a first electrical path from the first set of PICs to the IDCs, and the second position providing a second electrical path from the second set of PICs to the IDCs.
[0014] In still yet another embodiment, the present invention is a duplex communication jack having a housing with a first and a second aperture. The first aperture is made to receive multiple styles of plugs and includes an associated set of first jack components, and the second aperture is made to receive multiple styles of plugs and includes an associated set of second jack components. The first jack components include a first set of lower PICs, a first set of upper PICs, a first PCB, and a first set of connector pins. The second jack components include a second set of lower PICs, a second set of upper PICs, a second PCB, and a second set of connector pins. Each of the first and second PCBs have a first and second circuit, wherein the each of the circuits can be positioned between respective PICs and connector pins depending on the style of plug received within a respective aperture.
[0015] In still yet another embodiment, the present invention is a duplex communication jack having a housing with a first and a second aperture. The first aperture is made to receive multiple styles of plugs and includes an associated set of first jack components, and the second aperture is made to receive multiple styles of plugs and includes an associated set of second jack components. The first jack components include a first set of lower PICs, a first set of upper PICs, a first PCB, and a first set of connector pins. The second jack components include a second set of lower PICs, a second set of upper PICs, a second PCB, and a second set of connector pins. The first PCB is positioned over the second PCB where the first PCB is longer than the second PCB such that the first set of connector pins is positioned behind the second set of connector pins.
[0016] In still yet another embodiment, the present invention is a duplex communication jack having a housing with a first and a second aperture. The first aperture is made to receive multiple styles of plugs and includes an associated set of first jack components, and the second aperture is made to receive multiple styles of plugs and includes an associated set of second jack components. The first jack components include a first set of lower PICs, a first set of upper PICs, a first PCB, and a first set of connector pins being positioned normally with respect to the first PCB for at least a portion thereof. The second jack components include a second set of lower PICs, a second set of upper PICs, a second PCB positioned at least partially under the first PCB, and a second set of connector pins being positioned normally with respect to the second PCB for at least a portion thereof.
[0017] These and other features, aspects, and advantages of the present invention will become better-understood with reference to the following drawings, description, and any claims that may follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a system according to an embodiment of the present invention.
[0019] FIG. 2 illustrates an isometric view of a jack and corresponding plugs according to an embodiment of the present invention.
[0020] FIG. 3 illustrates an exploded isometric view of a jack according to an embodiment of the present invention.
[0021] FIG. 4 illustrates the movement of the PCB of the jack of FIG. 3 in response to the jack being mated to an RJ45 plug.
[0022] FIG. 5 illustrates the movement of the PCB of the jack of FIG. 3 in response to the jack being mated to an ARJ45 plug.
[0023] FIGS. 6A and 6B illustrate the interaction of the switching components with some other components of the jack of FIG. 3 .
[0024] FIG. 7 illustrates a rear isometric view of the front housing of the jack of FIG. 3 .
[0025] FIG. 8 illustrates the interaction of the PCB and the PCB stops of the jack of FIG. 3 .
[0026] FIG. 9A illustrates a schematic representation of the circuit, according to an embodiment, on the PCB of the jack of FIG. 3 used in RJ45 mode.
[0027] FIG. 9B illustrates a schematic representation of the circuit, according to an embodiment, on the PCB of the jack of FIG. 3 used in ARJ45 mode.
[0028] FIG. 10A illustrates a top view of one embodiment of the PCB used in the jack of FIG. 3 .
[0029] FIG. 10B illustrates a bottom view of the PCB of FIG. 10A .
[0030] FIGS. 11 and 12 illustrate the interaction of the plug interface contacts (PICs) and the insulation displacement contacts (IDCs) with the PCB of FIG. 10A when mated to an RJ45 plug.
[0031] FIGS. 13 and 14 illustrate the interaction of the PICs and the IDCs with the PCB of FIG. 10A when mated to an ARJ45 plug.
[0032] FIGS. 15 and 16 illustrate another embodiment of the PICs and the PCB which may be used in the jack of FIG. 3 .
[0033] FIG. 17A illustrates an exploded isometric view of the wire manager assembly of FIG. 3 .
[0034] FIG. 17B illustrates an isometric view of an assembled wire manager assembly of FIG. 17A .
[0035] FIG. 18 illustrates an embodiment of a process of assembly of the jack of FIG. 3 .
[0036] FIG. 19 illustrates a communication system according to an embodiment of the present invention.
[0037] FIG. 20 illustrates an exploded view of a jack according to an embodiment of the present invention.
[0038] FIG. 21A illustrates the jack of FIG. 20 mated with an RJ45 plug.
[0039] FIG. 21B illustrates the jack of FIG. 21A mated with an ARJ45 plug.
[0040] FIG. 22 illustrates a simplified schematic representation of a plug/jack/PHY combination according to an embodiment of the present invention.
[0041] FIG. 23 illustrates internal positioning of the PCB and dividers within the jack of FIG. 20 according to an embodiment of the present invention.
[0042] FIG. 24 illustrates the means for restraining the forwards/backwards movement of the PCB within the jack of FIG. 20 according to an embodiment of the present invention.
[0043] FIG. 25A illustrates a simplified schematic representation of an RJ45 plug mated to a first circuit of the jack of FIG. 20 according to an embodiment of the present invention.
[0044] FIG. 25B illustrates a simplified schematic representation of an ARJ45 plug mated to a second circuit of the jack of FIG. 20 according to an embodiment of the present invention.
[0045] FIG. 26A illustrates a top view of a PCB, which may be used within the jack of FIG. 20 , according to an embodiment of the present invention.
[0046] FIG. 26B illustrates a bottom view of the PCB of FIG. 26A
[0047] FIG. 27A illustrates an isometric view of the jack of FIG. 20 with a PCB of FIG. 26A mated with an RJ45 plug.
[0048] FIG. 27B illustrates a bottom isometric view of the jack/plug combination of FIG. 27A .
[0049] FIG. 27C illustrates a cross-sectional view of the jack/plug combination of FIG. 27A .
[0050] FIG. 28A illustrates an isometric view of the jack of FIG. 27A mated with an ARJ45 plug.
[0051] FIG. 28B illustrates a bottom isometric view of the jack/plug combination of FIG. 28A .
[0052] FIG. 28C illustrates a cross-sectional view of the jack/plug combination of FIG. 28A .
[0053] FIG. 29 illustrates a simplified schematic representation of a plug/jack/PHY combination according to another embodiment of the present invention.
[0054] FIG. 30 illustrates a simplified schematic representation of a plug/jack/PHY combination according to yet another embodiment of the present invention.
[0055] FIG. 31A illustrates an isometric view of another embodiment of a jack having another embodiment of the PCB therein mated with an ARJ45 plug.
[0056] FIG. 31B illustrates the jack of FIG. 31A mated with an RJ45 plug.
[0057] FIG. 32 illustrates an embodiment of a system according to an embodiment of the present invention.
[0058] FIG. 33 illustrates a bottom view of a PCB and connector pin layout according to another embodiment of the present invention.
[0059] FIG. 34 illustrates a bottom view of a PCB and connector pin layout according to yet another embodiment of the present invention.
[0060] FIG. 35 illustrates a communication system according to an embodiment of the present invention.
[0061] FIG. 36 illustrates an exploded view of a communication jack according to an embodiment of the present invention.
[0062] FIG. 37 illustrates some internal components of the jack of FIG. 36 .
[0063] FIG. 38A illustrates a first side of a first PCB of the jack of FIG. 36 .
[0064] FIG. 38B illustrates a second side of a first PCB of the jack of FIG. 36 .
[0065] FIG. 39 illustrates a first side of a second PCB of the jack of FIG. 36 .
[0066] FIG. 40 illustrates an isometric view of the two PCBs, PICs, and connector pins of the jack of FIG. 36 .
[0067] FIG. 41 illustrates a bottom-side view of the interaction of the connector pins with the PCBs within the jack of FIG. 36 .
DETAILED DESCRIPTION
[0068] In an embodiment, the present invention is a network jack capable of supporting two different modes of operation depending on the type of a plug that is inserted. In this embodiment, the jack can be mated with an RJ45 plug to operate at some network speeds (e.g., up to 10GBASE-T); and the same jack can be mated with an IEC 60603-7-71 style plug (hereinafter referred to as an “ARJ45 plug”) for higher speed applications (e.g., 40GBASE-T). Note that while references are made to an IEC 60603-7-71 plug, jacks according to the present invention are not limited to use with only those plugs, and instead may be used with other plugs which are commonly referred to in the telecommunication art as ARJ45 plugs or GG45 plugs.
[0069] An exemplary embodiment of the present invention is illustrated in FIG. 1 , which shows a copper structured cabling communication system 40 , which includes a patch panel 42 with jacks 44 and corresponding RJ45 plugs 46 . Respective cables 48 are terminated to jacks 44 , and respective cables 50 are terminated to plugs 46 . Although only RJ45 plugs 46 are illustrated, system 40 can also be used with ARJ45 plugs with associated cables. Once a plug 46 mates with a jack 44 data can flow in both directions through these connectors. Although the communication system 40 is illustrated in FIG. 1 as having a patch panel, alternative embodiments can include other active or passive equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, punch-down patch panels, coupler patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and power-over-Ethernet equipment as can be found in data centers and or telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers, and other peripherals as can be found in workstation areas. Communication system 40 can further include cabinets, racks, cable management and overhead routing systems, and other such equipment.
[0070] Referring now to FIG. 2 , in one embodiment, jack 44 complies with Mini-Com® geometry as employed by Panduit Corp., and installs to Mini-Com® patch panels and faceplates. Examples of a compatible RJ45 plug 46 and a compatible ARJ45 plug 90 are also shown. FIG. 3 shows an exploded view of an embodiment of jack 44 . In this embodiment, jack 44 includes a front housing 52 , lower plug interface contacts (PICs) 54 ( 54 1-8 ), upper PICs 56 ( 56 3-6 ), dielectric structures 55 and 57 , a PCB 60 connected to a switching plate 70 and dividers 58 (collectively referred to as “the switching components”), a spring 66 positioned between a retention wall 52 a of the front housing 52 (see FIG. 7 ) and the switching components, insulation displacement contacts (IDCs) 72 ( 72 1 - 72 8 ), a wire manager assembly 78 , a rear housing 84 , and a rear cap 88 . The front housing 52 may be made of metal (or any other conductive material) and can include plug grounding tabs which can be used to electrically bond a shielded plug to jack 44 . Depending on the embodiment, the front housing 52 may be made entirely of metal or may have only some of its parts (e.g., the plug-receiving portion) made out of metal. Similarly, the rear housing 84 and the rear cap 88 may also be metal or may otherwise be made from a conductive material. Alternatively, the housing components may be formed from a non-conductive material such as, for example, plastic.
[0071] Based on the type of a plug that is inserted into the jack 44 , the PCB 60 is located at one of two possible locations. This enables the switching of the signal paths between PICs 54 , 56 and one of two independent circuits on PCB 60 .
[0072] As shown in FIGS. 4 and 5 , the jack 44 is provided with twelve plug interface contacts (PICs 54 1-8 and PICs 56 3-6 ) which are at least partially held in place with dielectric structures 55 , 57 . The PICs 54 and 56 are positioned such that their proximal ends contact the plug contacts of a plug, and their distal ends make contact with contact pads on the PCB 60 . PICs 54 1 through 54 8 are arranged in a fashion to mate with a traditional RJ45 plug, and each subscript number corresponds to the plug contact number of a plug having its plug contacts laid out in accordance with ANSI/TIA-568-C.2. PICs 54 1 , 54 2 , 54 7 , and 54 8 are also arranged to mate with four of the eight plug contacts of an ARJ45 plug. The remaining four plug contacts of an ARJ45 plug mate with PICs 56 3 , 56 4 , 56 5 , and 56 6 .
[0073] The switching between the RJ45 and ARJ45 functionality states of the jack 44 is achieved primarily by incorporating independent circuits on the PCB 60 and switching between those circuits by moving the PCB 60 in a generally horizontal direction along the x-axis, as shown by an arrow in FIGS. 4 and 5 . Each circuit provides an electrical path from appropriate PICs to respective IDCs.
[0074] To achieve the necessary switching, PCB 60 incorporates a switching plate 70 (preferably made from a dielectric material such as, but not limited to, plastic) and dividers 58 which allow the PCB to be pushed and guided along an appropriate path. These elements are illustrated in FIGS. 6A and 6B . Dividers 58 are comprised of a top vertical divider 62 , a bottom vertical divider 68 , and a horizontal divider 64 . Preferably, dividers 58 are made from a material which has electromagnetic shielding properties, and in some embodiments dividers 58 are metal. When the jack 44 is assembled, the top vertical divider 62 is partially positioned within guide path 80 a of the wire manager 80 and partially within guide path guide path 52 b of the front housing 52 (see FIG. 7 ), the bottom vertical divider 68 is partially positioned within guide path 80 b of the wire manager 80 and partially within guide path guide path 52 c of the front housing 52 , and the horizontal divider 64 is partially positioned within guide path 80 c of the wire manager 80 . The top vertical divider 62 includes a protrusion 62 a which acts as a post for the spring 66 . When the top vertical divider 62 is positioned within the guide path 52 b , the spring 66 becomes trapped between the retention wall 52 a and the divider 62 , and biases the divider 62 along with the PCB 60 towards the front of the jack 44 . This retains the PCB 60 in a forward position at all times except for when an ARJ45 plug is inserted.
[0075] In addition to guiding the PCB 60 , dividers 58 help with crosstalk reduction. In order to maintain some level of isolation between the four signal pairs and reduce unwanted crosstalk therebetween in the IDC region, horizontal divider 64 and vertical dividers 62 and 68 are assembled and positioned between the four pairs of IDCs 72 . This arrangement of dividers 58 enables the formation of a quadrant for each pair of wires. Grounding the dividers 58 (when the dividers are metal) may help maintain the continuity of a shield from the plug cable to the jack and therethrough, and reduce undesired crosstalk.
[0076] Note that some embodiments of the present invention may omit the horizontal divider 64 and may instead only use the vertical dividers 62 and 68 . In these embodiments, the PCB 60 itself may provide shielding properties and act as the necessary divider. Alternatively, the PCB 60 may be extended to replace the horizontal divider 64 so long as it does not interfere with the wire manager assembly 78 .
[0077] To retain the PCB 60 within certain bounds along the x-axis, front stops 52 d and rear stops 84 a are positioned on the inside of the front housing 52 and the rear housing 84 , respectively, as shown in FIG. 8 . The stops 52 d and 84 a are positioned approximately on the same plane as the PCB 60 and are designed to come in contact with the corners 96 of the PCB 60 (see FIG. 10A ). The front stops 52 d limit the amount of forward displacement that the PCB 60 may undergo. Thus, when the PCB 60 is biased forward via the spring 66 , it rests against the front stops 52 d in a forward position. The rear stops 84 a limit the amount of rearward displacement that the PCB 60 may undergo when the PCB 60 is moved back. Thus, when an appropriate plug (e.g., an ARJ45 plug) is inserted into the jack 44 and that plug displaces the PCB 60 into its second position, the rear stops 84 a prevent the PCB 60 from moving too far by having the rear corners 96 rest against the stops 84 a . When that plug is removed, the spring 66 causes the PCB 60 to again move into its forward position and once again engage the front stops 52 d . Stops 52 d and 84 a may help ensure that the PICs and ICDs contact the appropriate contact pads on the PCB 60 .
[0078] One embodiment of the PCB 60 together with a corresponding arrangement of the PICs is shown in FIGS. 9A-14 . In this embodiment, the PCB 60 is provided with two separate circuits; the first circuit is used for RJ45 connectivity and the second circuit is used for ARJ45 connectivity. FIGS. 9A and 9B illustrate schematic representations of these circuits, respectively. Note that not all circuit elements are shown, and instead only active signal paths between the PICs and the IDCs are generally represented. As shown in FIGS. 10A and 10B , the first circuit comprises contact pads 92 1 - 92 8 , 93 3 - 93 6 , and 94 1 - 94 8 . Contact pads 92 1 - 92 8 are designed to contact the distal ends of the PICs 54 1 - 54 8 , respectively, and provide an electrical path to pads 94 1 - 94 8 which are designed to contact IDCs 72 1 - 72 8 . Contact pads 93 3 - 93 6 are designed to contact the distal ends of PICs 56 3 - 56 4 , respectively, and are grounded through the PCB 60 . The interaction between the contacts and the PCB is illustrated in FIG. 11 .
[0079] As shown in FIG. 12 , the first circuit is activated when there is no plug inserted into jack 44 or when an RJ45 plug is inserted. In this state, spring 66 forces PCB 60 forward where contact pads 92 1 - 92 8 on the top side of the PCB 60 are in alignment with the distal ends of the PICs 54 1-8 . The same positioning of the PCB 60 also causes the IDC contact pads 94 1-8 to also align with the distal ends of the IDCs 72 1-8 , respectively.
[0080] When an RJ45 plug 46 is inserted into jack 44 , the plug contacts engage the PICs 54 1-8 in the jack 44 and thereby establish continuity between the plug 46 and the cable terminated at the IDCs 72 1-8 near the far end of the jack 44 . As is typical in RJ45 jacks (e.g., CAT6A), various crosstalk compensation techniques may be used to counteract the inherent crosstalk that exists in an RJ45 plug. This compensation circuitry, which may include discrete and/or distributed capacitive and/or inductive elements between conductors (e.g., C13, C35, C46 and C68 shown schematically in FIG. 9A ) may be realized on internal and/or external layers of the PCB 60 . Other compensation elements which help optimize return loss, far-end crosstalk, balance, and etc. can also be included. In some instances, while the jack 44 is engaged with an RJ45 plug 46 , the unused PICs 56 3 , 56 4 , 56 5 , and 56 6 can introduce unintended coupling and crosstalk between signal pairs in the jack 44 . To help reduce or prevent this unintended coupling and crosstalk from occurring, PICs 56 3-6 are grounded by way of contact pads 93 3 - 93 6 on the PCB 60 , which are connected to a grounding source.
[0081] The second circuit on the PCB 60 comprises contact pads 92 ′ 1 - 92 ′ 8 , 93 ′ 3 - 93 ′ 6 , and 94 ′ 1 - 94 ′ 8 . Referring to FIG. 13 , as in the first circuit, contact pads 92 ′ 1 - 92 ′ 8 contact the distal ends of the PICs 54 1 - 54 8 , respectively. However, of those, only contact pads 92 ′ 1 , 92 ′ 2 , 92 ′ 7 , and 92 ′ 8 provide an electrical path to contact pads 94 ′ 1 , 94 ′ 2 , 94 ′ 7 , and 94 ′ 8 . The remaining contact pads 92 ′ 3 , 92 ′ 4 , 92 ′ 5 , and 92 ′ 6 can be grounded through the PCB 60 . As for contact pads 93 ′ 3 - 93 ′ 6 , these pads contact the distal ends of PICs 56 3 - 56 6 , respectively, and in this case provide an electrical path to contact pads 94 ′ 3 , 94 ′ 4 , 94 ′ 5 , and 94 ′ 6 .
[0082] With reference to FIG. 14 , when an ARJ45 style plug 90 is inserted into the jack 44 the nose feature 91 on the front of the plug engages the switching plate 70 mounted to the PCB 60 . As plug 90 is inserted further into the jack 44 , the nose feature 91 applies force against the switching plate 70 , and displaces the plate 70 and the PCB 60 horizontally in a rearward direction.
[0083] As the PCB 60 travels into its rearward position, the PICs 54 1-8 and 56 3-6 , and IDCs 72 1-8 lose contact with contact pads 92 1 - 92 8 , 93 3 - 93 6 , and 94 1 - 94 8 , and instead come into contact with contact pads 92 ′ 1 - 92 ′ 8 , 93 ′ 3 - 93 ′ 6 , and 94 ′ 1 - 94 ′ 8 , respectively. Once the ARJ45 jack is fully inserted into the jack 44 , contact pads 92 ′ 1 - 92 ′ 8 , 93 ′ 3 - 93 ′ 6 , and 94 ′ 1 - 94 ′ 8 on the PCB 60 should align with the distal ends of the PICs and the distal ends of the IDCs. Stops 84 a prevent the PCB 60 from traveling beyond its intended position. At this point, plug contacts of the ARJ45 plug engage the PICs 54 k , 54 2 , 56 3 , 56 4 , 56 5 , 56 6 , 54 7 , and 54 8 in the jack 44 and thereby establish continuity between the plug 90 and the cable terminated at the IDCs 72 near the far end of the jack 44 .
[0084] By switching to a second circuit, the compensation circuitry that is used in the RJ45 operation mode is disconnected from the signal path under ARJ45 operation. As such, separate independent circuitry may be employed on the second circuit if so desired. By having separate circuits, the compensation circuitry required during the RJ45 mode of operation has little to no impact on the jack's 44 electrical performance while operating in the ARJ45 mode. This isolation may be advantageous when meeting the high bandwidth performance targets of jack 44 . Furthermore, to reduce unintentional coupling and achieve improved return loss, insertion loss, and electrical balance performance at higher frequencies, contact pads 92 ′ 3 , 92 ′ 4 , 92 ′ 5 , and 92 ′ 6 , and thus PICs 54 3 , 54 4 , 54 5 , and 54 6 , are preferably grounded via the PCB 60 .
[0085] Preferably, PICs 54 and 56 , and IDCs 72 are designed to be or resilient nature, causing the distal ends thereof to springingly press against the contact pads on the PCB 60 . To help ensure a smooth transition between the contact pads, the distal ends of the PICs 54 and 56 , and IDCs 72 are provided with curved feet 100 (see FIG. 13 ) which may act as ramps. This design may help ensure a constant force on the contact pads and it may also help ensure that in the process of sliding on and off the contact pads of the PCB 60 , contaminants or oxidation that may be present on the surface of the PCB 60 contact pads will be wiped away; thereby, providing a robust connection between the PICs, the IDCs, and the circuitry in between.
[0086] Another embodiment of the present invention is illustrated in FIGS. 15-16 where a PCB 61 together with a corresponding arrangement of the PICs, including two additional contacts 59 , is shown. While the entire jack 44 is not illustrated, one of ordinary skill in the art will understand that PCB 61 can substitute for the PCB 60 in the jack 44 and the additional contacts 59 may be implemented in a manner that is similar to the PICs 54 of the previously described embodiment.
[0087] The PCB 61 retains some features of the PCB 60 , including contact pads 92 1 - 92 8 , 93 3 - 93 6 , and 94 1 - 94 8 which contact respective PICs and IDCs in the RJ45 mode of operation, contact pads 92 ′ 1 - 92 ′ 8 , 93 ′ 3 - 93 ′ 6 , and 94 ′ 1 - 94 ′ 8 which contact respective PICs and IDCs in the ARJ45 mode of operation, and any potential interconnecting circuitry. However, PCB 61 includes additional contact pads 95 0 , 95 9 , 95 ′ 0 , and 95 ′ 9 which are designed to contact the two additional contacts 59 0 and 59 9 .
[0088] When operating PCB 60 in ARJ45 mode, PICs 54 1 and 54 2 are mated with their corresponding plug contacts of the ARJ45 plug and PIC 54 3 is connected to ground. With the position of PIC 54 3 being adjacent to PIC 54 2 , an impedance discontinuity may occur. Even and odd mode impedance of PIC 54 1 will be inherently higher than PIC 54 2 . This impedance discontinuity can results in an increase in electrical reflections at the plug/jack interface and an increase in mode conversion. The differential return loss, insertion loss, and crosstalk performance of signal-pair 1:2 may be degraded due to this inherent condition of the jack. Thus, to avoid these performance degradations, even and odd mode impedances of PICs 54 1 and 54 2 should be equal and matched to the characteristic impedance of the cable. By introducing contact 59 0 , which is grounded in the ARJ45 mode of operation, adjacent to PIC 54 1 in the PCB 61 the impedances discontinuity may be reduced or otherwise eliminated. This can help provide a balanced configuration of ground conductors and signal conductors (Ground-Signal-Signal-Ground), which can become increasingly advantageous relative to signal integrity as the bandwidth increases.
[0089] A similar concern exists with PICs 54 7 and 54 8 in the ARJ45 mode of operation. PICs 54 7 and 54 8 are mated with their corresponding plug contacts of the ARJ45 plug and PIC 54 6 is grounded. With PIC 54 6 being adjacent to PIC 54 7 , even and odd mode impedance of PIC 54 8 will be inherently higher than PIC 54 7 . By adding an additional grounded contact 59 9 adjacent to PIC 54 8 , a more balanced (Ground-Signal-Signal-Ground) configuration is created and performance degradations may be reduced or otherwise eliminated.
[0090] To achieve the necessary grounding, the side contacts 59 0 and 59 9 are grounded through PCB contact pads 95 ′ 0 and 95 ′ 9 (which themselves are grounded through the PCB), respectively, which are engaged by the by the contacts 59 0 and 59 9 when the jack 44 is operating in the ARJ45 operating mode. Furthermore, the side contacts 59 0 and 59 9 are slightly offset relative to PICs 54 1-8 to allow the plug body to be fully inserted without interfering with or plastically deforming contacts 59 0 and 59 9 . The plug body can also be beneficially modified to shield the side contacts 59 0 and 59 9 .
[0091] Another possible use of contacts 59 0 and 59 9 is to incorporate them into the crosstalk compensation circuitry that is likely to be implemented when jack 44 is operating in the RJ45 mode, as shown in FIG. 16 . By grounding contacts 59 0 and 59 9 via contacts pads 95 0 and 95 9 (which are grounded via the PCB 61 ), those contacts may provide an additional way of reducing or minimizing the imbalance effect caused by the split pair 3:6 coupling to the signal pair 1:2 and the signal pair 7:8. Thus, balancing on the 1:2 and 7:8 signal pairs may be improved. Furthermore, since 95 0 , 95 9 , 95 ′ 0 , and 95 ′ 9 are grounded, pads 95 0 and 95 ′ 0 may be combined into a single contact pad which will be in contact with the contact 59 0 regardless of the mode of operation, and pads 95 9 and 95 ′ 9 may also be combined into a single contact pad which will also be in contact with the contact 59 9 regardless of the mode of operation.
[0092] The jack 44 may be terminated to any number of communication cables 48 including shielded cables. Since the jack 44 may be employed in environments where operational speeds exceed 10GBASE-T, the jack may be terminated to braid shield cables and foil/braid shield cables. Those skilled in the art will be succulently familiar with these cables, and thus no further description is necessary regarding structure thereof. To help terminate the cable 48 to the jack 44 , a wire manager assembly 78 shown in FIGS. 17A and 17B is used.
[0093] The wire manager assembly 78 includes a wire manager 80 , foil terminators 76 , a ferrule 86 , and IDC inserts 82 . Four IDC inserts 82 are positioned at the front end of the wire manager 80 such that the wires 103 inserted into the wire manager are laid over the inserts 82 . The IDC inserts 82 include recessed portions designed to support and retain the cable wires 103 in place when the insulation of those wires is displaced during the IDC termination process. Prior to termination of the wires 103 , the ferrule 86 , and the rear cap 88 (see FIG. 3 ) are slipped over the cable 48 . Thereafter, wire pairs 110 are separated and are inserted into the wire manager 80 with the braids of the cable being positioned over the ferrule. The wire pairs 110 are positioned over the IDC inserts 82 and the foil terminators 76 are placed over the foil of the wire pairs 110 and the cable braids. The foil terminators can be either pushed to fit in the wire manager 80 , crimped over the wire pairs 110 , or otherwise secured such that an electrical path is formed from the foil of the wire pairs to the foil terminators. The back end of foil terminators 76 can be crimped, or otherwise secured, over the braids of the cable 48 and the ferrule 86 , thereby completing the electrical path from the foil of the wire pairs to the braids.
[0094] To complete the cable termination process, the wire manager assembly is attached to the rear housing 84 . Thereafter, together with the wire manager assembly 78 , the rear housing 84 is pushed up into the front housing 52 , as shown in FIG. 18 , causing the IDCs 72 (which are held rigedly in place within the front housing 52 ) to engage and terminate wires 103 . Note that depending on the embodiment of the jack 44 , the horizontal divider 64 may be short enough not to interfere with the upward movement of the wire manager 80 . This configuration may allow the jack 44 to be assembled such that the switching components are installed in the front housing 52 prior to the wire termination step. In alternate embodiments where the horizontal divider 64 would interfere with the upward movement of the wire manager 80 , the jack 44 may be assembled by first terminating the jack to the cable, and then positioning the switching components internally. However, these two methods should not be considered limiting in any way, and other assembly methods are fall within the scope of the present invention. Once the rear housing 84 has been joined to the front housing 52 , the rear cap 88 is positioned over the rear end of the jack 44 .
[0095] Another exemplary embodiment of the present invention is illustrated in FIG. 19 , which shows a copper structured cabling communication system 240 with jacks 244 , an RJ45 plug 46 , an ARJ45 plug 90 , and an equipment/NIC card PCB 243 . The RJ45 plug and the ARJ45 plug each have a respective communication cable 50 terminated thereto, and each of the jacks 244 is connected to the equipment PCB 243 via connector pins (see FIG. 20 ). When either of the plugs 46 or 90 is mated to any of the jacks 244 , bi-directional data flow can be established through the plug/jack combination, and between the equipment and the communication cable 50 .
[0096] Although the present embodiment can be used in communication system 240 as shown in FIG. 19 , other communication systems according to the present invention can include equipment other than shown here. The equipment of the present invention can be passive equipment or active equipment. Examples of passive equipment can be, but are not limited to, modular patch panels, angled patch panels, wall jacks, etc. Examples of active equipment can be, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and Power-Over-Ethernet equipment as can be found in data centers/telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers and other peripherals as can be found in workstation areas. Communication systems according to the present invention can further include cabinets, racks, cable management and overhead routing systems, and other such equipment.
[0097] One embodiment of the jack 244 is shown in FIG. 20 which shows an exploded view of said jack. In this embodiment, jack 244 includes a front housing 252 , a rear housing 253 , PICs 254 ( 254 1-8 ), upper PICs 256 ( 256 3-6 ), dielectric structures 255 and 257 , a PCB 260 connected to a switching plate 270 and dividers 262 , 268 (collectively referred to as “the switching components”), a spring 266 positioned between a retention wall 252 a (see FIGS. 23 and 27C ) and the switching components, connector pins 276 , and a rear cap 288 . The front housing 252 may be made of metal (or any other conductive material) and can include plug grounding tabs which can be used to electrically bond a shielded plug to jack 244 . Alternatively, the housing may be made of plastic. Depending on the embodiment, the front housing 252 may be made entirely of metal or may have only some of its parts (e.g., the plug-receiving portion) made out of metal. Similarly, the rear housing 253 and the rear cap 288 may also be metal or may otherwise be made from a conductive material.
[0098] Based on the type of a plug that is inserted into the jack 244 , the PCB 260 is located at one of two possible locations. This enables the switching of the signal paths between PICs 254 , 256 and one of two independent circuits on PCB 260 .
[0099] As shown in FIGS. 21A and 21B , the jack 244 is provided with twelve plug interface contacts (PICs 254 1-8 and PICs 256 3-6 ) which are at least partially held in place with dielectric structures 255 , 257 . The PICs 254 and 256 are positioned such that their proximal ends contact the plug contacts of a plug, and their distal ends make contact with contact pads on the PCB 260 . PICs 254 1 through 254 8 are arranged in a fashion to mate with a traditional RJ45 plug, and each subscript number corresponds to the plug contact number of a plug having its plug contacts laid out in accordance with ANSI/TIA-568-C.2. PICs 254 1 , 254 2 , 254 7 , and 254 8 are also arranged to mate with four of the eight plug contacts of an ARJ45 plug. The remaining four plug contacts of an ARJ45 plug mate with PICs 256 3 , 256 4 , 256 5 , and 256 6 .
[0100] The switching between the RJ45 and ARJ45 functionality states of the jack 244 is achieved primarily by incorporating independent circuits on the PCB 260 and switching between those circuits by moving the PCB 260 in a generally horizontal (longitudinal) direction along the x-axis, as shown in FIGS. 21A and 21B . Each circuit provides an electrical path from appropriate PICs to respective connector pins. A simplified exemplary schematic representation of the separation of the two circuits is shown in FIG. 22 .
[0101] To achieve the necessary switching, PCB 260 incorporates a switching plate 270 (preferably made from a dielectric material such as, but not limited to, plastic) and dividers 262 , 268 which allow the PCB to be pushed and guided along an appropriate path. Dividers 262 , 268 are comprised of a top divider 268 and a bottom divider 262 . Preferably, the dividers are made from a material which has electromagnetic shielding properties, and in some embodiments the dividers are metal. As shown in FIG. 23 , when the jack 244 is assembled, the top divider 268 is partially positioned within guide path 280 a and the bottom divider 262 is partially positioned in within guide path 280 b . The top divider 268 includes a protrusion 268 a which acts as a post for the spring 266 . When the top divider 268 is positioned within the guide path 280 a , the spring 266 becomes trapped between the retention wall 252 a and the divider 268 , and biases the divider 268 along with the PCB 260 towards the front of the jack 244 . This retains the PCB 260 in a forward position at all times except for when an ARJ45 plug is inserted.
[0102] In addition to guiding the PCB 260 , dividers 262 , 268 help with crosstalk reduction. In order to maintain some level of isolation between the four signal pairs and reduce unwanted crosstalk therebetween in the middle and rear sections of the jack 244 , dividers 262 and 268 are assembled and positioned between some of the four signal pairs. Grounding the dividers (when the dividers are metal) may help maintain the continuity of a shield from the plug cable to the jack and therethrough, and reduce undesired crosstalk. Note that selection of the materials for the PCB 260 may also factor into the amount of crosstalk which exists within the jack since various dielectric materials may reduce some levels of undesired crosstalk.
[0103] To retain the PCB 260 within certain bounds along the x-axis, front stops 252 b and rear stops 252 c are positioned on the inside of the jack 244 . Referring to FIG. 24 , the stops 252 b and 252 c are positioned approximately on the same plane as the PCB 260 and are designed to come in contact with the corners 296 of the PCB 260 . The front stops 252 b limit the amount of forward displacement that the PCB 260 may undergo. Thus, when the PCB 260 is biased forward via the spring 266 , it rests against the front stops 252 b in a forward position. The rear stops 252 c limit the amount of rearward displacement that the PCB 260 may undergo when the PCB 260 is moved back. Thus, when an appropriate plug (e.g., an ARJ45 plug) is inserted into the jack 244 and that plug pushes the PCB 260 into its second position, the rear stops 252 c prevent the PCB 260 from moving too far by having the rear corners 296 rest against the stops 252 c . When that plug is removed, the spring 266 causes the PCB 260 to again move into its forward position and once again engage the front stops 252 b . Stops 252 b and 252 c may help ensure that the PICs and connector pins contact the appropriate contact pads on the PCB 260 .
[0104] One embodiment of the PCB 260 together with a corresponding arrangement of the PICs is shown in FIGS. 25A-28C . In this embodiment, the PCB 260 is provided with two separate circuits; the first circuit is used for RJ45 connectivity and the second circuit is used for ARJ45 connectivity. FIGS. 25A and 25B illustrate schematic representations of these circuits, respectively. Note that not all circuit elements are shown, and instead only active signal paths between the PICs and the connector pins are represented. As shown in the top and bottom views of the PCB 260 shown in FIGS. 26A and 26B , the first circuit comprises contact pads 292 1 - 292 8 , 293 3 - 293 6 , and 294 1 - 294 8 . Contact pads 292 1 - 292 8 are designed to contact the distal ends of the PICs 254 1 - 254 8 , respectively, and provide an electrical path to contact pads 294 1 - 294 8 which are designed to contact connector pins 276 1 - 276 8 . Contact pads 293 3 - 293 6 are designed to contact the distal ends of PICs 256 3 - 256 6 , respectively, and are grounded through the PCB 260 .
[0105] Referring to FIGS. 27A-27C , the first circuit is activated when there is no plug inserted into jack 244 or when an RJ45 plug is inserted. In this state, spring 266 forces PCB 260 forward where contact pads 292 1 - 292 8 on the top side of the PCB 260 are in alignment with the distal ends of the PICs 254 1-8 . The same positioning of the PCB 260 also causes the connector pin contact pads 294 1-8 to also align with the distal ends of the connector pins 276 A1-A8 , respectively.
[0106] When an RJ45 plug 46 is inserted into jack 244 , the plug contacts engage the PICs 254 1-8 in the jack 244 and thereby establish continuity between the plug 46 and the equipment on which the jack 244 is mounted on. As is typical in RJ45 jacks (e.g., CAT6A), various crosstalk compensation techniques may be used to counteract the inherent crosstalk that exists in an RJ45 plug. This compensation circuitry, which may include discrete and/or distributed capacitive and/or inductive elements between conductors (e.g., C13, C35, C46 and C68 shown schematically in FIG. 25A ), may be realized on internal and/or external layers of the PCB 260 . Other compensation elements which help optimize return loss, far-end crosstalk, balance, and etc. can also be included. In some instances, while the jack 244 is engaged with an RJ45 plug 46 , the unused PICs 256 3 , 256 4 , 256 5 , and 256 6 can introduce unintended coupling and crosstalk between signal pairs in the jack 244 . To help reduce or prevent this unintended coupling and crosstalk from occurring, PICs 256 3-6 are grounded by way of contact pads 293 3 - 293 6 on the PCB 260 , which are connected to a grounding source.
[0107] In addition to the aforementioned compensation components, the first circuit used for the RJ45 mode of operation can include one or more various magnetics modules 272 (e.g., transformers, inductors, or the like). Those skilled in the art will recognize the need for the magnetics elements when using the jack on various kinds equipment. A V cc or a center tap signal can be added to convene the PHY's need for DC Biasing of the data signals. Biasing is typically needed for driving differential pairs in the PHY. It is used as a method of establishing predetermined voltages and/or currents to set an appropriate operating point. The DC Biasing signal can be inserted into the circuit using center taps on the magnetic modules in the RJ45 operation mode. Furthermore, an On/Off switch comprised of the contact pad 297 and connector pins 276 B1 and 276 B2 is included in the currently described embodiment to indicate to the PHY the type of the plug inserted to the jack. When in the RJ45 mode of operation, the connector pins 276 B1 and 276 B2 are in contact with the contact pad 297 ; when not in the RJ45 mode of operation, the connector pins 276 B1 and 276 B2 lose contact with the contact pad 297 . In other words, the On/Off switch acts as an operation mode indicator for the PHY. This may allow the PHY to detect the mode of operation to utilize the correct compensation/correction or data processing schemes.
[0108] The second circuit on the PCB 260 comprises contact pads 292 1 - 292 ′ 8 , 293 ′ 3 - 293 ′ 6 , and 294 ′ 1 - 294 ′ 8 . As in the first circuit, contact pads 292 ′ 1 - 292 ′ 8 contact the distal ends of the PICs 254 1 - 254 8 , respectively. However, of those, only contact pads 292 ′ 1 , 292 ′ 2 , 292 ′ 7 , and 292 ′ 8 provide an electrical path to pads 294 ′ 1 , 294 ′ 2 , 294 ′ 7 , and 294 ′ 8 . The remaining contact pads 292 ′ 3 , 292 ′ 4 , 292 ′ 5 , and 292 ′ 6 can be grounded through the PCB 260 . As for contact pads 293 ′ 3 - 293 ′ 6 , these pads contact the distal ends of PICs 256 3 - 256 6 , respectively, and in this case provide an electrical path to pads 294 ′ 3 , 294 ′ 4 , 294 ′ 5 , and 294 ′ 6 .
[0109] With reference to FIGS. 28A-28C , when an ARJ45 style plug 90 is inserted into the jack 244 the nose feature 91 on the front of the plug engages the switching plate 270 mounted to the PCB 260 . As plug 90 is inserted further into the jack 244 , the nose feature 91 applies force against the switching plate 270 , and displaces the plate 270 and the PCB 260 horizontally in a rearward direction.
[0110] As the PCB 260 travels into its rearward position, the PICs 254 1-8 and 256 3-6 , and connector pins 276 1-8 lose contact with contact pads 292 1 - 292 8 , 293 3 - 293 6 , and 294 1 - 294 8 , and instead come into contact with contact pads 292 ′ 1 - 292 ′ 8 , 293 ′ 3 - 293 ′ 6 , and 294 ′ 1 - 294 ′ 8 , respectively. Once the ARJ45 jack is fully inserted into the jack 244 , contact pads 292 ′ 1 - 292 ′ 8 , 293 ′ 3 - 293 ′ 6 , and 294 ′ 1 - 294 ′ 8 on the PCB 260 should align with the distal ends of the PICs and the distal ends of the connector pins. Stops 252 c prevent the PCB 260 from traveling beyond its intended position. At this point, plug contacts of the ARJ45 plug engage the PICs 254 1 , 254 2 , 256 3 , 256 4 , 256 5 , 256 6 , 254 7 , and 254 8 in the jack 244 and thereby establish continuity between the plug 90 and the equipment to which the connector pins 276 are mounted to.
[0111] To reduce unintentional coupling and achieve improved return loss, insertion loss, and electrical balance performance at higher frequencies, contact pads 292 ′ 3 , 292 ′ 4 , 292 ′ 5 , and 292 ′ 6 , and thus PICs 254 3 , 254 4 , 254 5 , and 254 6 , are preferably grounded via the PCB 260 .
[0112] By switching to a second circuit, the compensation circuitry that is used in the RJ45 operation mode is disconnected from the signal path under ARJ45 operation. Likewise, the magnetics components which can make up a part of the first circuit are also disconnected from the signal path. As such, separate independent circuitry may be employed on the second circuit if so desired. By having separate circuits, the compensation circuitry required during the RJ45 mode of operation and any accompanying magnetics have little to no impact on jack's 244 electrical performance while operating in the ARJ45 mode. This isolation may be advantageous when meeting the high bandwidth performance targets of jack 244 . It may also be advantageous in providing the user with an ability to utilize the same jack across a wide range of operating frequencies while utilizing two separate circuits where each circuit can be optimized for a targeted frequency range of operation.
[0113] In addition to the elements described above, the second circuit may include a bias-tee component that can be utilized in the ARJ45 mode of operation to insert a DC biasing signals into the data signals. Furthermore, other components may be added to and/or included on the second circuit as deemed necessary by design requirements. For example, the second circuit may include isolation (DC blocking) components and upper band common-mode rejection components/magnetics. These elements would remain separate from the elements implemented on the first circuit.
[0114] FIGS. 29 and 30 illustrate exemplary schematic representations of two embodiments of the present invention. Both figures show the separation of circuits between the RJ45 and the ARJ45 modes of operation. In FIG. 29 , the first circuit provides a path from the plug to the PHY via the CAT6a compensation circuitry and the one or more magnetic module, with an optional DC biasing component connected to the magnetic module. On the other hand, the second circuit provides a path from the plug to the PHY that bypasses all of the first circuit's components. In this embodiment, the second circuit includes a DC isolation component and a bias-tee component with an input for DC biasing. Similarly, in FIG. 30 both of the circuits comprise separate components and establish primarily separate data paths from the plug to the PHY. In the embodiment of FIG. 30 , the first circuit includes a CAT6a compensation component and at least one magnetic module with a Power over Ethernet (POE) and a DC biasing input, and the second circuit includes a DC isolation component with two bias-tee components with one bias-tee receiving a POE input and the other bias-tee receiving a DC biasing input. Note that separating the circuits does not exclude the sharing of some components such as some of the PICs and the connector pins which may remain operational for both modes of operation.
[0115] In both modes of operation of jack 244 , return loss, insertion loss, electrical balance, and/or other electrical performance characteristic may be further improved by providing grounded connector pins 276 C1-C4 . To achieve this improvement, each of the grounded connector pins can be placed within certain proximity to each pair of the potentially data-carrying connector pins 276 A . Connector pins 276 C1-C4 remain in contact with contact pads G 1-4 regardless of the mode of operation and stay grounded via those contact pads and/or by way of connecting to a ground on the equipment to which the jack 244 is mounded to. Note that the dimensions of the grounded connector pins may vary in any number of ways. For example, the width of the grounded connector pins may be narrower than, equal to, or wide than any of the pairs of the potentially data-carrying connector pins which are positioned adjacent to any one of the grounded connector pins. Similarly, the dimensions of the grounded contact pads G 1-4 can be varied so as to accommodate the size of the grounded contact pins.
[0116] Preferably, PICs 254 and 256 , and connector pins 276 are designed to be or resilient nature, causing the distal ends thereof to springingly press against the contact pads on the PCB 260 . To help ensure a smooth transition between the contact pads, the distal ends of the PICs 254 and 256 , and connector pins 276 are provided with curved feet 300 (see FIG. 27C ) which may act as ramps. This design may help ensure a constant force on the contact pads and it may also help ensure that in the process of sliding on and off the contact pads of the PCB 260 , contaminants or oxidation that may be present on the surface of the PCB 260 contact pads will be wiped away; thereby, providing a robust connection between the PICs and the contact pins.
[0117] Another embodiment of the present invention is illustrated in FIGS. 31A and 31B where a PCB 261 together with a corresponding arrangement of the PICs, including two additional contacts 259 , is shown. While the entire jack 244 is not illustrated, one of ordinary skill in the art will understand that PCB 261 can substitute for the PCB 260 in the jack 244 and the additional contacts 259 may be implemented in a manner that is similar to the PICs 254 of the previously described embodiment.
[0118] The PCB 261 retains some features of the PCB 260 , including all the contact pads of the previous embodiment and any potential interconnecting circuitry. Furthermore, the PCB 261 may be implemented with the same or similar magnetics components/configurations as described in the previous embodiments. However, PCB 261 includes additional contact pads 295 0 , 295 9 , 295 ′ 0 , and 295 ′ 9 which are designed to contact the two additional contacts 259 0 and 259 9 .
[0119] When operating PCB 260 in ARJ45 mode, PICs 254 1 and 254 2 are mated with their corresponding plug contacts of the ARJ45 plug and PIC 254 3 is connected to ground. With the position of PIC 254 3 being adjacent to PIC 254 2 , an impedance discontinuity may occur. Even and odd mode impedance of PIC 254 1 will be inherently higher than PIC 254 2 . This impedance discontinuity can results in an increase in electrical reflections at the plug/jack interface and an increase in mode conversion. The differential return loss, insertion loss, and crosstalk performance of signal-pair 1:2 may be degraded due to this inherent condition of the jack. Thus, to avoid these performance degradations, even and odd mode impedances of PICs 254 1 and 254 2 should be equal and matched to the characteristic impedance of the cable. By introducing contact 259 0 , which is grounded in the ARJ45 mode of operation, adjacent to PIC 254 1 in the PCB 261 the impedances discontinuity may be reduced or otherwise eliminated. This can help provide a balanced configuration of ground conductors and signal conductors (Ground-Signal-Signal-Ground), which can become increasingly advantageous relative to signal integrity as the bandwidth increases.
[0120] A similar concern exists with PICs 254 7 and 254 8 in the ARJ45 mode of operation. PICs 254 7 and 254 8 are mated with their corresponding plug contacts of the ARJ45 plug and PIC 254 6 is grounded. With PIC 254 6 being adjacent to PIC 254 7 , even and odd mode impedance of PIC 254 8 will be inherently higher than PIC 254 7 . By adding an additional grounded contact 259 9 adjacent to PIC 254 8 , a more balanced (Ground-Signal-Signal-Ground) configuration is created and performance degradations may be reduced or otherwise minimized.
[0121] To achieve the necessary grounding, the side contacts 259 0 and 259 9 are grounded through PCB contact pads 295 ′ 0 and 295 ′ 9 (which themselves are grounded through the PCB), respectively, which are engaged by the by the contacts 259 0 and 259 9 when the jack 244 is operating in the ARJ45 operating mode. Furthermore, the side contacts 259 0 and 259 9 are slightly offset relative to PICs 254 1-8 to allow the plug body to be fully inserted without interfering with or plastically deforming contacts 259 0 and 259 9 . The plug body can also be beneficially modified to shield the side contacts 259 0 and 259 9 .
[0122] Another possible use of contacts 259 0 and 259 9 is to incorporate them into the crosstalk compensation circuitry that is likely to be implemented when jack 244 is operating in the RJ45 mode. By grounding contacts 259 0 and 259 9 via contacts pads 295 0 and 295 9 (which are grounded via the PCB 261 ), those contacts may provide an additional way of reducing or minimizing the imbalance effect caused by the split pair 3:6 coupling to the signal pair 1:2 and the signal pair 7:8. Thus, balancing on the 1:2 and 7:8 signal pairs may be improved. Furthermore, since 295 0 , 295 9 , 295 ′ 0 , and 295 ′ 9 are grounded, pads 295 0 and 295 ′ 0 may be combined into a single contact pad which will be in contact with the contact 259 0 regardless of the mode of operation, and pads 295 9 and 295 ′ 9 may also be combined into a single contact pad which will also be in contact with the contact 259 9 regardless of the mode of operation.
[0123] In another embodiment, the PCB which may be used in the jack 244 may have staggered connector pins. This arrangement may be useful when two jacks are positioned on an equipment circuit board opposite of each other as shown in FIG. 32 . In this configuration, if the equipment circuit board if relatively thin, the contact pin arrangement shown in FIGS. 27B and 28B may cause a conflict between the top jack and the bottom jack. To avoid such interference, the contact pins (and accordingly the contact pads on the bottom side of the PCB) can be laid out in a staggered fashion, such that when two opposing jacks are mounted to the same circuit board over the same footprint, their contact pins do not interfere with each other. One embodiment of such a configuration is shown in FIG. 33 , which shows the bottom view of a PCB 360 . Separation between the connector pins could be increased or decreased depending on performance, space, or other requirements. The layout of the contact pads on the PCB 360 and the corresponding contact pin arrangement may be implemented in conjunction with any other embodiments described herein.
[0124] As noted previously, it is also possible to add POE functionality in certain embodiments of the present invention. When doing so, it may be necessary to provide a POE input/output to the various components of the jack. One example of achieving this is shown in FIG. 34 . This figure shows an embodiment of a PCB 361 and a corresponding connector pin arrangement for use in the jack. Compared to the previous embodiments, PCB 361 includes four additional contact pads 298 which remain in contact with four connector pins 276 D regardless of the mode of operation. The additional connector pins 276 D and corresponding contact pads 298 can be used as a means to transmit/receive POE signals between the various components of the jack and the equipment on which it is mounted on.
[0125] Another exemplary embodiment of the present invention is illustrated in FIG. 35 , which shows a copper structured cabling communication system 440 . System 440 includes a duplex jack 444 mounted on an equipment/NIC card PCB 446 . The jack 444 includes two plug receiving apertures 445 , where the jack 444 can be mated to two plugs simultaneously. In the currently descried embodiment, the jack 444 can be mated with plugs having different form factors. FIG. 35 shows the jack 444 mated with an RJ45 plug 46 and an ARJ45 plug 90 . Note that either of the apertures 445 can accept either plug style. Thus, while the ARJ45 plug 90 is illustrated as being mated with the top aperture, the same aperture can accept an RJ45 plug. Likewise, the bottom aperture can accept an ARJ45 plug. The represented communication system 440 is a typical application for this type of connector when used in a structured cabling environment such as a data center. When plugs 46 , 90 are mated with the jack 444 , bidirectional communication can take place between communication cables 50 and the equipment PCB 446 .
[0126] While the present embodiment is shown as used in the communication system 440 of FIG. 35 , it can also be used in any suitable type of equipment, including passive equipment or active equipment. Examples of passive equipment include, but are not limited to, modular patch panels, angled patch panels, wall jacks, etc. Examples of active equipment include, but are not limited to, Ethernet switches, routers, servers, physical layer management systems, and Power-Over-Ethernet equipment as can be found in data centers/telecommunications rooms; security devices (cameras and other sensors, etc.) and door access equipment; and telephones, computers, fax machines, printers and other peripherals as can be found in workstation areas. Communication systems according to the present invention can further include cabinets, racks, cable management and overhead routing systems, and other such equipment.
[0127] FIG. 36 shows an exploded view of the system 440 including the jack 444 and the equipment PCB 446 . The jack 444 includes a front housing 450 and a rear housing 451 . The housings 450 and/or 451 can be made from any conductive or semi-conductive material, including metal. Alternatively, the housing is made from plastic. The front housing 450 includes a first aperture 445 1 and a second aperture 445 2 . Each aperture 445 1 and 445 2 can include conductive plug tabs to establish an electrical connection between the plug housing of a mated plug and the jack 444 . Furthermore, each aperture 445 1 and 445 2 includes an associated set internal components. In particular, the first aperture 445 1 is associated with a first set of lower PICs 452 , a first set of upper PICs 453 , a first set of support structures 454 , a first jack PCB 455 , and a first set of connector pins 456 . The second aperture 445 2 is associated with a second set of lower PICs 457 , a second set of upper PICs 458 , a second set of support structures 459 , a second jack PCB 460 , and a second set of connector pins 461 . Each of the PCBs 455 and/or 460 can include magnetics components 462 mounted thereon. Those having ordinary skill in the art will be familiar with the use and implementation of such magnetics components. The jack 444 further includes a connector pin assembly 463 and a rear cover 488 .
[0128] FIG. 37 illustrates the internal components of the jack 444 in greater detail. As noted previously, the jack 444 can be mated either with an RJ45 or an ARJ45 plug. This multi-plug compatibility is achieved by way of having switchable PCBs 455 and 460 .
[0129] The switching mechanism for the first PCB 455 includes a switching plate 470 , a first vertical divider 471 , a second vertical divider 472 , and a spring 473 . The spring 473 is positioned between an internal housing wall (not shown) and a part of the first vertical divider 471 such that the PCB 455 is biased in a forward position unless an ARJ45 plug is inserted into the aperture 445 1 . The switching mechanism for the second PCB 460 includes a switching plate 474 , a first vertical divider 475 , a second vertical divider 476 , and a spring 477 . The spring 477 is positioned between an internal housing wall (not shown) and a part of the first vertical divider 475 such that the PCB 460 is biased in a forward position unless an ARJ45 plug is inserted into the aperture 445 2 . The vertical dividers 471 , 472 , 476 , 477 are positioned within appropriate guide paths, such as guide path 500 provided within the connector pin assembly 463 and other potential guide paths within the jack housing(s) (not shown). As a result, the vertical dividers help guide the PCBs 455 , 460 between their possible positions and may provide electromagnetic shielding between internal jack components. This can help reduce crosstalk between respective signal pairs, and improve the jack's performance and/or its tenability.
[0130] As noted, the PCBs 455 , 460 remain in their forward-biased position when the jack is not mated to any plugs. The switching plates 470 , 474 are positioned sufficiently far back within the jack 444 such that when an RJ45 plug is mated therewith, the plug does not interfere with the switching plates 470 , 474 , and the PCBs 455 , 460 remain in their forward-biased position. This results in the distal ends of the lower PICs 452 , 457 and upper PICs 453 , 458 interfacing with a first set of contact pads on the PCBs 455 , 460 . However, when an ARJ45 plug is mated with the jack, the longer nose of the ARJ45 plug pushes on the switching plates 470 , 474 towards the rear of the jack, causing the PCBs 455 , 460 to also move into their second, rearward position, respectively. When then PCBs 455 , 460 switch into the second position, the distal ends of the lower PICs 452 , 457 and upper PICs 453 , 458 lose contact with the first set of contact pads and come into contact with a second set of contact pads on the PCBs 455 , 460 . In addition to switching between the first and second sets of contact pads which interface the PICs, moving the PCBs 455 , 460 between the available positions causes the connector pins to also interface two separate sets of contact pads.
[0131] Implementing switchable PCBs as described above can allow for separation of circuits for respective plugs. For example, when an RJ45 plug is mated with aperture 445 1 , a first circuit on the PCB 455 may be used to transmit electrical signals between the PICs and the connector pins. This first circuit may include any desired circuitry, including, but not limited to, compensation circuitry typically found in RJ45 jacks (e.g., CAT6a jacks) and/or magnetics modules (e.g., transformers, inductors, or the like). However, when an ARJ45 plug is mated with aperture 445 1 , the PCB's 455 movement causes a second circuit (that is different from the first circuit) to be positioned between the PICs and the connector pins. This second circuit could also have any desired circuitry components thereon, where such components can be utilized by the telecommunication taking place over the ARJ45 plug. The components on the second circuit can include, but are not limited to, compensation circuitry, magnetics components, current isolation components, and/or current biasing components. Note that the two primary circuits which handle RJ45 and ARJ45 communication can be separate and independent of each other. The same examples are equally applicable to aperture 445 2 and the corresponding internal components.
[0132] Due to the vertical stacking of the apertures 445 and the respective internal components, there is a need to stagger the connector pins of each respective PCB so that said connector pins can interface to the equipment PCB 446 . This can be achieved by implementing different PCB layouts. One example of the first PCB 455 is shown in FIGS. 38A (first side) and 38 B (second side). The first side of the PCB 455 includes a first set of PIC contact pads 492 1-8 , 493 3-6 and a second set of PIC contacts pads 492 ′ 1-8 , 493 ′ 3-6 . The second side of the PCB 455 includes a first set of connector pin contact pads 494 1-8 and a second set of connector pin contact pads 494 ′ 1-8 . As noted previously, the PCB 455 includes two separate circuits. The first circuit includes the PIC contact pads 492 1-8 and the connector pin contact pads 494 1-8 , which are linked together, respectively, via first circuit elements (e.g., traces on the PCB 455 ). The second circuit includes PIC contact pads 492 ′ 1-2 , 493 ′ 3-6 , and 492 ′ 7-8 , and the connector pin contact pads 494 ′ 1-8 , which are linked together, respectively, via the second circuit elements (e.g., traces on the PCB 455 ). In addition, grounding pads G 455 1-4 are also provided on the second side of the PCB 455 .
[0133] When an RJ45 plug is mated with aperture 445 1 , the distal ends of the PICs contact the first set of PIC contact pads 492 1-8 , 493 3-6 and the distal ends of the potentially data-carrying connector pins 456 DATA contact the first set of connector pin contact pads 494 1-8 . While the upper PICs 453 are grounded via the contact pads 493 3-6 , the lower PICs 452 act as conduits for signals traveling between the plug contacts and the contact pads 492 1-8 . Since the contact pads 492 1-8 are connected to the first circuit, which is in turn connected to the connector pin contact pads 494 1-8 , signals can travel between the plug 46 and equipment PCB 446 via the connector pins 456 DATA and the first circuit on the PCB 455 . Grounding the unused upper PICs 453 in the RJ45 mode of operation may help improve the electrical performance of the jack.
[0134] When an ARJ45 plug is mated with aperture 445 1 , the distal ends of the PICs contact the second set of PIC contact pads 492 ′ 1-8 , 493 ′ 3-6 and the distal ends of the potentially data-carrying connector pins 456 DATA contact the second set of connector pin contact pads 494 ′ 1-8 . In this mode of operation, the PICs which interface with contact pads 492 ′ 1-2 , 493 ′ 3-6 , and 492 ′ 7-8 act as conduits for signals traveling between the plug contacts and the PCB 455 . Since the contact pads 492 ′ 1-2 , 493 ′ 3-6 , and 492 ′ 7-8 are connected to the second circuit, which is in turn connected to the connector pin contact pads 494 ′ 1-8 , signals can travel between the plug 90 and equipment PCB 446 via the connector pins 456 DATA and the second circuit on the PCB 455 . To improve the jack's performance, the unused PICs can be grounding via PIC contact pads 492 ′ 3-6 .
[0135] To further improve the jack's electrical performance (e.g., return loss, insertion loss, electrical balance, and/or other electrical performance characteristics), connector pins 456 G can be positioned within certain proximity to the potentially data-carrying connector pins 456 DATA , and grounded via contact pads G 455 1-4 . Connector pins 456 G remain in contact with contact pads G 455 1-4 regardless of the mode of operation.
[0136] While the first PCB 455 includes contact pads on both sides thereof, the second PCB 460 has contact pads situated only on a single side. This layout is shown in FIG. 39 . As shown therein, the PCB 460 includes a first set of PIC contact pads 495 1-8 , 496 3-6 , and a second set of PIC contacts pads 495 ′ 1-8 , 496 ′ 3-6 . The PCB 460 further includes a first set of connector pin contact pads 497 1-8 and a second set of connector pin contact pads 497 ′ 1-8 . Like PCB 455 , PCB 460 includes two separate circuits.
[0137] The first circuit includes the PIC contact pads 495 1-8 and the connector pin contact pads 497 1-8 , which are linked together, respectively, via first circuit elements (e.g., traces on the PCB 460 ). The second circuit includes PIC contact pads 495 ′ 1-2 , 496 ′ 3-6 , and 495 ′ 7-8 , and the connector pin contact pads 497 ′ 1-8 , which are linked together, respectively, via the second circuit elements (e.g., traces on the PCB 460 ). In addition, the PCB 460 includes grounding pads G 460 1-4 .
[0138] When an RJ45 plug is mated with aperture 445 2 , the distal ends of the PICs contact the first set of PIC contact pads 495 1-8 , 496 3-6 and the distal ends of the potentially data-carrying connector pins 461 DATA contact the first set of connector pin contact pads 497 1-8 . While the upper PICs 458 are grounded via the contact pads 496 3-6 , the lower PICs 457 act as conduits for signals traveling between the plug contacts and the contact pads 495 1-8 . Since the contact pads 495 1-8 are connected to the first circuit, which is in turn connected to the connector pin contact pads 497 1-8 , signals can travel between the plug 46 and equipment PCB 446 via the connector pins 461 DATA and the first circuit on the PCB 460 . Grounding the unused upper PICs 458 in the RJ45 mode of operation may help improve the electrical performance of the jack.
[0139] When an ARJ45 plug is mated with aperture 445 2 , the distal ends of the PICs contact the second set of PIC contact pads 495 ′ 1-8 , 496 ′ 3-6 and the distal ends of the potentially data-carrying connector pins 461 DATA contact the second set of connector pin contact pads 497 ′ 1-8 . In this mode of operation, the PICs which interface with contact pads 495 ′ 1-2 , 496 ′ 3-6 , and 495 ′ 7-8 act as conduits for signals traveling between the plug contacts and the PCB 460 . Since the contact pads 495 ′ 1-2 , 496 ′ 3-6 , and 495 ′ 7-8 are connected to the second circuit, which is in turn connected to the connector pin contact pads 497 1-8 , signals can travel between the plug 90 and equipment PCB 446 via the connector pins 461 DATA and the second circuit on the PCB 460 . To improve the jack's performance, the unused PICs can be grounding via PIC contact pads 495 ′ 3-6 .
[0140] To further improve the jack's electrical performance (e.g., return loss, insertion loss, electrical balance, and/or other electrical performance characteristics), connector pins 461 G can be positioned within certain proximity to the potentially data-carrying connector pins 461 DATA , and grounded via contact pads G 460 1-4 . Connector pins 461 G remain in contact with contact pads G 460 1-4 regardless of the mode of operation.
[0141] Note that in alternate embodiments the positioning of the PIC contact pads along with the respective PICs may vary. In other words, while the PIC contact pads on the PCB 455 are positioned on one side thereof, in alternate embodiments those PIC contact pads may be positioned on the opposite side. Consequently, the PICs will have to be adjusted to ensure appropriate mating. The positioning of the PIC contact pads on the PCB 460 may also be altered in a similar manner.
[0142] Additionally, PCB 455 and/or 460 can include optional mode indicator contact pads which can interface mode indicator connector pins. These contact pads may be configured to contact the mode indicator connector pins in a particular mode of operation, thereby signaling to the equipment that the jack (or a part thereof) is operating in a particular mode. For example, if the mode indicator contact pads come in contact with the mode indicator connector pins in the RJ45 operating mode but not in the ARJ45 operating mode, this electrical connection can be used as a mode-of-operation signal.
[0143] In additional embodiments, the jack can include additional lower PICs which can be grounded to help improve the jack's electrical performance even further. For example, lower PICs 452 may include one additional PIC on each side of said set of PICs where the additional PICs interface with additional grounded contact pads on the PCB 455 regardless of operation. This can help provide a balanced configuration of ground conductors and signal conductors (Ground-Signal-Signal-Ground) in an ARJ45 operating mode, and this balanced transmission line configuration may become increasingly advantageous relative to signal integrity as the bandwidth increases. The same configuration may be implemented on the lower PICs 457 and the second PCB 460 .
[0144] Furthermore, PICs 452 , 453 , 457 , 458 and connector pins 456 , 461 are preferably designed to be or resilient nature, causing the distal ends thereof to springingly press against the contact pads on the PCBs 455 , 460 . To help ensure a smooth transition between the contact pads, the distal ends of the PICs 452 , 453 , 457 , 458 and connector pins 456 , 461 are provided with curved feet which may act as ramps. This design may help ensure a constant force on the contact pads and it may also help ensure that in the process of sliding on and off the contact pads, contaminants or oxidation that may be present on the surface of the contact pads will be wiped away; thereby, providing a robust connection between the PICs and the connector pins.
[0145] In order to stager the connector pins 456 and 461 so that they do not interfere with each other, the first PCB 455 is longer than the second PCB 460 . This configuration allows the connector pin contact pads 494 of the PCB 455 to be positioned further back within the jack 444 relative to the connector pin contact pads 497 of the PCB 460 . This provides the space necessary to position the respective connector pins for both PCBs. The relative placement of the connector pin contact pads and the connect pins is shown in FIGS. 40 and 41 .
[0146] To help reduce the potential crosstalk between connector pins 456 or between the connector pins 456 and connector pins 461 , said connector pins are mounted within the connector pin assembly 463 . The connector pin assembly 463 may provide an electromagnetic shield between the connector pins and may also act as a physical support for said pins. This can be especially helpful in case of the connector pins 456 which are longer than connector pins 461 , and therefore more susceptible to deformation.
[0147] Note that while this invention has been described in terms of several embodiments, these embodiments are non-limiting (regardless of whether they have been labeled as exemplary or not), and there are alterations, permutations, and equivalents, which fall within the scope of this invention. Additionally, the described embodiments should not be interpreted as mutually exclusive, and should instead be understood as potentially combinable if such combinations are permissive. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that claims that may follow be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. | Embodiments of the present invention are generally related to communication connectors, and more specifically, to communication connectors such as jacks which are compatible with more than one style of a plug. In one embodiment, the electrical and mechanical design of a jack in accordance with the present invention may extend the usable bandwidth beyond the IEC 60603-7-71 requirement of 1000 MHz to support potential future applications such as, but not limited to, 40GBASE-T. In addition, the jack may be backwards compatible with lower speed BASE-T applications (e.g., 10GBASE-T and/or below) when an RJ45 plug is mated to the jack. | 7 |
BACKGROUND OF THE INVENTION
This invention relates generally to earth borehole apparatus and specifically to apparatus for centralizing well logging and/or completion equipment in the borehole.
Borehole centralizers are often used as a part of a string of well logging instruments traversed in a borehole by means of a cable. These centralizers have a plurality of contact members which are urged against the borehole walls, causing the centralizer body and the associated well logging instrumentation to be centered in the borehole.
Difficulty may occur when these centralizers are used with other borehole contact instruments, such as a caliper. A caliper is a device having a plurality of contact arms which contact the borehole sidewalls and by various means relate signals indicative of the size of the borehole. It is to be understood that when a multi-armed instrument such as a centralizer or caliper traverses an uncased borehole, grooves or tracks in the borehole sidewalls will typically result. When the arms of an instrument such as a caliper are located directly below the arms of a centralizer, the arms of the caliper will track the grooves made by the arms of the centralizer and therefore measure the indention or track in the borehole made by the centralizer arm rather than yielding a true reading of the borehole diameter. Therefore, it is desirable to be able to index or offset the centralizer arms from those of a caliper or similar instrument.
However, where tracking errors are not a problem, for example, as with instruments which do not contact the borehole, it is desirable for the centralizer arms to be able to freely rotate around the centralizer body and hence around the instrument string. This rotation is desirable because (a) it is desirable to allow any natural twist in the support cable to be released and (b) to prevent placing additional twist in the support cable due to the tendency of the centralizer arms to track spirally in the borehole. While it is possible to have a different centralizer for each purpose, it is desirable for reasons of both cost and efficiency to have one centralizer with contact arms capable either of free rotation or of being fixedly offset with relation to whatever other multi-armed instrument is being used.
Prior art in the well logging field has typically relied upon devices such as set screws or compressible collars on the contact arm carriers to secure an offset of arm indexing. These devices depend upon friction to maintin a position and do not provide a positive mechanical lock for the arm position. Therefore, changes in temperature, forces exerted upon the arms while traversing the well, or other borehole conditions could cause the arms to rotate away from their indexed position. Additionally, since the adjusting mechanisms are exposed to the borehole environment, they are subject to corrosion and fouling, thus tending further to decrease their effectiveness.
Accordingly, the present invention overcomes the deficiencies of the prior art by providing a simple mechanical means for providing a positive mechanical lock on the rotation of the contact arms of a borehole centralizer or similar device while also allowing free rotation of such arms when desired.
SUMMARY OF THE INVENTION
A centralizer for use in an earth borehole having an elongated shaft supporting a plurality of contact arms which are forced against the borehole sidewalls and may be either locked in a fixed position or left free to rotate around such shaft. The contact arms are pivotally mounted between two slidable and rotatable members. These members are acted upon by coil springs serving to draw them together, thereby forcing the contact arms out and against the sides of the borehole. The force exerted upon the contact arms is adjustable by a means for varying the state of expansion of the coil springs.
The contact arms may be either left free to rotate or be securely locked in position and restricted to non-rotational movement. These arms are carried between two contact arm carriers, each arm carrier having a radially serrated surface. An indexing member having a complimentarily serrated surface is mated with each arm carrier and placed so projections on the indexing members mate with recesses in the support shaft. When this combination is secured in place the arms are held in intransigent rotational relation.
Accordingly, it is a feature of the present invention to provide a new and improved centralizer for use in earth boreholes.
It is still another feature of the invention to provide a new and improved borehole coentralizer with contact arms which may be indexed throughout a range of positions and positively locked in any of such positions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the borehole centralizer apparatus of this invention joined to a caliper apparatus suspended in an earth borehole, shown in cross-section.
FIGS. 2a-b when joined together at common lines a--a illustrate a cross-sectional view of the centralizer apparatus of this invention.
FIG. 3 is a more detailed view of the components of the indexing means of this invention.
FIGS. 4a-b are a detailed view of the contact arm carrier and the indexing member of the centralizer apparatus of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is illustrated a borehole centralizer 1 affixed to a borehole caliper 2 in a common logging configuration, disposed within an earth borehole 6, shown in cross-section, suspended by a cable 3. The cable 3 would normally be connected to a hoisting unit (not illustrated) at the surface, in a manner well known and conventional in the art.
The borehole centralizer 1 has an elongated shaft 4 with cablehead fittings 5a, 5b threadably connected at each end so as to allow the centralizer to be connected between the cable 3 and a logging instrument 2 as illustrated, or in combination, above or below other logging instruments.
Referring now to FIG. 2, there is shown the borehole centralizer 1 in cross-section. The centralizer is constructed upon a shaft 4 which has a longitudinal aperture 20 therethrough, containing one or more electrical cables 7 or other means for passing electrical signals between the cableheads 5a and 5b at each end of shaft 4.
Disposed towards each end of shaft 4 are contact arm carriers 10a and 10b. Each arm carrier 10a and 10b has a threaded extension 21a and 21b, the threads on such extensions having a full radius equal to that of a cross-section of identical coil springs 8a and 8b. The arm carriers 10a and 10b are slidably and rotatably mounted on shaft 4 with the threaded extensions 21a and 21b facing the center of shaft 4. Located centrally on shaft 4 are two adjusting retainers 12a and 12b. Each adjusting retainer 12a and 12b has a first end threaded in the manner described above to mate with coil springs 8a and 8b. Disposed toward the second end of each adjusting retainer 12a and 12b is an extension having conventional threads. These adjusting retainers 12a and 12b are rotatably and slidably mounted on shaft 4 with the conventionally threaded extensions facing centrally where they are threadably coupled with complimentarily threaded adjusting collar 9. Threadably mated to each pair of arm carriers 10a and 10b and spring retainers 12a and 12b is coil spring 8a or 8b. Coil springs 8a and 8b are threadably mounted in a state of extension causing them to simultaneously exert a force drawing arm carriers 10a and 10b toward the center of shaft 4. Such movement of arm carriers 10 and 10b is limited by stop collars 11a and 11b secured to shaft 4 by bolts 24a, 24b, 24c, and 24d. (Shown in greater detail in FIG. 3.)
A plurality of identical contact arms 14a, 14b are distributed around the radius of shaft 4 and are pivotally connected between arm carriers 10a and 10b by means of pivot pins 13a, 13b, 13c and 13d. While these contact arms may take many forms the preferred embodiment utilizes arms each consisting essentially of a bow spring 15a or 15b interconnected between two rigid arms 16a and 16b or 16c and 16d.
As the centralizer is used in a borehole the force exerted by coil springs 8a and 8b draws arm carriers 10a and 10b toward the center of shaft 4, forcing contact arms 14a and 14b diagonally away from shaft 4 so that bow springs 15a and 15b contact the sides of the borehole. The equal force exerted on the identical contact arms 14a and 14b causes them to apply equal force against the borehole walls, thereby maintaining shaft 4 centralized in the hole. The pressure exerted on the walls of the borehole may be changed to adjust for variances in hole size or sidewall consistency by means of adjusting collar 9. As adjusting collar 9 is rotated clockwise it acts upon adjusting retainers 12a and 12b, drawing them centrally, away from the arm carriers 10a and 10b, increasing the expansion of coil springs 8a and 8b, and thereby increasing the force exerted on contact arms 14a and 14b. A reduction of contact arm pressure is accomplished in the reverse manner from above, by rotating adjusting collar 9 counter-clockwise.
As discussed earlier with respect to the prior art, it is often desirable to secure the contact arms 14a and 14b in a fixed rotative position relative to the shaft and therefore, in turn, to the remainder of the string of logging/completion instruments. The present invention accomplishes this by a positive-locking indexing means.
Referring now to FIG. 3, there is shown the indexing apparatus of this borehole centralizer in greater detail. Because the indexing apparatus at each end of the centralizer is identical, only one need be described in detail for illustrative purposes. Arm carrier 10b is slidably and rotatably mounted on shaft 4. Shaft 4 has a longitudinal notch or recess 19b throughout the possible range of transitional movement of arm carrier 10b. Arm carrier 10b has a radially serrated inner surface 23 around the periphery of shaft passage 22 (shown in more detail in FIG. 4a). An indexing member 18b is used to hold shaft 4 and arm carrier 10b in intransigent rotational relation. In the preferred embodiment, this indexing member 18b is a half-ring collar with a radially serrated surface complimentary to the serrated surface of arm carrier 10b, and also having a tab or projection on its inner radius, (shown in more detail in FIG. 4b) such tab or projection being matable with the notch or recess 19b in shaft 4.
To prevent rotation of arm carrier 10b about shaft 4, indexing member 18b is placed such that its projection mates with the recess 19b in shaft 4 and its serrations are enmeshed with those of arm carrier 10b. Indexing member 18b is secured in position with locking cap 17b, which is threadably joined to arm carrier 10b, restricting arm carrier 10b and thereby the contact arms 14a and 14b to non-rotational movement. Although indexing means at one end only of the shaft will suffice to prevent rotation of the contact arms 14a and 14b, the preferred embodiment utilizes such means at each end of shaft 4 to minimize stress between the indexing member projection and shaft recess 19b, and to prevent excessive torquing of the contact arms 14a and 14b as the centralizer traverses the borehole.
Referring now to FIGS. 4a-b, it can be seen that the possible angles of indexing adjustment are dependent upon the angles of the radial serrations of the arm carrier 10b, illustrated in FIG. 4a, and the indexing member 18b, illustrated in FIG. 4b. The angle of indexing will be approximately equal to the crest to crest tooth angle of these serrations.
Referring again to FIG. 2, for applications in which it is desirable to allow the centralizer contact arms 14a and 14b to freely rotate it is necessary only to loosen locking caps 17a, 17b and remove indexing member 18a and 18b, thus leaving the contact arms 14a and 14b free to rotate about shaft 4. Locking caps 17a and 17b are then replaced and the centralizer is ready for use in the borehole.
Thus it should be appreciated that there has been illustrated and described herein the preferred embodiment of the present invention which finds utility in centralizing well logging and/or completion apparatus in a well while allowing the centralizing means to be either indexed and positively in plurality of positions or freely rotatable so as to optimize the operations being conducted. However, those skilled in the art will recognize that obvious modifications can be made without departing from the spirit of the invention. For example, while the illustrated embodiment shows the use of a half-ring locking member, this could be replaced with a full collar and woodruff key assembly. Additionally, although the preferred embodiment utilizes an arm carrier with an inner serrated surface, the serrations could instead be placed around the circumference of the arm carrier. Furthermore, although not illustrated, those skilled in the art will recognize that such instruments may contain three or four contact arms to better maintain centralization of the instrument in the borehole. | An earth borehole instrument having a plurality of contact arms which are forced against the borehole side-walls so as to centralize the instrument in the hole. The contact arms may be either left free to rotate or may be positively locked in a number of non-rotational positions. This locking is done by fixedly engaging an indexing member, which is restricted to movement only in translation as to the instrument shaft, with the contact arms, thereby similarly restricting their movement. | 4 |
BACKGROUND OF THE INVENTION
Protection of the human ear from destructive influences such as loud noise, physical contact, and penetration by foreign substances, such as water and dirt, is an area which has only recently received the attention which it deserves. Because most ear injuries tend to detract from the enjoyment of life rather than cause extensive physical impairment, and because the causes of those ear injuries which normally do cause serious physical impairment were not known, historically little attention has been paid to protecting the ear. In recent years, however, considerable interest in ear protection has developed from a diverse range of sources. This interest has been brought about not only because of medical science's recognition that serious physical impairments can result from inner ear infections which in turn are sometimes caused by penetration of the ear by foreign material, but also due to more subtle influences in society. For example, people are no longer satisfied with the conclusion that disfigurements such as "cauliflower" ear are prices which participants in contact sports must pay, or that total or partial deafness are the price that workers in certain occupations must pay. This latter concept is most graphically expressed in the pioneering noise level standards set out by recent state and federal regulations concerning working conditions.
Because the various deleterious influences are normally not coexistent and because each one of them most commonly exists in a fairly specific environment, the development of protective devices for the various influences have developed more-or-less independently of one another. The first major category of ear protectors are ear plugs, which are small, resilient elements which are inserted directly into the ear canal. Ear plugs are primarily of value to keep foreign material (such as water or dust) out of the ears. If properly designed, they can also provide fairly effective protection against sound. The main advantages of ear plugs are that they are relatively inexpensive, that they are not cumbersome, and that they do not detract seriously from the appearance of the user. However, they can present sanitation problems, can be uncomfortable, and, because of their inconspicuousness, can cause some problems in the enforcement of their use.
The second major division of ear protectors are the yoke-type or earphone-type protectors. This type normally involves a pair of rigid cups each of which contains sound deadening material and is used in such a way as to surround the ear of the user. The cups are held in place by a U-shaped spring. The cups are connected to the ends of the spring and the bight of the spring or yoke passes over the top of the head of the user. The advantage of this system is that the device provides some protection to the outside of the ear, the device is relatively comfortable, and enforcement of use is relatively easy. The problems with this arrangement are that the device is easily displaced from the head and rendered inoperative, is relatively heavy and cumbersome, is relatively expensive, and does detract considerably from the appearance of the user.
The third basic type of ear protector is a helmet either of the soft or the hard variety. The soft helmet is normally made of flexible fabric and encloses the head of the user except for necessary openings. Normally, a resilient ring or pad is provided to surround or enclose the ears of the user. This type of arrangement is exemplified by the helmet used in wrestling or boxing. Although the main purpose in most applications is to protect the exterior of the ear from the type of contact which results in a "cauliflower" ear, enclosing pads also have the effect of attenuating noise and to some extent, excluding foreign material from the ear. Soft helmets are normally light in weight, and tend to stay in place, thus giving continuous protection to the user. On the other hand, they are normally expensive, uncomfortable to use, difficult to put on and take off, and have an ugly appearance. Hard helmets, which have a rigid shell enclosing the head of the user and a resilient inner layer to provide cushioning against the head, provide additional protection against physical contact, but are heavier and more awkward. These and other difficulties experienced with the prior art devices have been obviated in a novel manner by the present invention.
It is, therefore, an outstanding object of the invention to provide an ear protector which gives the ear suitable protection against physical contact, noise, and penetration by foreign matter.
Another object of this invention is the provision of an ear protector which is light in weight and is not cumbersome.
A further object of the present invention is the provision of an ear protector which minimizes its contact with the outside or inside of the ear both to increase comfort and reduce sanitary problems.
It is another object of the instant invention to provide an ear protector which is easy to put on and take off and yet is not easily, accidently displaced.
A still further object of the invention is the provision of an ear protector which minimizes detraction from the physical appearance of the user and yet is sufficiently conspicuous to allow easy enforcement of use.
It is a further object of the invention to provide an ear protector which is simple and inexpensive to manufacture.
It is a still further object of the present invention to provide an ear protector which can be completely emersed in liquid and is capable of being completely sanitized.
Another object of the invention is the provision of an ear protector which is made almost entirely of flexible materials so that the protector can be stored in a small space and under no circumstances can produce sharp rigid projections.
With these and other objects in view, as will be apparent to those skilled in the art, the invention resides in the combination of parts set forth in the specification and covered by the claims appended hereto.
SUMMARY OF THE INVENTION
This invention involves an ear protector for protecting the ears of a user from physical contact, loud noises, and penetration by foreign materials. The ear protector involves a head strap which surrounds the head of the user and two ear protector units, each attached to the strap and adapted to surround the outer portion of an ear. This unit consists of a rigid ring attached to the head strap and on which is mounted a resilient ring. The rings are hermetically sealed into a flexible container. Because the head strap is bifurcated and attached to widely-spaced portions of the rigid ring, the pressure exerted by the head strap on the ring is uniformly distributed around the outside of the ear.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of its structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a perspective view of an ear protector embodying the principles of the present invention as it would appear in use on a human head,
FIG. 2 is an exploded view of the various elements which make up the ear protector shown in FIG. 1,
FIG. 3 is a sectional view through an ear protector unit and a sealing mold embodying the principles of the present invention, and
FIG. 4 is an elevation view showing the surfaces of the ear protector which would be in contact with the head of the user and the position of the head strap with respect to the ear protector units.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, in which are best shown the general features of the present invention, the ear protector, indicated generally by the numeral 10, is shown as having a head strap 11 and an ear protector unit 12. A second unit 13 is located on the other side of the head. In FIG. 1, the ear protector 10 is shown on the head of a user 14 with the ear protector unit 12 enclosing the outer ear of the user. Because the head strap 11 is elastic, the unit 12 is pressed snugly against the head forming a tight seal around the enclosed ear.
FIG. 2 shows an exploded view of the head strap 11 and ear protector unit 12. The ear protector unit 12 includes a relatively rigid ring 15, a resilient 16, a permanent attenuating patch 17, an outer container 18, an inner container 19 and a temporary attenuating patch 21.
The rigid ring 15 is a thin, flat plate cut in an oval shape. The inner peripheral edge 22 has a major axis of 3 inches and a minor axis of 2 inches. The dimension is sufficient to surround the helix of the external portion of the human ear. In the preferred embodiment the rigid disk would be formed of plastic but metal might be substituted.
The head strap is composed of two portions, a rear portion 23 which extends around the back of the head of the user, and a front portion 24 which extends around the front, forehead of the user. In the vicinity of the ear protector units the portions of the head strap are bifurcated into strap ends 25, 26, 27, and 28. The strap ends are attached to the rigid ring so that the ends which are attached to the same portion of the head strap are approximately at diametrically-opposed positions on the ring. The head strap is formed of liquid immersible, elastic fabric of an open weave.
Also attached to the rigid ring is a resilient, plastic foam ring 16. The resilient ring 16 is attached concentrically to the inner (toward the users head) surface of the rigid ring 15.
The inner container 19 acts mainly to enclose the rigid ring 15 and the resilient ring 16. The inner container involves an outwardly (with respect to the user) or upwardly (as shown in FIG. 2) convex dome 29 surrounded by a peripheral upwardly or outwardly concave trough 30. At the extreme upper and outer peripheral edge of the trough is a sealing edge 31 which encircles the trough and dome. The inner container 19 is formed of a soft, thermoplastic material and is vacuum molded into shape so that the thickness of the upper portion of the dome 29 is considerably less than the walls of the trough.
The removable sound attenuating patch 21 is of oval shape corresponding to the shape of the dome 29. The patch 21, however, is slightly larger so that it fits into the dome with a friction fit. The patch 21 is formed of a resilient, foam plastic material.
The outer container 18 has a central dome 32 and a peripheral outwardly-directed rim 33. The outer container is formed of flexible, thermoplastic material similar to that from which the inner container 19 is formed. The outer container also has a peripheral outer sealing edge 34 which corresponds in shape and size to the sealing edge 31 of the inner container.
The permanent attenuating patch 17 is a piece of foam plastic shaped to conform to the surface of the dome 29 and the dome 32. The patch 17 would be permanently positioned between the aforementioned domes.
It should be noted that the permanent patch 17, the flexible ring 16, and the temporary patch 21 are all made of the same material. Likewise, the outer container 18 and the inner container 19 are made of the same material.
A major asset of the present invention is the remarkable ease by which the individual components can be assembled into a final useful product. Initially the ends 25, 26, 27, and 28 of the head strap portions 23 and 24 are attached to the rigid rings 15 of each of the ear protector units 12 and 13. The flexible ring 16 is then attached to the rigid ring 15. Next, the temporary patch 21 is placed inside the dome 29 of the inner container 19. The inner container 19 is then placed in a first sealing mold 38 as shown in FIG. 3. The first sealing mold is provided with a peripheral first sealing surface 35 which lies adjacent the sealing edge 31 of the inner container 19.
Next, the assembly including the rigid ring 15, the resilient ring 16, and the head strap 11 is placed so that the resilient ring 16 is in the trough 30 of the inner container 19. The permanent patch 17 is then placed over the dome 29. The outer container 18 is placed over the permanent patch 17, so that the permanent patch 17 is within the dome 32 and the sealing edge 34 of the outer container 18 is correspondingly engaged to the sealing edge 31 of the inner container 19. A second sealing mold 36 is then placed over the outer container 18. A sealing surface 37 is provided on the sealing mold 36 and this sealing surface is positioned adjacent the sealing edge 34 of the outer container 18. Finally, heat is generated at the sealing surfaces 35 and 37 causing thermoplastic sealing of the sealing edges 31 and 34 together. In the preferred embodiment, the head straps 11 would be formed of an open mesh of elastic material so that the seal formed between the sealing edges 34 and 31 would pass through the head strap 11 to allow a hermetic seal around the entire edge.
The ear protector unit 12 can then be removed from the molds and a similar operation carried out to form the ear protector unit 13. FIG. 4 shows a view of the completed head protector except that the head strap 11 would be continuous, including connection of portion 23.
FIG. 1 shows the preferred embodiment of the present invention in use on the head of a user 14. the head strap 11 is placed around the head with a portion 24 over the forehead and the portion 23 around the back of the head. The unit 12 is so placed that the inner container 19 surrounds and encloses the external ear of the user. Likewise, unit 13 would surround and enclose the other ear of the user.
Because the elastic strap surrounds the head of the user, the ear protector is securely held on the head and is not easily displaced. The tension on the ear protector units 12 and 13 caused by the elastic straps is distributed evenly around the periphery of the rigid ring because of the diametrically-opposed positions of the connections between the head strap 11 and the rigid ring 15 and because the straps pass from the rigid ring at four widely spaced locations. This causes a uniform pressure throughout resilient pad 16 and the inner container 19 on the head of the user, around the ear. Thus, a good seal is formed around the ear against penetration by foreign material (including liquids and gases) without placing any pressure on the ear itself. Because the ear protector is formed almost entirely of soft material (with the exception of the completely enclosed rigid ring), the unit can be compressed to a relatively small size and does not contribute to injury should the user be exposed to physical contact. Because the ear protector is made entirely of light weight materials, the device itself is extremely light in weight and does not inhibit movement of the user. The ear protector is completely submersible in liquid either when used, or when being cleaned. The temporary patch 21 can be replaced should it become unsanitary. Additional sound attenuating material such as patches 21, can be added to increase the total sound attenuation of the ear protector, and the permanent patch 17 can be designed to suit the intended purpose.
It is obvious that minor changes may be made in the form and construction of the invention without departing from the material spirit thereof. It is not, however, desired to confine the invention to the exact form herein shown and described, but it is desired to include all such as properly come within the scope claimed. | An ear protector for excluding foreign material and noxious noise from the ear. The ear protector includes two units attached to a head strap which encircles the head of the user. Each unit includes a rigid ring which encircles the ear of the user and to which the head strap is attached, a resilient ring coaxially mounted on the rigid ring, and a flexible container into which a rigid ring and resilient ring are hermetically sealed. | 0 |
FIELD OF THE INVENTION
This invention relates to a catheter design and a system and a method for removing plaque from blood vessels.
BACKGROUND OF THE INVENTION
Current technology for non-surgical treatment of coronary artery disease largely involves ballon angioplasty. A catheter is threaded through a guiding catheter placed into the entrance of the coronary ostia. The balloon catheter, containing an inner guide, wire is passed through the guiding catheter. The guide wire is advanced under fluoroscopic control just past the lesion. The balloon catheter is then advanced so that the balloon is in the stenotic area and the balloon inflated to a high pressure with a contrast liquid. The plaque is hence compressed and the vessel wall dilated. Although quite successful, there is a re-stenosis rate of about 30% within six months. Laser angiography is under intensive development but has a long way to go before becoming clinically significant treatment method, if it ever does. Mechanical and electrocautery methods are also under development.
SUMMARY OF THE INVENTION
According to this invention, the removal of intra-arterial plaque is accomplished using a multi-lumen catheter to deliver an abrasive slurry to the area of stenosis. The abrasive slurry contains inert abrasive particles suspended in a radiopaque aqueous or non-aqueous liquid. The use of a radiopaque medium would allow the cardiologist to visualize the progression of plaque removal.
The invention is embodied in a system for removing plaque from vessels in a patient, which may be human or animal. The system comprises a catheter which defines an inflow lumen having an input aperture opening externally of the catheter at a first location on the catheter and a withdrawal lumen having a removal aperture opening externally of the catheter at a second location spaced from said first location, slurry input means for forcing a slurry of particles in a liquid into the input lumen and the input aperture, and slurry withdrawal means for removing slurry through the removal aperture and withdrawal lumen. The system may further comprise means for measuring fluid pressure in the vessel and controlling the pumping rate and/or withdrawal rate as a function of the measured pressure.
The catheter may include at least one inflatable balloon which forms at least one inflation lumen and, in one embodiment, includes a distal inflatable balloon and a proximal inflatable balloon and defines inflation lumen for inflating said balloons, the distal balloon being distal of the input aperture, the proximal balloon being proximal of the removal aperture.
The invention is embodied in the catheter as described and in a method of removing plaque from vessels. In this method, at least a portion of a vessel which is partially occluded by plaque is fully or partially isolated from the remainder of the vessel. A slurry is then forced to flow in contact with the plaque in the vessel to abrade the plaque. All or part of the slurry is withdrawn from the vessel. The slurry may be formed of a radiopaque liquid and abrasive particles or of liquid and particles which are insoluble in such liquid but soluble in blood serum. Water, ethyl alcohol or other liquids which are physiologically acceptable may be used in connection with conventional abrasives such as aluminum oxide or silicon carbide or with particles of a solid which are insoluble or only slightly soluble in the liquid. The particles may, of course, be insoluble in the liquid by reason of the saturation of the liquid with the material of which the particles are formed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a partial longitudinal cross-sectional view of a blood vessel with one embodiment of the catheter of this invention adjacent an area of stenosis in position to remove plaque from the vessel.
FIG. 2 is a lateral cross-sectional view of the catheter of FIG. 1 taken along lines 2--2 of FIG. 1.
FIG. 3 is a partial longitudinal, partial cross-sectional view of a blood vessel with another embodiment of the catheter of this invention encompassing an area of stenosis in position to remove plaque from the vessel.
FIG. 4 is a lateral cross-sectional view of the catheter of FIG. 3 taken along lines 4--4 of FIG. 3.
FIG. 5 is lateral cross-sectional view of the catheter of FIG. 3 taken along lines 5--5 of FIG. 3.
FIG. 6 is a schematic drawing of a pumping system which may be used as a part of the overall system of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The catheters shown in the figures and described below are intended only to describe the function of the catheters and the basic functional structure needed to carry out the desired function. The specific arrangement of conduits, etc., is presented to illustrate the functional features and not to illustrate the preferred, or even a practical construction. The precise configuration will depend upon the desired method of manufacture, the type of equipment available to the particular manufacturer, etc. For example, the catheters are shown as generally round, but they may be oval or any other shape. The exemplar catheters are shown in a configuration which could be extruded as an integral unit, but the same functional characteristics can be obtained by bundling a number of conduits.
A general overview description of both embodiments of the invention will be provided for a quick understanding, following which a detailed description of the functional structure of the catheters will be provided.
FIG. 1 shows one method of delivery of an abrasive slurry to the site of the occlusion or partial occlusion. It consists of a catheter 10 with three lumen. Lumen 14 is used to inflate balloon 20 forming a leak-proof seal with the lumen of the vessel V. The tip of the catheter is passed just proximal to the area of occlusion or stenosis S made up of plaque deposit. The balloon is inflated, and an abrasive slurry is pumped through lumen 26 and ejected against the plaque deposit as shown by the arrows 26a and withdrawn through lumen 28, as shown by arrow 28a. This arrangement will allow the opening up of completely occluded vessels.
It may be necessary to minimize the amount of residue slurry remaining or lost in the patient during treatment. In this case an alternative arrangement, shown in FIG. 3, is provided. In this embodiment, catheter 40 with two balloons 46 and 48 is used, the balloon 48 being passed through the area of stenosis S. The balloons will then be inflated via lumen 44, isolating the stenotic area between them. The abrasive slurry will be delivered through lumen 60 in the catheter 40 to scour out the area of plaque buildup. The slurry/plaque mixture will be withdrawn through lumen 62. The portion of the vessel with the highest plaque deposit, and hence the narrowest flow section, will be subjected to the maximum liquid flow velocity resulting in the highest scouring or cutting action and plaque removal rate taking place at this site.
In either case, the catheter may initially be placed by means of a guide wire, 24 in FIGS. 1 and 2 and guide wire 56 in FIGS. 3, 4 and 5. The removed plaque will be carried away by the returning slurry. Following the completion of the plaque removal process, a washing period will follow to remove most of the abrasive particles. Undoubtedly some will remain, although the amount can be minimized by careful balloon design. Deflation of the proximal balloon, followed by a withdrawal of blood or perfusate will remove particles trapped by that upstream balloon. Means may be provided to measure the pressure in the stenotic area being treated and/or to permit blood flow to bypass the stenotic area under treatment.
Use of abrasive particles in the size range of less than five microns will allow to particles to pass through, and not block, the capillaries. An accurate knowledge of the quantity of abrasive medium at the commencement of the procedure, and a careful assay of the amount of the abrasive medium collected following the procedure will allow an assessment to be made of the residue remaining in the patient. Assuming a final diameter of the vessel of 2.0 mm, a catheter diameter of 0.75 mm, and a distance between balloons, as shown in FIG. 3, of 1 cm, then the volume contained between balloons and cannula and the final lumen of the vessel will be 0.024 ml. Assuming that 90% of this volume can be swept free of the slurry, and that the slurry originally contains 30% abrasive particles by volume, then the amount of abrasive residue remaining in the patient will be 0.0006 ml or 2.4 mg., using as exemplary slurry particles aluminum oxide, which has a density 3.97 and which is available 99.999% pure. Returning now to the Figures, a detailed description of the structure for carrying out the desired function is provided.
The vessel V may be any vessel in the body but, most often, will be an arterial vessel which is largely or partially occluded by plaque as indicated by the area of stenosis S.
The catheter 10 of FIGS. 1 and 2 comprises an integrally extruded or formed elongate flexible structure 12 in which is formed the several lumen. Lumen 14 in communication through an aperture 18 communicates outside the main structure of the catheter for inflating a balloon 20 secured to the catheter in fluid-tight relation. Balloon catheters of many constructions and types are known and any number of precise structures and methods of construction may be used in making the catheters and the balloons. Many polymers, for example, are known to be quite suitable for the manufacture of catheters and balloons.
The catheter forms a generally central lumen 22 which is adapted to receive radiopaque guide wire 24. In practice, the guide wire is often inserted into the artery or other vessel and followed by X-ray visualization techniques to the location of the stenosis. At that point in the procedure, the catheter is guided over and along the wire to the desired location adjacent to the stenosis.
The catheter forms slurry lumen 26 and slurry outflow lumen 28. The abrasive slurry is pumped, by any convenient pumping mechanism, through the lumen 26 where it is ejected at high velocity toward the occlusion, as shown by the arrows 26a. The slurry, the plaque particles which are dislodged, and any other liquid or solid particles in the vicinity are withdrawn through lumen 28 by any suitable pumping means, as shown by the arrow 28a.
The catheter of FIGS. 3, 4 and 5 is similar in most respects to that shown in FIGS. 1 and 2, and is manufactured using the same body of known technology, but has additional functional structure. The catheter 40 defines a lumen 44 which communicates with and inflates proximal balloon 46 and distal balloon 48. The catheter also defines a general central lumen 54 for receiving and following guide wire 56, in the manner described with respect to guide wire 24 in the embodiment of FIG. 1. In use, the distal balloon 48 is passed through the occlusion and the balloons are inflated thereby isolating the occluded portion of the vessel between the inflated balloons. A lumen 50 may be formed to communicate to the exterior of the catheter for measuring the pressure in the isolated portion of the vessel between the balloons for monitoring the pressure therein to prevent over pressuring the vessel. The lumen also defines a slurry inflow lumen 60 and a slurry outflow lumen 62. The inflow lumen 60 communicates through the external surface of the catheter with the interior of the vessel in the zone isolated between the balloon permitting the slurry to be ejected at high velocity against the stenotic portion of the vessel. The outflow lumen 62 also communicates through the external surface of the catheter with the interior of the vessel in the zone isolated between the balloon permitting the slurry, which carries the dislodged plaque, to be removed from the isolated zone of the vessel under treatment.
The catheter may also define a passage 70 which communicates proximally of the proximal balloon with the vessel and, through either the central lumen 54 or another lumen 72, or both, distally of the distal balloon 48 thereby permitting blood flow to by-pass the portion of the vessel being treated. It may be important in certain instances that the portions of the body or organs supplied by the vessel be perfused by at least some blood flow to permit the cleaning operation to continue long enough to provide maximum benefit. For example, during the period of treatment it may be desirable to provide blood perfusion to the distal myocardium. Complete perfusion may be obtained by removing the guide wire and pumping oxygenated blood through the central lumen or permitting blood to flow around the treatment zone via a bypass lumen system.
The pumping means for providing a high velocity jet of slurry and the means for withdrawing the slurry and plaque particles may be of any type. A very simple but reliable pumping system is simply a container of slurry elevated to provide a liquid head sufficient to produce a high velocity jet and another container lower than the patient for establishing a negative head for withdrawing the slurry-plaque mixture.
During the flow of the abrasive slurry, it is desirable that the liquid pressure within the area between the two balloons remains in the physiological pressure range of 21/2 psi, although higher pressures could be used if necessary. To avoid cavitation in the return flow passage of the catheter, the overall pressure drop across the catheter may not exceed about 15 psi. To reduce the pressure drop across the catheter, the major part of the overall length of the catheter may be made significantly larger in diameter than that of the distal portion. For example, the distal portion might be 10 cm in length, and of 1-2 mm in diameter, while the proximal portion might be 125 cm in length and of 3-6 mm diameter. The slurry inflow passage and the return passage would be correspondingly larger in the increased diameter section of the catheter. The large diameter for the proximal section of the catheter is permissible because only the distal 10 cm of the catheter is passed into the coronary artery. The proximal portion of the catheter passes through the larger arteries of the body. The femoral artery in the groin, the catheter entry point into the patient, is the smallest vessel that would need to be transversed.
A special delivery/exhaust positive displacement pump may also be used. This will permit the quantity of slurry withdrawn from the catheter to be controlled such that this quantity is substantially the same as that delivered though the catheter. Such a pumping arrangement may be used to prevent over extension or over pressurizing the artery during scouring. The fluid pressure in the vessel may also be monitored and used to control the pumping and/or withdrawal rate. For example, a pressure sensing lumen such as lumen 50 shown in FIGS. 3 and 4 may be used to provide a pressure feedback to adjust the relative delivery and/or withdrawal flow delivered by the pump(s). Such feedback can be achieved by any number of devices. For example, a third small capacity balancing pump, the speed and direction of which is controlled by a pressure feedback signal, may be used. Certain-volume pumps such as bellows pumps, piston pumps or peristaltic pumps, etc., may be used and the pumping rates carefully controlled as a function of the pressure in the portion of the vessel under treatment and/or the volume of material being withdrawn from that portion of the vessel.
FIG. 6 depicts, schematically, one pumping system which may used with and as part of the invention. A slurry source 100 is provided from which slurry is drawn through conduit 102 by pump 104 and delivered through conduit 106 to lumen 60, in FIG. 3, or lumen 26 in FIG. 1, to provide a jet of slurry in the treatment area. The slurry, carrying removed plaque, is withdrawn through conduit 110 by pump 112 and dumped through conduit 114 to a container 116 for disposal. Pressure may be sensed from lumen 50 in FIG. 3, or by any convenient pressure sensor. In the example, the pressure is applied through a conduit 120 to a transducer and microprocessor in controller 122 which provides control signals to the pumps 104 and 112 through conductors 124 and 126, respectively, for controlling the pumping and/or withdrawal rates.
It is convenient to provide a slurry of solid abrasive particles in a radiopaque liquid. This permits the physician to monitor the progress of plaque removal and the amount of enlargement of the vessel. Iodine-containing and other radiopaque liquids and solutions are well-known and widely used in studying circulation. Any of these liquids may be used.
The particles may be physiologically inert abrasives such as aluminum oxide or silicon carbide in the size range of less than five microns may, for example, be used. Particles of this size or smaller will pass through and not block the capillaries. Other bio-compatible particles, such as particulate hydroxyapatite, may also be used.
Particles of a substance which is solid and only slightly soluble in the carrier liquid forming the slurry but which will dissolve in blood may also be used. In this example, there are no particles remaining in the circulatory system following the procedure as described. For example, glucose (hexose) crystals slurried in ethyl alcohol in which a sufficient amount of iodine is dissolved to provide radiopacity may be used. The iodine may, of course, be omitted. Glucose is only slightly soluble in ethyl alcohol but quite soluble in water and would readily dissolve in the comparatively large volumes of blood serum into which it would be mixed following the procedure. Following the procedure using only alcohol and glucose, the patient would experience, at worst, a slight rise in blood sugar and a mild case of intoxication. Inclusion of the iodine may add the warm flush usually accompanying the use of iodine-containing radiopaque solutions.
Uric acid has very low solubility, 1 gram in 15,000 grams, of cold water and is more soluble in warm water, 1 gram in 2,000 grams of warm water. Uric acid is soluble in glycerol. A slurry of uric acid particles in cold, or even in warm, water, with or without a radiopaque constituent, may be used as the abrasive medium. Once the abrasion of plaque is complete, warm water, e.g. 105-110 F. or glycerol or a warm aqueous glycerol solution may be used to flush out the uric acid particles. Uric acid crystals are also insoluble in a acidic aqueous solution of about Ph 5.5 or lower, but relatively soluble when the Ph is raised above about 7.5 or above. A slurry of uric acid particles in an acid solution may be used as the abrasive medium. Once the plaque removal is complete, a basic solution may be used to flush out the residual uric acid particles. Many biologically acceptable acids and bases are available and may be used to provide the proper Ph. In addition, blood, being a higher Ph than the acidic slurry solution will dissolve the particles quite readily. Such particles as may remain ultimately will be excreted in the urine.
It is noted that this invention is particularly well adapted to the removal of calcified plaque which is more susceptible to abrasion and less susceptible to dissolution than ordinary uncalcified plaque. Furthermore, it is usually impossible to remove all of a plaque formation using the conventional balloon catheter - mechanical removal technique while, with this invention, the entire plaque formation can be removed and the removal monitored by X-ray visualization equipment, all with very much reduced risk of dislodging emboli which might block circulation in a distant portion of the vascular system. Obviously, the present invention could combine conventional balloon angioplasty with the techniques previously described, if this were desirable in certain instances.
Many variations are, of course, permissible and contemplated within the scope of the invention. For example, separate inflating lumen for multiple balloon catheters may be provided, and other combinations of solids and liquids may be used to obtain the desired result.
INDUSTRIAL APPLICATION
This invention is suitable for use in the practice of medicine and surgery on humans and in veterinary practice. | A method of removing plaque from vessels by at least partially isolating a portion of a vessel which is partially occluded by plaque from the remainder of the vessel, forcing a slurry to flow in contact with the plaque in the vessel to abrade the plaque, and withdrawing the slurry from the vessel, and apparatus for carrying out the method, are disclosed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a rain gutter system for receiving water run-off and rejecting leaves and other debris and, more particularly, to shielded eaves troughs and to a bracket which is form-retaining and supports the shielded trough on the building and which may also be used to fasten the trough to the building.
The invention is specifically directed to an improved gutter and leaf shield system in which the rain water runs faster than in prior art gutters because of added rain run-off capacity and in which the gutter and integral leaf shield is better suited to continuous roll forming and the bracket implements form retaining of and support for the added material required to increase rain water run-off.
2. Description of the Prior Art
There are several patented designs of shielded eaves troughs and brackets for supporting them on a building, some of which are described in the patents discussed below.
In my patent, U.S. Pat. No. 4,757,649, incorporated herein by reference, I disclose an integral gutter and leaf shield in which the shield is formed with a double-curved convolute to direct rain into the trough. I fastened the integral shield and gutter to the wall beneath the roof by a fastener which passed through the integral back wall to the building wall.
U.S. Pat. No. 836,012, patented by G. Cassen, Nov. 13, 1906, describes a trough having a back wall that is higher than the front wall. A separate shield which extends from the top of the back wall slopes forward and downward. The front of the shield turns downward, ending just rearward of the top edge of the front wall. A pair of brace straps attach the shield and trough to the building at intervals along the length of the trough.
One of the braces is a strap attached at one end to the top of the front of the shield, and at the other end to the top of the roof. The other brace is a bar attached at one end to the back wall of the trough by a screw which passes through the bar, the trough wall and the vertical side wall of the building. The other end of the bar is bifurcated to provide an upturned and a downturned attachment tab. The upturned tab is attached to the front end of the shield, and the downturned tab is attached to the trough by the top edge of the front wall.
U.S. Pat. No. 2,672,832, patented Mar. 23, 1954 by A. K. Goetz, describes a trough having a back wall higher than the front wall. The top of the back wall has a V-shaped longitudinal, horizontally arranged groove. The rear edge of the shield has a matching groove so that the rear edge can seat on the back wall groove.
A pair of nails attach the shield and trough, respectively, to the building. The first nail has a threaded back end and passes through the back wall and into the vertical side wall of the building. A screw which passes through the downward turned front of the shield engages the threaded back end of the nail and forces the shield toward the building wall so that the shield is seated on the back wall groove. The nail arrangement is repeated at intervals along the length of the shield and trough assembly. The shield may be removed for cleaning the trough by removing the screws.
The second nail is through the front end of the trough and into the side wall of the building. An elongated tubular spacer on the nail prevents collapsing of the trough when the second nail is hammered into the side wall.
U.S. Pat. No. 2,873,700, patented Feb. 17, 1959 by H. C. Heier, describes a trough having a back wall that is higher than the front wall. A generally flat rearward section of the shield extends forward from the top of the back wall. Angling slightly downward, it extends forward of the front wall and ends just rearward of the front wall. The ends of the trough and shield sections are interconnected by brackets which are fastened to the wall of the building by screws.
A series of the spacers along the length of the shielded trough assembly provides slot openings to the trough for receiving water that moves down over the shield. The front end of the shield is fastened to the top of the front wall of the trough by way of a screw through the shield, through a wedge-shaped spacer between the shield and front wall and through the front wall.
U.S. Pat. No. 4,493,588, patented by G. Duffy, Jan. 15, 1985, describes a trough having a back wall which is nailed to a roof under the shingles, extends forward and down from the roof in a curve that then turns back under the eaves, whereupon the wall reverses direction and forms a suspended trough, the front wall of which has a screen that contacts the front of the curved back wall just below the forwardmost part of the curve, so that water flowing down over the curve enters the trough via the screen.
A strap is attached by one end to the rear surface of the back wall near the bottom of the inward turned curve over the trough and attached by the other end to the eaves soffit.
U.S. Pat. No. 4,497,146, patented Feb. 5, 1985 by R. Demartini, describes a support strap having one end resting on the roof of the building. In juxtaposed support with the underside of a separate shield which is retrofitted on already installed gutters. The strip extends forward from the roof until it is about parallel with the front wall of the trough. The strip then curves back with the shield until it reaches the bottom end of the shield, whereupon the strip continues downward and is fastened to the upper part of the front wall of the trough, in order to support the shield on the trough. It is fastened to the trough either directly by a fastener or indirectly by attachment to the ferrule of a horizontal bolt that passes through the front and back walls of the trough normal to the back wall of the trough and into the vertical side wall of the building.
SUMMARY OF THE INVENTION
It is one object of the invention to provide an improved shielded trough for the eaves of a building incorporating the inventions of my prior patent, U.S. Pat. No. 4,757,649, but which has greater rain water run-off capacity.
It is another object to provide an integrally formed bracket for the shielded trough which both conforms to and supports the form of the shield at extended lengths of the shielded trough and supports the trough as well instead of supporting the shield on the trough or the trough from the shield.
It is another object that the form conforming and support bracket be enclosed within the shielded trough.
It is another object that the form supporting bracket can be independent of fasteners that attach the shielded trough to the building.
It is another object that the form supporting bracket can be independent of fasteners.
It is another object that the form supporting bracket can alternatively be fastened to the wall of the building by a fastener through the back of the shielded trough while in place within the shielded trough.
It is another object of the invention that the form supporting bracket can be easily moved along the length of the shielded trough within the shielded trough.
It is yet another object that the form supporting bracket can be moved the length of the shielded trough, even though the trough may be installed on a building.
It is still another object that the form supporting bracket can be moved along within the shielded trough by applying through the longitudinal opening in the front of the shielded trough, urging force against the supporting bracket.
It is still another object that the form supporting bracket can be a single piece unitary molded construction.
Other objects and advantages will be apparent to one reading the ensuing description.
In designing the shielded trough of the invention, I extended the flat bottom of the gutter of my patented leaf rejecting gutter into an upwardly concave section to increase the capacity of the gutter. I also extended and bent the lips of the trough and of the shield inwardly, both for the sake of safety and to enhance the rain gathering functions of the shield and trough.
Consequently, the design which already includes a shield, downwardly concave, double convolute in cross section proved easier to fabricate from sheet material, such as aluminum, through continuous rolling processes.
However, the addition of material also resulted in added weight and extended lengths of the shielded trough tended to bend intermediate their ends.
I, therefore, conceived of a bracket for the new shielded trough which could be located inside the shielded trough anywhere along the length of the shielded trough. I also redesigned the top of the shielded trough to accept fasteners externally of the shielded trough so that the bracket need not be secured to the building by fasteners extending through the back of the trough. I also designed the bracket with an extension so that alternatively it could be fastened to the building through the back of the shielded trough.
The new and improved shielded trough and bracket combination comprises a shield trough having a back wall which is supported against the wall of the building beneath the roof, an upwardly concave a trough integral with the back wall, a shield integral with the back wall and extending forward over the trough so that leaves are deflected from entering an opening between the front of the shield and the front wall of the trough to the interior of the shielded trough and so that water flowing over the shield enters the opening and into the trough; a bracket comprising a first wall in mating juxtaposed support with the inner side of the shield, a second wall having a back end extending from the back end of the first wall in the back of the shielded trough assembly, a front end of the second wall being in mating juxtaposed support with the formed upper end of the front wall of the trough.
A first bracket arm extends from the under side of the second wall and rests against the back wall of the shielded trough. It extends from the second wall between and spaced from the front and back ends of the second wall.
A bracket arm extends from the top side of the second wall and connects to the under side of the first wall.
In a preferred embodiment of the invention, a lateral extension from the back end of the first bracket arm provides a fastener receptor for fastening the bracket to the building wall and is accessible through the opening between the front of the trough and shield.
The bracket may freely slide within the shielded trough by applying sideways force to the bracket.
The front end of the first wall of the bracket ends in a backward facing upturned bend for engaging the backward facing upturned bend of the front of the shield.
The front of the trough ends in a backward facing downturned bend for engaging the backward facing downturned bend of the front end of the second wall of the bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention be more fully comprehended, it will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a diagrammatic side view of a shielded trough according to the invention;
FIG. 2 is a diagrammatic side view of the shielded trough of FIG. 1 and a form supporting bracket, according to the invention;
FIG. 3 is a rotated perspective view taken from 2 o'clock high, of the bracket of FIG. 2;
FIG. 4 is a front view of the shielded trough of FIG. 1 showing a portion of the form supporting bracket of FIG. 2 installed;
FIG. 5 is a diagrammatic side view of another form supporting bracket of the invention; and
FIG. 6 is a view of the bracket of FIG. 5 rotated 90 degrees clockwise, as seen from direction 6 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the invention in detail, it is to be understood that the invention is not limited in its application to the detail of construction and arrangement of parts illustrated in the drawings since the invention is capable of other embodiments and of being practiced or carried out in various ways. It is also to be understood that the phraseology or terminology employed is for the purpose of description only and not of limitation.
Referring to FIGS. 1, 2, 3 and 4, the integrally formed shielded trough 10 may be supplied in a length of choice. This may be 5', 10', 20' or any length desired, including as a continuous run from a roll forming machine on a construction site.
Shielded trough 10 includes shield 16 which is formed as a double convolute which extends forward (arrow 18) and downward (arrow 22) from the back wall 26 and continues around to a low point 42 that is rearward of the high point 44 of top 30 of the front wall 34. The front end 42 of the shield is curved inwardly and rearwardly and then upwardly to eliminate a sharp edge at the front of the shield.
Top 30 of front wall 34 of trough 38 is preferably curved inward (arrow 40).
Preferably, the front 50 of the shield extends forwardly enough so that leaves and debris moving down over shield 16 continues past opening 54 to the interior of shielded trough 10.
Preferably the downward slope and curve of the double curve convolute of the shield is such that water running down over the shield flows into opening 54 and is captured in trough 38 for runoff into a downspout (not shown).
The upwardly concave shape of the trough portion of the shielded trough represents an enlargement of the trough to increase capacity and that shape and the downward curve of the top of the front wall eliminates sharp bends at the front and back of the assembly for easier fabrication; i.e., to reduce the length and cost of roll forming machinery.
The form or shape of a shielded trough which contributes to collecting water and rejecting leaves and debris must be maintained over the length of the shielded trough in order to maintain its efficiency. Loss in the effective form at some place along the length of the assembly can result in damming the trough at that place and, in any event, in weakening the installed structure.
Bracket 58 supports the form of shielded trough 10 which may be attached to side wall 62 below the overhang of shingles 64, by a series of fasteners 66 spaced along the bended length of the shielded trough and extending through top vertical flange 26a formed by a 180 degree bend of the top end of the back wall 26 and back end of the shield.
The shielded trough and the form supporting bracket may be made of sheet metal or molded of plastic. It is preferred that the bracket be of one piece unitary plastic construction for sake of economy and resilience against bending forces which may be applied during installation of the bracket within the shielded trough.
Bracket 58 includes wall 74 which, at its front end 102 conforms to and is in mating juxtaposed relation with the inner curved surface of the top 30 of front wall 34 to support the trough 38 which is formed at that location as a rounded lip. Bracket wall 74 extends rearward and upward until it joins wall 76 at junction 80 close to the inside of bended flange 26a at the integral junction 78 of back wall 26 of shielded trough 10 and shield 16. Wall 76 extends forward in mating juxtaposed support with the inner side of shield 16 continuously in close support of the shield through the most forward point 88 of the front 50 of shield 16, as defined by a vertical tangent 90 to the front of the shield and around the inner surface of the curved front end of the shield.
Bracket arm 94 extends from bottom side 98 of wall 74, from a portion of wall 74 that is between and spaced from end 102 and turn 80 of wall 74. Bracket arm 94, being generally straight, extends obliquely to back wall 26 against which it rests to support the bracket, shield and trough.
Bracket arm 94 is preferably offset from center line 106 of back wall 26 so that a screw driver or other tool can access slot 110 in tab 114 directly through opening 54 without significant interference from wall 74, for attaching bracket arm 94 to back wall 26 and to side wall 62 by screw, nail or other fastener through slot 110, if so desired.
Bracket arm 118 extends from topside 120 of wall 74 from a portion of wall 74 that is spaced from end 102 and turn 80 of wall 74 to the inner side 124 of wall 76 at a portion of wall 76 that is between and spaced from front end 84 and the junction of the back end of wall 76 and flange 26a.
Shield 16 may be fastened to bracket arm 118 by screw 126 through shield 16, wall 76 and into bracket arm 118. Shield 16 may be fastened to only wall 76 by screwing through both at such locations as 132 or 134.
Preferably front wall 34 of trough 38 ends in a backward facing, downturn bend, such as a curve, which closely receives front end 102 of wall 74 that has the same turn. Preferably front end 50 of shield 10 ends in a backward facing upturned bend, such as a curve, which closely receives end 138 of wall 76 that has the same turn. This arrangement of engagements provides stable, form support for shielded trough 10 without fasteners between shielded trough 10 and form supporting bracket 58.
In the absence of need for fasteners through the bracket, bracket 58 may easily be moved to any location within the length of shielded trough 10 before and after installation of shielded trough 10 on a building wall. Normally a plurality of brackets 58 and spaced equally along the length of the trough. An installed shielded trough, however, may become distorted by a localized external force such as a falling branch or ice. It is a simple matter then to support the damaged area by sliding the nearest bracket to that location and restore the damaged area to reasonably good form.
Referring now to FIGS. 5 and 6, form supporting bracket 140 includes wall 144 which is attached at the junction 148 of walls 150 and 152. Wall 144 includes opening 156 for optionally receiving a fastener to fasten wall 144 in close contact with the back wall of a shielded trough in which bracket 140 is installed with wall 152 in matingly juxtaposed support with the inner side of the shield and wall 150 and with the front ends 166 and 168 of walls 152 and 150, respectively, in matingly juxtaposed support with the front ends of the walls of the shield and trough.
Bracket arm 158 is attached to walls 152 and 150. Bracket arm 160 is attached to wall 150 and 144 and thereby supports the bracket, shield and trough against the back wall of the trough assembly. Optionally, tab 162 extends from wall 150 so that it can be held by fingers, pliers, or other tool through the opening between the front end of the shield and the front end of the trough along the length of the shielded trough for applying force on bracket 140 to move it within the shielded trough along the length of the trough.
Although the present invention has been described with respect to details of certain embodiments thereof, it is not intended that such details be limitations upon the scope of the invention. It will be obvious to those skilled in the art that various modifications and substitutions may be made without departing from the spirit and scope of the invention as set forth in the following claims. | A trough with superimposed shield to reject leaves and allow water to enter the trough include a bracket which supports the shield and the trough and which rests on a back wall of the integral shield and trough. The front of the shield ends in a backward facing upturned curve for engaging the bracket. The front of the trough ends in a backward facing downturned curve for engaging the bracket. | 4 |
PRIORITY CLAIM
[0001] This application claims priority to U.S. Provisional Application No. 60/580,428 filed Jun. 17, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to construction templates. More specifically, the present invention relates to a mobile construction template for creating large segments of structural lattice framework that is used in warehouses that store barrels.
[0004] 2. Background
[0005] Support frames have long been used for supporting barrels of distilled spirits that are aged at wineries and distilleries. The interconnected lattice-work creates support racks on which rows of barrels are placed. This lattice-work has to be exceptionally strong as often several stories of racks are contained in each warehouse for housing thousands of barrels, each barrel weighing hundreds of pounds. The barrel racks must enable the barrels to be stored in an organized fashion, due to the need periodic relocation of each barrel during the ageing period, and to provide ultimately for removal of the barrels from the warehouse. It is well-known in the art that a certain amount of airflow is necessary between the barrels to promote proper maturation of the spirits and that uniformity of the racks will aid in maintenance of the desired airflow. Also, the supporting framework of these barrel racks is constructed using a series of almost identical segments of post and beam frames, that run parallel and that are stacked one frame upon another inside a warehouse.
[0006] A common method of constructing lattice-work is through the use of skilled carpenters inside the barrel warehouse. Each piece of the lumber used to make barrel support structures would be cut and assembled piece by piece inside the warehouse. To accelerate the construction, a need exists for a mobile construction template.
[0007] The prior art methods for hand-assembling the lattice-work did result in the racks being constructed in proper form, but the costs were high due to the wasted materials, hours of labor, and the need for carpenters with the requisite skills in the method. Wasted materials result from the individual construction of each element of the lattice-work, from sawing off the vertical support members, to fit and provide attachment to the horizontal barrel support members. Hours of hand labor were spent to orient and manually assemble the components of the lattice-work. Furthermore, skilled construction laborers are required since proper sizing and fit of each rack is necessary to achieve a level rack with the desired rack spacing, which allows for the periodic rotation and relocation of the barrels. In addition, when expansion of an existing warehouse is desired, the skilled labor force would have to work within the temperature and humidity conditions within the warehouse.
[0008] The present invention provides a construction template system designed to create full lattice segments on a mobile unit, which enables the construction of support frame and their placement for use in barrel warehouses, thereby reducing the production inefficiencies experienced through manual construction, and assembly inside a barrel warehouse.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is directed toward a system for the efficient production of lattice-work for storing barrels in a barrel warehouse. The construction template of the present invention comprises a combination different components used together in an effective manner.
[0010] The lattice construction system is based off of a mobile trailer allowing for relocation of the system near the work site, such as where a warehouse is being built or expanded. On the main bed are a multitude of near vertical members extending upward and along the length of the main bed, spaced parallel and equidistant. Each vertical member has a series of tabs extending near horizontally, which function in both stabilizing the vertical beams of the lattice segment and also in correctly positioning the barrel support beams for proper attachment of the vertical beams to the horizontal barrel support beams.
[0011] The described invention alleviates many of the problems associated with construction of lattice-work for supporting barrels full of spirits. One of the largest advantages of the lattice construction system is the correct orientation of each beam; the vertical members and extending tabs mandate proper height, spread, and angle of the lattice. This template system minimizes common construction errors by individual laborers working on a barrel warehouse. Additionally, in the case of a barrel warehouse expansion, less disruption is caused to the preexisting storage areas. Finally, the lattice construction system is mobile; the system can be also be used directly outside the barrel warehouse or in a remote location where construction may be more practical.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
[0013] FIG. 1 is a detailed front view of one embodiment of a lattice construction system;
[0014] FIG. 2 is a side view of one embodiment of a lattice construction system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] While the present invention will be described more fully hereinafter with reference to the accompanying drawings in which particular embodiments and methods are shown, it is to be understood from the outset that persons of ordinary skill in the art may modify the mobile construction template herein described and achieve the functions and results of this invention. Accordingly, the description is to be understood as illustrative and exemplary of workable embodiments within the broad scope of the invention, and not as limiting its scope. In the following descriptions, like numbers refer to similar features or like elements throughout.
[0016] Referring now to FIG. 1 , a front total view of an embodiment of a lattice construction system is shown. Affixed on a typical truck-drawn trailer 100 , or equivalent mobile unit, is the main horizontal bed 110 . The horizontal bed 110 provides structural integrity to the lattice construction system, and also offers an ideal walkway for laborers using the system. A plurality of vertical beam positioning members commonly designated at 120 are mounted onto the main horizontal bed 110 and extend upward. The vertical support beams of the lattice structure are positioned in contact with each vertical beam positioning member 120 . In the preferred embodiment, these vertical beam positioning members are not mounted vertically on the bed, but rather are in a tilted position. The tilting of these members 120 allows the workpiece beam to be laid against the positioning member so that the beam rests back against the member 120 and remains in that location while the further steps and parts are being worked with. The vertical beams may be cut to the desired length while in place against the positioning member, or precut to a predetermined length before being placed against the vertical positioning member. In that manner, the positioning member serves as a template for the vertical beam to be cut to the predetermined length, and as a template to locate the point at which the vertical beams will be joined to the horizontal beams to form a segment of the barrel support lattice.
[0017] Extending, perpendicularly outward, from the vertical beam positioning members 120 are position maintenance tabs 130 . The purpose of these tabs is to provide a support or rest for the horizontal beam members that will be joined to the vertical beams. The position maintenance tabs 130 maintain the position of the vertical support beams that form the lattice structure, and the tabs minimize lateral movement. In one preferred embodiment, the tabs are connected along the side of the vertical positioning member, and in other embodiments, the tabs are adjacent to those members. The position maintenance tabs 130 are positioned in an identical vertical arrangement on each respective vertical beam positioning member 120 so that the lowest position maintenance tab 130 of each vertical beam positioning member 120 is the exact distance above the main horizontal bed 110 as are each of the other lowest position maintenance tabs 130 on the other vertical beam positioning members 120 . So too, the distance between each of the vertical beam positioning members 120 is the same, across the bed. In the preferred embodiment, each vertical positioning member has a pair of maintenance tabs, starting with a first pair near the lower end of the member, and the desired number of pairs placed above that first pair. In that manner, the tabs are located at an equal, predetermined distance on the vertical beam positioning members 120 . The horizontal beams may be cut to the desired length while in place on the maintenance tabs, or precut to a predetermined length before being placed on the tabs. These elements provide a template for joining the horizontal beam resting on the tabs to the vertical beam on the positioning member.
[0018] Post clamps 140 secure each vertical support beam and square the beam in tight contact with each vertical beam positioning member. The claims may be adjustable so that they can be used to hold the horizontal beams in place as well. The post clamps may be clamps that are manually tighten, or in other embodiments, the securing hardware may secure using friction against the beam or may gouge the wooden beam. In one preferred embodiment, the clamp mechanism slides along the vertical positioning member such that it is moved up or down to contact the beam or beam near the point where the vertical beam and horizontal beam are to be joined. A further utilitarian feature of the mobile unit provide electrical power along the bed of the platform, with the preferred embodiment having an electrical conduit 160 that runs behind the vertical beam positioning members 130 in a zig-zag fashion. Finally, stability beams 170 run horizontally, attached to the rear side of the vertical support position members 120 providing strength and stability to the lattice construction system. By this method of joining upright members to cross beams, to form a matrix of beams joined at its interstices with hardware typical of such construction, results in large frames to support barrels being made more efficiently.
[0019] FIG. 2 . illustrates a side view of the same embodiment of the lattice construction system. From this angle, the fold-down walkway 200 is visible, providing an area behind the vertical beam positioning members 120 for laborers to traverse.
[0020] FIG. 3 . illustrates a front view of an embodiment of the lattice construction system with containment bins 300 . These bins can be used to store tools, attachment materials, and other various supplies for operation of the lattice construction system. From this angle, the electrical connections 160 are visible, providing easy accessibility for any tools that require electrical power.
[0021] The mobile apparatus is taken to the desired location, and the components of the construction template are erected on the bed of the trailer, which has prepositioning footings in the bed or slots 112 therethrough, which accept the lower end of the vertical positioning member. With this embodiment, vertical support beams of the lattice structure are placed in contact with each respective vertical beam positioning member 120 , and in between the sets of position maintenance tabs 130 , which in the preferred embodiment extend from each vertical beam positioning member 120 . Also, in one preferred embodiment, each vertical beam positioning member 120 is comprised of two, parallel metal struts 120 A and 120 B, and the distance between those struts is adequate for the vertical beam to be placed between them. In this embodiment, the struts act as a template to align the vertical beam in perpendicular relation to the barrel support beams to which the vertical beams are joined to form a segment of the support frame for the barrels. In the working arrangement, the lower end of the vertical beam is placed in a footing 121 at the base of the vertical beam positioning member 120 , on the trailer-mounted bed, and laid back in alignment with the struts on that member. As the work progresses, vertical beams are placed against each of the vertical beam positioning members. The barrel support beams are positioned horizontally, resting up the position maintenance tabs 130 . In this manner, the barrel support beams extend across the construction template, at an uniform height, and in contact with each vertical support beam. Once the beams are in place, the post clamps are secured over, to, or around the beams, which minimizes movement of the beams as they are joined. The barrel support beams and vertical support beams can then be fixed together at their various intersections by either brackets, long nails or other suitable joining hardware, or suitable construction adhesives. Thus, the lattice construction system created a segment of a lattice-work with beams meeting perfectly at perpendicular angles with each beam in a position and with spacing predetermined by the template of the lattice construction system.
[0022] For the installation of the lattice segments in the barrel warehouse, the completed support segments are either carried off the trailer 100 to the barrel warehouse site, or when assembled at the construction site, the lattice segments are lifted directly off the trailer by crane slings and lowered into place in the proper orientation within the warehouse being built or expanded. In a typical circumstance, the completed frame is lifted from the trailer-mounted template, and placed on footings in the warehouse, then another frame is lifted onto the frame on the footing, and so forth, until the desired number of levels for barrel storage is reached.
[0023] The entire lattice construction system is relatively simple but yet highly efficient, requiring few laborers and little maintenance, providing a number of advantages over the manual construction of barrel racks. The lattice construction system can be operated by semi-skilled workers since the system orients the beams at the proper angles and height. The mobile unit provides a work area on the bed 110 , and additionally, the preferred embodiment includes a walkway 200 that extends off the bed. This walkway enables workers to work from both sides of the template, which is useful to placing and joining the beams. In working arrangement, workers on one side of the bed will pass the beams to workers on the bed, who will place those on the template, and then workers on the bed and the walkway will affix the joining hardware. The support segments can be constructed outside of the warehouse and subsequently installed, allowing for much less construction time inside the warehouse. All that is necessary is the proper securing of the segment in the warehouse. The mobile lattice construction system can be utilized away from the warehouses in hilly or confined places, at a better construction location. With those barrel warehouses located on hilltops, the lattice construction system eliminates the need to construct barrel racks in non-ideal locations. | A construction template mounted on a mobile platform. The template is useful in the assembly of racks made for storing barrels, typically barrels of distilled spirits in a warehouse. | 0 |
[0001] This application is a continuation-in-part of applicants pending application Ser. No. 10/718,156 of same title filed Nov. 20, 2003.
BACKGROUND
[0002] 1. Field
[0003] This invention relates to devices for cleaning submerged structural surfaces of water bodies such as the bottoms of swimming pools, spas and the like, and particularly concerns unique structure of a water jet operative vacuum type cleaner for removing and filtering out leaves and other such debris from said structural surfaces.
[0004] 2. Prior Art
[0005] A device of this general type is described in U.S. Pat. No. 6,502,269B1 the disclosure of which is hereby incorporated herein by reference in its entirety. A major problem with the cleaner of this patent is that the water-debris intake of the cleaner is in direct fluid communication with intake of the jet pump. In situations where the pool debris contains organic material such as leaves or small pieces of sticks or the like, the pump intake filer will rapidly clog and render the cleaner inoperative.
[0006] Principal objects therefore of the invention are: to provide a water jet vacuum type, pool cleaning device which is easy to use and maintain and which preferably utilizes a battery operated water jet pump which, in normal use, virtually cannot be clogged with pool debris; and to provide such device in a structurally simple design and at an economical cost.
SUMMARY OF THE INVENTION
[0007] A water jet vacuum cleaning device for vacuuming debris from underwater structural surfaces, said device comprising a housing providing a suction cavity communicating with a debris-water inlet formed thru said housing, said device being moveable along said surfaces with said inlet being in close proximity to said surfaces, said housing being formed with a debris-water discharge conduit having a debris-water outlet which is surrounded by a mesh filter bag extending outside of said housing for entrapping debris, a water ejector tube mounted in said cavity generally in axial alignment with said discharge conduit and adapted for connection exteriorly of said housing to a source of high pressure water or air or the like, said ejector tube further having a water ejector end located within said cavity and spaced from a debris-water inlet of said discharge conduit to provide a debris entry gap positioned intermediate of and communicating with said inlet and outlet, whereby when water is ejected from said ejector end across said gap and into said discharge conduit the pressure within said cavity will be reduced sufficiently to suck water-debris from said surfaces and into said discharge conduit for transport to said outlet and therethrough into said filter bag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention and its objects will become further apparent from the drawings herein wherein the various figures are not drawn necessarily to scale or proportion and are intended to facilitate understanding of the invention, and wherein:
[0009] FIG. 1 is a side view of the present device in operating position adjacent a pool bottom surface with portions of the housing of the device broken away for clarity;
[0010] FIG. 2 is a top view of the present device without the filter bag and taken along line 2 - 2 in FIG. 1 with portions of the housing broken away for clarity;
[0011] FIG. 3 is a cross-sectional view taken along line 3 - 3 in FIG. 2 ;
[0012] FIG. 4 is a cross-sectional view taken along line 4 - 4 in FIG. 3 and showing flow area as double cross-hatched;
[0013] FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 3 and showing flow area as double cross-hatched
DETAILED DESCRIPTION
[0014] Referring to the drawings and with particular reference to the claims herein, the present water jet cleaning device 10 for underwater vacuuming of debris 11 from structural surfaces such as bottom 12 of swimming pools or other water bodies comprises a substantially closed housing 14 formed by wall means generally designated 16 preferably of structural plastic such as PVC, cellulosics, butyrates, polyamides, polyolefin or the like, or metal or ceramic, and providing a suction cavity 18 . This cavity can be of any operator convenient volumetric capacity and configuration, however the configuration shown in the drawings is preferred with a preferred capacity of from about 400 ml. to about 2,500 ml., most preferably from about 1,000 ml. to about 1,500 ml.
[0015] A debris-water suction inlet 20 extends thru said wall means into said cavity. This inlet is of a typical elongated generally rectangular configuration of, for example, a flow area of about 10 in 2 to about 16 in 2 for a cavity capacity of from about 1,000 to about 1,500 ml. The height of the inlet rim 22 from the surface 12 should be preferably from about ⅛ inch to about ½ inch for best results and this height is maintained, e.g., by a pair of wheels 24 mounted on the housing sides adjacent the inlet.
[0016] A debris-water discharge conduit 26 formed by said wall means has an exit end 28 surrounded by a mesh filter bag 30 of natural or synthetic fibers or thin flat strips or the like and extending exteriorly of said housing and of any desired capacity for entrapping said debris. The filter bag inlet end is affixed in groove 31 encircling an enlarged filter bag attachment collet 33 into which a removable retaining snap ring or band 35 is secured. This collet is threaded into rim 37 provided by wall means 16 . Conduit 26 has an entry end portion 32 opening into said cavity, and further has a flow axis 34 . End portion 32 is depicted in FIG. 3 as a dotted line 36 marking the terminus of the funnel shaped portions 38 of wall 16 . In this regard it also marks the outlet end of suction cavity 18 .
[0017] A fluid ejector tube 40 is mounted in cavity 18 and extends thru wall means 16 and has a flow axis 42 , a fluid inlet 44 on a distal end portion thereof which is adapted for connection exteriorly of said cavity to a source 46 of high pressure fluid. This tube further has a fluid ejector end or nozzle 48 located within said cavity and spaced from said entry end 32 of said conduit and thus provides a debris entry gap 50 communicating with said entry end. The ejector tube flow axis 42 and the conduit flow axis 34 are in general alignment for maximizing the suction and transport effect of stream 52 indicated as dotted arrow lines. The term “general alignment” means a preferred deviation from true alignment of no more than about 30°, and most preferably no more than about 10°.
[0018] The flow area 54 of the exit end 28 of said conduit is from about 1.5 to about 30 times, preferably 5.0-20.0 times the flow area 55 of the ejector end 48 of said tube, whereby when fluid stream 52 is ejected from said ejector end and across said gap 50 and thru said discharge conduit 26 and into said filter bag 30 the pressure within said cavity 18 will be reduced sufficiently to suck water-debris from said surfaces up to and into said stream for transport into said filter bag container without the inlet 45 of said high pressure source 46 or the inlet 44 of said tube being exposed to said debris. It is noted that the present construction affords a practically obstructionless passageway from inlet 20 to exit 28 for the debris.
[0019] The various parts or portions such as wall means 16 , tube 40 , conduit 26 , the housing 56 of electric battery operated water pump 46 , the attachment collet 33 for the fine mesh filter bag 30 , and the operators handle section 62 may be formed as a monolithic structure by plastic injection molding or the like, or may be individually provided and plastic welded or adhesively assembled together to form the device.
[0020] Handle 62 shown in FIG. 1 preferably carries the electrical leads 64 which extends upwardly thru handle extension 66 to a battery in the manner shown for example by the aforesaid U.S. Pat. No. 6,502,269 B1, particularly items 12 and 13 described in column 5 thereof.
[0021] In preferred embodiments the specifications given below are desirable, wherein the flow areas of 54 and 55 are as stated, with the proviso that the ratio limits (of areas 54 / 55 ) of 1.5-30.0 should be adhered to for best results.
Structure Preferred Most Preferred Pump 46 capacity 200-2,000 gal/hr 500-1,000 gal/hr Gap 50 Length 0.5 in.-6.0 in. 1.0 in.-4.0 in. 1/d of inner portion 43 1/1 to 15/1 3/1 to 6/1 Flow Area of 54 0.2 in 2 to 7.0 in 2 0.3 in 2 to 3.0 in 2 Flow Area of 55 0.02 in 2 to 0.4 in 2 0.04 in 2 to 0.2 in 2 Pump Motor 6-24 V. 12-20 V. Mesh opening dia. of filter 100μ-350μ 150μ-250μ
[0022] The best mode known at this time is for the diameter (inside) of 26 to be from about 0.75 in. to about 2.0 in., and the diameter (inside) of 40 to be from about 0.125 in. to about 0.5 in.
[0023] The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications will be effected with the spirit and scope of the invention. | A portable vacuuming device for underwater removal of leaves or the like from pool bottoms and other structural surfaces, the device employing a water pump to feed a water jet within a suction cavity wherein the water inlet for the pump is exterior to the cavity and to the housing of the device. | 4 |
“This is a continuation of U.S. Ser. No. 08/690,535 filed Jul. 31, 1996”, now U.S. Pat. No. 5,945,100.
BACKGROUND OF THE INVENTION
The present invention is generally in the area of delivery vehicles, for therapeutic agents for the treatment of tumors, especially brain tumors.
One-third of all individuals in the United States alone will develop cancer. Although the five-year survival rate has risen dramatically to nearly fifty percent as a result of progress in early diagnosis and the therapy, cancer still remains second only to cardiac disease as a cause of death in the United States. Twenty percent of Americans die from cancer, half due to lung, breast, and colon-rectal cancer.
Designing effective treatments for patients with cancer has represented a major challenge. The current regimen of surgical resection, external beam radiation therapy, and/or systemic chemotherapy has been partially successful in some kinds of malignancies, but has not produced satisfactory results in others. In some malignancies, such as brain malignancies, this regimen produces a median survival of less than one year. For example, 90% of resected malignant gliomas recur within two centimeters of the original tumor site within one year.
Though effective in some kinds of cancers, the use of systemic chemotherapy has had minor success in the treatment of cancer of the colon-rectum, esophagus, liver, pancreas, and kidney and melanoma. A major problem with systemic chemotherapy for the treatment of these types of cancer is that the systemic doses required to achieve control of tumor growth frequently result in unacceptable systemic toxicity. Efforts to improve delivery of chemotherapeutic agents to the tumor site have resulted in advances in organ-directed chemotherapy, as by continuous systemic infusion, for example. However, continuous infusions of anticancer drugs generally have not shown a clear benefit over pulse or short-term infusions. Implantable elastomer access ports with self-sealing silicone diaphragms have also been tried for continuous infusion, but extravasation remains a problem. Portable infusion pumps are now available as delivery devices and are being evaluated for efficacy. (See Harrison's Principles of Internal Medicine 431-446, E. Braunwald et al., ed., McGraw-Hill Book Co. (1987) for a general review).
In the brain, the design and development of effective anti-tumor agents for treatment of patients with malignant neoplasms of the central nervous system have been influenced by two major factors: 1) the blood-brain barrier provides an anatomic obstruction in the normal brain, potentially limiting access of drugs to some regions of the tumors; and 2) the drugs given at high systemic levels are generally cytotoxic. Efforts to improve drug delivery to the tumor bed in the brain have included transient osmotic disruption of the blood brain barrier, cerebrospinal fluid perfusion, local delivery from implanted polymeric controlled release devices and direct infusion into a brain tumor using catheters. Each technique has had significant limitations. Disruption of the blood brain barrier increased the uptake of hydrophilic substances into normal brain, but did not significantly increase substance transfer into the tumor. Only small fractions of agents administered into the cerebrospinal fluid actually penetrated into the brain parenchyma. Controlled release biocompatible polymers for local drug delivery have been utilized for contraception, insulin therapy, glaucoma treatment, asthma therapy, prevention of dental caries, and certain types of cancer chemotherapy. (Langer, R., and D. Wise, eds, Medical Applications of Controlled Release, Vol. I and II, Boca Raton, CRC Press (1986)) Brain tumors have been particularly refractory to chemotherapy. One of the chief reasons is the restriction imposed by the blood-brain barrier. Agents that appear active against certain brain tumors, such as gliomas, in vitro may fail clinical trials because insufficient drug penetrates the tumor. Although the blood-brain barrier is disrupted at the core of a tumor, it is largely intact at the periphery where cells actively engaged in invasion are located. Experimental intratumoral regimens include infusing or implanting therapeutic agents within the tumor bed following surgical resection, as described by Tomita, T, J. Neuro-Oncol. 10:57-74 (1991). Drugs that have been used to treat tumors by infusion have been inadequate, did not diffuse an adequate distance from the site of infusion, or could not be maintained at sufficient concentration to allow a sustained diffusion gradient. The use of catheters has been complicated by high rates of infection, obstruction, and malfunction due to clogging. See T. Tomita, “Interstitial chemotherapy for brain tumors: review” J. Neuro-Oncology 10:57-74 (1991).
Delivery of a low molecular weight, lipid soluble chemotherapeutic, 1,3-bis(2-chloroethyl)-1-nitrosourea (BCNU), in a polymer matrix implanted directly adjacent to brain tumors has some efficacy, as reported by Brem, et al., J. Neurosurg. 74:441-446 (1991); Brem, et al., Eur. J. Pharm. Biopharm. 39(1):2-7 (1993); and Brem, et al., “Intraoperative Chemotherapy using biodegradable polymers: Safety and Effectiveness for Recurrent Glioma Evaluated by a Prospective, Multi-Institutional Placebo-Controlled Clinical Trial” Proc. Amer. Soc. Clin. Oncology May 17, 1994. Polymer-mediated delivery of BCNU was superior to systemic delivery in extending survival of animals with intracranial 9L gliosarcoma and has shown some efficacious results in clinical trials. However, BCNU is a low molecular weight drug, crosses the blood-barrier and had previously been demonstrated to have some efficacy when administered systemically.
For example, one promising chemotherapeutic, camptothecin, a naturally occurring alkaloid isolate from Camptotheca acuminata, a tree indigenous to China, which exerts its pharmacological effects by irreversibly inhibiting topoisomerase I, an enzyme intimately involved in DNA replication, has been shown to have strong cytotoxic anti-tumor activity against a variety of experimental tumors in vitro, such as the L1210 and rat Walker 256 carcinosarcoma (Venditti, J. M., and B. J. Abbott, Lloydia 30:332-348 (1967); Moertel, C. G., et al., Cancer Chemother. Rep. 56(1):95-101 (1972)). Phase I and II clinical trials of camptothecin in human patients with melanoma and advanced gastrointestinal carcinoma, however, have shown unexpectedly severe systemic toxicity with poor tumoral responses, and clinical investigation therefore halted. (Gottlieb, J. A., and J. K. Luce, Cancer Chemother. Rep. 56(1):103-105 (1972); Moertel, C. G., et al., Cancer Chemother. Rep. 56(1):95-101 (1972); Muggia, F. M., et al., Cancer Chemother. Rep. 56(4):515-521 (1972)). Many other chemotherapeutics which are efficacious when administered systemically must be delivered at very high dosages in order to avoid toxicity due to poor bioavailability. For example, paclitaxel (taxol) has been used systemically with efficacy in treating several human tumors, including ovarian, breast, and non-small cell lung cancer. However, maintenance of sufficient systemic levels of the drug for treatment of tumors has been associated with severe, in some cases “life-threatening” toxicity, as reported by Sarosy and Reed, J. Nat. Med. Assoc. 85(6):427-431 (1993). Paclitaxel is a high molecular weight (854), highly lipophilic deterpenoid isolated from the western yew, Taxus brevifolia, which is insoluble in water. It is normally administered intravenously by dilution into saline of the drug dissolved or suspended in polyoxyethylated castor oil. This carrier has been reported to induce an anaphylactic reaction in a number of patients (Sarosy and Reed (1993)) so alternative carriers have been proposed, such as a mixed micellar formulation for parenteral administration, described by Alkan-Onyuksel, et al., Pharm. Res. 11(2), 206-212 (1994).
Gene transfer is rapidly becoming a useful adjunct in the development of new therapies for human malignancy. Tumor cell expression of histocompatibility antigens, cytokines, or growth factors (e.g., IL-2, IL-4, GMCSF) appears to enhance immune-mediated clearance of malignant cells in animal models, and expression of chemo-protectant gene products, such as p-glycoprotein in autologous bone marrow cells, is under study as a means of minimizing marrow toxicity following administration of otherwise lethal doses of chemotherapeutic agents.
Theoretically, the most direct mechanism for tumor cell killing using gene transfer is the selective expression of cytotoxic gene products within tumor cells. Classical enzymatic toxins such as pseudomonas exotoxin A, diphtheria toxin and ricin are unlikely to be useful in this context, since these enzymes kill only cells in which they are expressed, and no current gene transfer vector is capable of gene delivery to a sufficiently high percentage of tumor cells to make use of the above recombinant enzymes.
Another strategy that has been developed to selectively kill tumor cells involves the delivery to replicating tumor cells and expression of genes encoding toxic prodrugs such as the Herpes simplex virus thymidine kinase (HSV-tk) gene followed by treatment with ganciclovir. Ganciclovir is readily phosphorylated by the HSV-tk, and its phosphorylated metabolites are toxic to the cell. Very little phosphorylation of ganciclovir occurs in normal human cells. Although only those cells expressing the HSV-tk should be sensitive to ganciclovir (since its phosphorylated metabolites do not readily cross cell membranes), in vitro and in vivo experiments have shown that a greater number of tumor cells are killed by ganciclovir treatment than would be expected based on the percentage of cells containing the HSV-tk gene. This unexpected result has been termed the “bystander effect” or “metabolic cooperation”. It is thought that the phosphorylated metabolites of ganciclovir may be passed from one cell to another through gap junctions.
Although the bystander effect has been observed in initial experiments using HSV-tk, the limitations present in all current gene delivery vehicles mean that a much greater bystander effect than previously noted will be important to successfully treat human tumors using this approach. One of the difficulties with the current bystander toxicity models is that bystander toxicity with metabolites that do not readily cross the cell membrane will not be sufficient to overcome a low efficiency of gene transfer (e.g., transfection, transduction, etc.). In the known toxin gene therapy systems, the efficiency of transduction and/or transfection in vivo is generally low. An existing protocol for treating brian tumors in humans uses retroviral delivery of HSV-tk, followed by ganciclovir administration. In rat models, using HSV-tk in this context, tumor regressions have been observed (Culver, et al., Science, 256:1550-1552 (1992). The HSV-tk approach has not proven sufficient in humans thus far, although some tumor regressions have been observed.
Similarly, the usefulness of E. coli cytosine deaminase (which converts 5-fluorocytosine to 5-fluorouracil and could theoretically provide substantial bystander toxicity) in this regard remains to be established. Initial studies have shown that cytosine deaminase expression followed by treatment with 5-fluorocytosine in clonogenic assays leads to minimal bystander killing (C. A., Mullen, C. A., M. Kilstrup, R. M. Blaese, Proc. Natl. Acad. Sci. USA, 89:33-37 (1992).
Prodrug activation by an otherwise non-toxic enzyme (e.g., HSV-tk, cytosine deaminase) has advantages over the expression of directly toxic genes, such as ricin, diphtheria toxin, or pseudomonas exotoxin These advantages include the capability to titrate cell killing, optimize therapeutic index by adjusting either levels of prodrug or of recombinant enzyme expression, and interrupt toxicity by omitting administration of the prodrug. However, like other recombinant toxic genes, gene transfer of HSV-tk followed by treatment with ganciclovir is neither optimized to kill bystander cells nor is it certain bystander toxicity will occur in vivo as has been characterized in vitro. An additional problem with the use of the HSV-tk or cytosine deaminase to create toxic metabolites in tumor cells is the fact that the agents activated by HSV-tk (ganciclovir, etc.) and cytosine deaminase (5-fluorocytosine) will kill only cells that are synthesizing DNA (Balzarini, et al., J. Biol. Chem., 268:6332-6337 (1993), and Bruce and Meeker, J. Natl. Cancer Inst., 38: 401-405 (1967). Even if a considerable number of nontransfected cells are killed, one would not expect to kill the nondividing tumor cells with these agents.
It is therefore an object of the present invention to provide vehicles that increase the efficiency of delivery of therapeutic reagents, including viral vectors, cells, nucleic acids, antibodies and other proteins, lipids, and carbohydrates, to tumors, especially brain tumors.
It is a further object of the present invention to provide vehicles that are useful for direct delivery into tumors of drugs in solid or liquid form, as well as genetic material, including genetic material contained within cells.
SUMMARY OF THE INVENTION
The major problem with current direct delivery techniques of therapeutic reagents into solid tumors, especially of cells or large volumes of recombinant DNA reagents or drugs, has been resistance of the tissues to the influx of the fluid and/or cells, resulting in low quantities of the fluid and/or cells penetrating into and remaining in the tumor tissue to be treated. Increased penetration and/or reduced backflow and diversion through the point of entry, so that more material is introduced into and remains in the tumor, is obtained through the use of a viscous vehicle, most preferably having a similar density to tissue, for the material to be delivered. Preferred materials include solutions or suspensions of a polymeric material which gel or solidify at the time of or shortly after injection or implantation. In the preferred embodiment, the solution is injected via a catheter into regions of the tumor to be treated.
DETAILED DESCRIPTION OF THE INVENTION
The general criteria for vehicles for delivery to solid tumors are that the materials must not inactivate the chemotherapeutic agent and must impart to the delivered material a density or viscosity similar to that of tissue.
Materials to be Delivered
As used herein, chemotherapeutic agents include synthetic organic or inorganic drugs, biologically active materials which replace or supplement a normal function such as hormones, angiogenic or anti-angiogenic factors, immunomodulators, and cytotoxic agents such as plantinum based chemotherapeutics, for example, cisplantinum, BCNU and other nitrosourea compounds, cytokines, and others known to those skilled in the art, and genetically engineered materials. Genetically engineered materials include RNA or DNA encoding a toxin, ribozymes, external guide sequences for RNAase P, antisense, triplex forming oligonucleotides, selective or targeted mutagens, and combinations thereof. The genetically engineered materials can be in solution, in suspension, incorporated into a plasmid or viral vector, and/or in a cell.
Gene transfer can be obtained using direct transfer of genetic material, in a plasmid or viral vector, or via transfer of genetic material in cells or carriers such as cationic liposomes. Such methods are well known in the art and readily adaptable for use in the gene mediated toxin therapies described herein. Further, these methods can be used to target certain diseases and cell populations by using the targeting characteristics of the carrier. Transfer vectors can be any nucleotide construction used to deliver genes into cells (e.g., a plasmid), or as part of a general strategy to deliver genes, e.g., as part of recombinant retrovirus or adenovirus (Ram et al. Cancel Res. 53:83-88, 1993). Many types of cells can be transfected using these techniques and reagents. A preferred cell type for treatment of brain tumors is fibroblasts. Bone marrow stem cells and hematopoietic cells are relatively easily removed and replaced from humans, and provide a self-regenerating population of cells for the propagation of transferred genes. When in vitro transfection of cells is performed, once the transfected cells begin producing the proteins encoded by the genes, the cells can be added back to the patient to establish entire pooled populations of cells that are expressing the transfected genes.
One of the most promising methods of gene transfer utilizes recombinant viruses. The development of recombinant adenoviruses as well as retroviral vectors for this purpose has had a number of applications. As used herein, a retrovirus is an animal virus belonging to the virus family of Retroviridae, including any types, subfamilies, genus, or tropisms. Retroviral vectors, in general, are described by Verma, I. M., Retroviral vectors for gene transfer. In MICROBIOLOGY-1985, American Society for Microbiology, pp. 229-232, Washington, 1985, which is incorporated by reference herein. Examples of methods for using retroviral vectors for gene therapy are described in U.S. Pat. Nos. 4,868,116 and 4,980,286; PCT applications WO 90/02806 and WO 89/07136; and Mulligan, Science 260:926-932 (1993); the teachings of which are incorporated herein by reference.
The construction of replication-defective adenoviruses is described by Berkner et al., 1987 J. Virology 61:1213-1220 (1987); Massie et al., 1986 Mol. Cell. Biol. 6:2872-2883 (1986); Haj-Ahmad et al., 1986 J. Virology 57:267-274 (1986); Davidson et al., 1987 J. Virology 61:1226-1239 (1987); Zhang “Generation and identification of recombinant adenovirus by liposome-mediated transfection and PCR analysis” BioTechniques 1993 15:868-872. The benefit of the use of these viruses as vectors is that they are limited in the extent to which they can spread to other cell types, since they can replicate within an initial infected cell, but are unable to form new infectious viral particles. Recombinant adenoviruses have been shown to achieve high efficiency gene transfer after direct, in vivo delivery to airway epithelium, hepatocytes, vascular endothelium, CNS parenchyma and a number of other tissue sites, as reported by Morsy, 1993 J. Clin. Invest. 92:1580-1586; Kirshenbaum, 1993 J. Clin. Invest. 92:381-387; Roessler, 1993 J. Clin. Invest. 92:1085-1092; Moullier, 1993 Nature Genetics 4:154-159; La Salle, 1993 Science 259:988-990; Gomez-Foix, 1992 J. Biol. Chem. 267:25129-25134; Rich, 1993 Human Gene Therapy 4:461476; Zabner, 1994 Nature Genetics 6:75-83; Guzman, 1993 Circulation Research 73:1201-1207; Bout, 1994 Human Gene Therapy 5:3-10; Zabner, 1993 Cell 75:207-216; Caillaud, 1993 Eur. J. Neuroscience 5:1287-1291; and Ragot, 1993 J. Gen. Virology 74:501-507. Recombinant adenoviruses achieve gene transduction by binding to specific cell surface receptors, after which the virus is internalized by receptor-mediated endocytosis, in the same manner as wild type or replication-defective adenovirus, as reported by Chardonnet and Dales, 1970 Virology 40:462-477; Brown and Burlingham, 1973 J. Virology 12:386-396; Svensson and Persson, 1985 J. Virology 55:442-449; Seth, et al., 1984 J. Virol. 51:650-655; Seth, et al., Mol. Cell. Biol. 1984 4:1528-1533; Varga et al., 1991 J. Virology 65:6061-6070 (1991); Wickham et al., 1993 Cell 73:309-319).
The materials may be in solution, suspension (for example, incorporated into microparticles, liposomes, or cells). These may be targeted to a particular cell type via antibodies, receptors, or receptor ligands. The following references are examples of the use of this technology to target specific proteins to tumor tissue (Senter, et al., Bioconjugate Chem., 2:447-451, 1991; Bagshawe, K. D., Br. J. Cancer, 60:275-281, 1989; Bagshawe, et al., Br. J. Cancer, 58:700-703, 1988; Senter, et al., Bioconjugate Chem., 4:3-9, 1993; Battelli, et al., Cancer Immunol. Immunother., 35:421-425, 1992; Pietersz and McKenzie, Immunolog. Reviews, 129:57-80, 1992; and Roffler, et al., Biochem. Pharmacol, 42:2062-2065, 1991. Vehicles such as “stealth” and other antibody conjugated liposomes (including lipid mediated drug targeting to colonic carcinoma), receptor mediated targeting of DNA through cell specific ligands, lymphocyte directed tumor targeting, and highly specific therapeutic retroviral targeting of murine glioma cells in vivo. The following references are examples of the use of this technology to target specific proteins to tumor tissue (Hughes et al., Cancer Research, 49:6214-6220, 1989; and Litzinger and Huang, Biochimica et Biophysica Acta, 1104:179-187, 1992). In general, receptors are involved in pathways of endocytosis, either constitutive or ligand induced. These receptors cluster in clathrincoated pits, enter the cell via clathrin-coated vesicles, pass through an acidified endosome in which the receptors are sorted, and then either recycle to the cell surface, become stored intracellularly, or are degraded in lysosomes. The internalization pathways serve a variety of functions, such as nutrient uptake, removal of activated proteins, clearance of macromolecules, opportunistic entry of viruses and toxins, dissociation and degradation of ligand, and receptor-level regulation. Many receptors follow more than one intracellular pathway, depending on the cell type, receptor concentration, type of ligand, ligand valency, and ligand concentration. Molecular and cellular mechanisms of receptor-mediated endocytosis is reviewed by Brown and Greene, DNA and Cell Biology 1991 10:6, 399-409.
As discussed above, a strategy that has been developed to selectively kill tumor cells involves the delivery to replicating tumor cells and expression of genes encoding toxic prodrugs such as the HSV-tk gene followed by treatment with ganciclovir. Ganciclovir is readily phosphorylated by the HSV-tk, and its phosphorylated metabolites are toxic to the cell. Very little phosphorylation of ganciclovir occurs in normal human cells. Examples of other genetically engineered cells that can be delivered as described herein include cells transfected with the E. coli Deo D gene (purine nucleoside phosphorylase (PNP)) and subsequently treating with a nontoxic nucleoside analog (e.g., deoxyadenosine or deoxyguanosine analogs, including N7 analogs), which is converted to a toxic purine analog. E. coli PNP differs from human PNP in its acceptance of adenine- and certain guanine-containing nucleoside analogs as substrates. E. coli PNP expressed in tumor cells cleaves the nucleoside, liberating a toxic purine base analog. Purine bases freely diffuse across cell membranes, whereas nucleoside monophosphates generally remain inside the cell in which they are formed. The substrate administered to the cells is 9-(β-D-2-deoxyerythropentofuranosyl)-6-methylpurine (MeP-dR). A toxic adenine analog formed after conversion by E. coli PNP can be converted by adenine phosphoribosyl transferase to toxic nucleotides and kill all transfected cells, and diffuse out of the cell and kill surrounding cells that were not transfected (bystander cells).
Sites for Delivery
Although described herein primarily with reference to treatment of tumors, it will be understood by those skilled in the art that other tissues in need of treatment could be treated using the delivery system described herein. Tumors to be treated will generally be solid tumors, which can be located anywhere in the body. Tumors for which the delivery vehicle is particularly useful are brain tumors. Other tissues which can be treated include liver, pancreas, colon, lung, and nervous tissue, including normal and abnormal tissues in the central nervous system. As used herein, the term “tissue” will encompass both normal and transformed tissues, including solid tumors.
Density or Viscosity Modifying Materials
A variety of materials are known which can be adapted for use in the method described herein. It is not required that the material be biocompatible if the treatment is designed to kill tumors; for example, a vehicle which includes a cytotoxic compound such as ethanol may be used to facilitate delivery and efficacy of a chemotherapeutic agent to tumors.
Preferred materials are polymers which solidify or gel at the site of delivery. Polymeric solutions or suspensions can be formulated which solidify by formation of ionic or covalent coupling of the polymer, for example, through interactions with cations such as calcium, changes in pH, changes in temperature, and polymerization.
Polymer Solutions
The polymeric material which is mixed with cells or other materials for injection into the body should preferably form a hydrogel A hydrogel is defined as a substance formed when an organic polymer (natural or synthetic) is cross-linked via covalent, ionic, or hydrogen bonds to create a three-dimensional open-lattice structure which entraps water molecules to form a gel. Naturally occurring and synthetic hydrogel forming polymers, polymer mixtures and copolymers may be utilized as hydrogel precursors. Examples of materials which can be used to form a hydrogel include polysaccharides such as alginate and modified alginates, synthetic polymers such as polyphosphazines, and polyacrylates, which are crosslinked ionically, or block copolymers such as Pluronics or Tetronics™, polyethylene oxide-polypropylene glycol block copolymers which are crosslinked by temperature or pH, respectively. Other materials include proteins such as fibrin, polymers such as polyvinylpyrrolidone, hyaluronic acid and collagen.
Natural Polymer Solutions
In one embodiment, the polymers are natural polymers such as proteins and polysaccharides. In the preferred embodiment, the protein solution is cryoprecipitate or fibrinogen derived from the patient to be treated. Proteins and polysaccharides can be ionically linked, typically by the addition of cations, crosslinked chemically for example using glutaraldehyde, or by chemical denaturation.
In a particularly preferred embodiment, cryoprecipitate is prepared from a plasma sample obtained directly from the patient. One unit of human blood consists of approximately 350 to 450 mls, which is preferably collected in ACD (citric acid-dextrose) anticoagulant, although other acceptable anticoagulants can be used such as ethylene diamine tetraacetate. The red blood cells are removed by centrifugation or filtration, and the separated plasma chilled at 4 C. until cryoprecipitate is formed, typically about three days. Cryoprecipitate consists predominantly of fibrinogen Fresh frozen plasma can also be used.
Purified fibrinogen is also available from commercial suppliers such as Sigma Chemical Co., Baxter Diagnostics, and Ortho Pharmaceuticals. As used herein, the term “fibrinogen” is intended to encompass either cryoprecipitate or purified fibrinogen, unless specifically stated otherwise. Other materials that can be used as a source of fibrinogen besides cryoprecipitate, fresh frozen plasma, and purified fibrinogen, include factor VIII concentrate, platelet concentrate, and platelet rich plasma. Proteins other than fibrinogen can be substituted for the fibrinogen where the protein can be prepared and crosslinked using a physiologically acceptable crosslinker such as calcium. An advantage of the fibrinogen is that it is readily obtained in sufficient quantities merely by drawing blood from the intended recipient so that there is no problem with patient rejection of the implant or introduction of infectious agents harbored by the fibrinogen donor.
Alginate is a carbohydrate polymer isolated from seaweed, which can be crosslinked to form a hydrogel by exposure to a divalent cation such as calcium, as described, for example in WO 94/25080, the disclosure of which is incorporated herein by reference. Alginate is ionically crosslinked in the presence of divalent cations, in water, at room temperature, to form a hydrogel matrix. Due to these mild conditions, alginate has been the most commonly used polymer for hybridoma cell encapsulation, as described, for example, in U.S. Pat. No. 4,352,883 to Lim. In the Lim process, an aqueous solution containing the biological materials to be encapsulated is suspended in a solution of a water soluble polymer, the suspension is formed into droplets which are configured into discrete microcapsules by contact with multivalent cations, then the surface of the microcapsules is crosslinked with polyamino acids to form a semipermeable membrane around the encapsulated materials.
Examples of other materials which can be used to form a hydrogel include modified alginates. Modified alginate derivatives may be synthesized which have an improved ability to form hydrogels. The use of alginate as the starting material is advantageous because it is available from more than one source, and is available in good purity and characterization. As used herein, the term “modified alginates” refers to chemically modified alginates with modified hydrogel properties. Naturally occurring alginate may be chemical modified to produce alginate polymer derivatives that degrade more quickly. For example, alginate may be chemically cleaved to produce smaller blocks of gellable oligosaccharide blocks and a linear copolymer may be formed with another preselected moiety, e.g. lactic acid or ε-caprolactone. The resulting polymer includes alginate blocks which permit ionically catalyzed gelling, and oligoester blocks which produce more rapid degradation depending on the synthetic design. In the embodiment wherein modified alginates and other anionic polymers that can form hydrogels which are malleable are used to encapsulate cells, the hydrogel is produced by cross-linking the polymer with the appropriate cation, and the strength of the hydrogel bonding increases with either increasing concentrations of cations or of polymer. Concentrations from as low as 0.001 M have been shown to cross-link alginate. Higher concentrations are limited by the toxicity of the salt. Alternatively, alginate polymers may be used, wherein the ratio of mannuronic acid to guluronic acid does not produce a firm gel, which are derivatized with hydrophobic, water-labile chains, e.g., oligomers of ecaprolactone. The hydrophobic interactions induce gelation, until they degrade in the body.
Additionally, polysaccharides which gel by exposure to monovalent cations, including bacterial polysaccharides, such as gellan gum, and plant polysaccharides, such as carrageenans, may be crosslinked to form a hydrogel using methods analogous to those available for the crosslinking of alginates described above. Polysaccharides which gel in the presence of monovalent cations form hydrogels upon exposure, for example, to a solution comprising physiological levels of sodium. Hydrogel precursor solutions also may be osmotically adjusted with a nonion, such as mannitol, and then injected to form a gel.
Synthetic Ionically Cross-linkable Polymers
In general, these polymers are at least partially soluble in aqueous solutions, such as water, buffered salt solutions, or aqueous alcohol solutions, that have charged side groups, or a monovalent ionic salt thereof. Examples of polymers with acidic side groups that can be reacted with cations are poly(phosphazenes), poly(acrylic acids), poly(methacrylic acids), copolymers of acrylic acid and methacrylic acid, poly(vinyl acetate), and sulfonated polymers, such as sulfonated polystyrene. Copolymers having acidic side groups formed by reaction of acrylic or methacrylic acid and vinyl ether monomers or polymers can also be used. Examples of acidic groups are carboxylic acid groups, sulfonic acid groups, halogenated (preferably fluorinated) alcohol groups, phenolic OH groups, and acidic OH groups.
Examples of polymers with basic side groups that can be reacted with anions are poly(vinyl amines), poly(vinyl pyridine), poly(vinyl imidazole), and some imino substituted polyphosphazenes. The ammonium or quaternary salt of the polymers can also be formed from the backbone nitrogens or pendant imino groups. Examples of basic side groups are amino and imino groups.Methods for the synthesis of the polymers described above are known to those skilled in the art. See, for example Concise Encyclopedia of Polymer Science and Polymeric Amines and Ammonium Salts, E. Goethals, editor (Pergamen Press, Elmsford, N.Y. 1980). Many polymers, such as poly(acrylic acid), are commercially available.
The water soluble polymer with charged side groups is crosslinked by reacting the polymer with an aqueous solution containing multivalent ions of the opposite charge, either multivalent cations if the polymer has acidic side groups or multivalent anions if the polymer has basic side groups. Examples of cations for cross-linking of the polymers with acidic side groups to form a hydrogel are monovalent cations such as sodium, and multivalent cations such as copper, calcium, aluminum, magnesium, strontium, barium, and tin, and di-, tri- or tetra-functional organic cations such as alkylammonium salts. The preferred cations for cross-linking of the polymers with acidic side groups to form a hydrogel are divalent and trivalent cations such as copper, calcium, aluminum, magnesium, strontium, barium, and tin. Aqueous solutions of the salts of these cations are added to the polymers to form soft, highly swollen hydrogels and membranes. Aqueous solutions of the salts of these cations are added to the polymers to form soft, highly swollen hydrogels and membranes. The higher the concentration of cation, or the higher the valence, the greater the degree of cross-linking of the polymer. Concentrations from as low as 0.005 M have been demonstrated to cross-link the polymer. Higher concentrations are limited by the solubility of the salt.
The preferred anions for cross-linking of the polymers to form a hydrogel are monovalent, divalent or trivalent anions such as low molecular weight dicarboxylic acids, for example, terepthalic acid, sulfate ions and carbonate ions. Aqueous solutions of the salts of these anions are added to the polymers to form soft, highly swollen hydrogels and membranes, as described with respect to cations.
A variety of polycations can be used to complex and thereby stabilize the polymer hydrogel into a semi-permeable surface membrane. Examples of materials that can be used include polymers having basic reactive groups such as amine or imine groups, having a preferred molecular weight between 3,000 and 100,000, such as polyethyleneimine and polylysinc. These are commercially available. One polycation is poly(L-lysine); examples of synthetic polyamines are: polyethyleneimine, poly(vinylamine), and poly(allyl amine). There are also natural polycations such as the polysaccharide, chitosan.
Polyanions that can be used to form a semi-permeable membrane by reaction with basic surface groups on the polymer hydrogel include polymers and copolymers of acrylic acid, methacrylic acid, and other derivatives of acrylic acid, polymers with pendant S 0 3 H groups such as sulfonated polystyrene, and polystyrene with carboxylic acid groups.
Synthetic Polymers Crosslinkable by Hydrogen Bonding
Other polymeric hydrogel precursors include polyethylene oxide-polypropylene glycol block copolymers such as Pluronics™ or Tetronics™, which are crosslinked by hydrogen bonding and/or by a temperature change, as described in Steinleitner et al., Obstetrics & Gynecology, 77:48-52 (1991); and Steinleitner et al., Fertility and Sterility, 57:305-308 (1992).
Polymer mixtures also may be utilized. For example, a mixture of polyethylene oxide and polyacrylic acid which gels by hydrogen bonding upon mixing may be utilized. In one embodiment, a mixture of a 5% w/w solution of polyacrylic acid with a 5% w/w polyethylene oxide (polyethylene glycol, polyoxyethylene) 100,000 can be combined to form a gel over the course of time, e.g., as quickly as within a few seconds.
Synthetic Covalently Crosslinkable Polymers
Covalently crosslinkable hydrogel precursors also are useful. For example, a water soluble polyamine, such as chitosan, can be cross-linked with a water soluble diisothiocyanate, such as polyethylene glycol diisothiocyanate. The isothiocyanates will react with the amines to form a chemically crosslinked gel. Aldehyde reactions with amines, e.g., with polyethylene glycol dialdehyde also may be utilized. A hydroxylated water soluble polymer also may be utilized.
Alternatively, polymers may be utilized which include substituents which are crosslinked by a radical reaction upon contact with a radical initiator. For example, polymers including ethylenically unsaturated groups which can be photochemically crosslinked may be utilized, as disclosed in WO 93/17669, the disclosure of which is incorporated herein by reference.
In this embodiment, water soluble macromers that include at least one water soluble region, a biodegradable region, and at least two free radical-polymerizable regions, are provided The macromers are polymerized by exposure of the polymerizable regions to free radicals generated, for example, by photosensitive chemicals and or light. Examples of these macromers are PEG-oligolactyl-acrylates, wherein the acrylate groups are polymerized using radical initiating systems, such as an eosin dye, or by brief exposure to ultraviolet or visible light. Additionally, water soluble polymers which include cinnamoyl groups which may be photochemically crosslinked may be utilized, as disclosed in Matsuda et at., ASAID Trans., 38:154-157 (1992).
Density Modifying Agents
Although described herein particularly with reference to polymers which increase the viscosity and/or density of the material to be injected into the tissue to be treated, other materials could also be used which are not polymers. Many agents which increase viscosity or density are routinely used, especially in the food and medical industry. Generally, these include proteins such as albumin, sugars such as dextran, glucose and fructose, and strarches, although these are technically polymers. As used herein, the term “polymers ” encompasses the addition of monomers or single unit material that function to increase the viscosity and/or density of the solution to be injected into the tissue to be treated.
Polysaccharides that are very viscous liquids or are thixotropic, and form a gel over time by the slow evolution of structure, are especially useful. For example, hyaluronic acid, which forms an injectable gel with a consistency like a hair gel, may be utilized. Modified hyaluronic acid derivatives are particularly useful. As used herein, the term “modified hyaluronic acids” refers to chemically modified hyaluronic acids. Modified hyaluronic acids may be designed and synthesized with preselected chemical modifications to adjust the rate and degree of crosslinking and biodegradation. For example, modified hyaluronic acids may be designed and synthesized which are esterified with a relatively hydrophobic group such as propionic acid or benzylic acid to render the polymer more hydrophobic and gel-forming, or which are grafted with amines to promote electrostatic self-assembly Modified hyaluronic acids thus may be synthesized which are injectable, in that they flow under stress, but maintain a gel-like structure when not under stress. Hyaluronic acid and hyaluronic derivatives are available from Genzyme, Cambridge, Mass. and Fidia, Italy.
Other materials that are dense and/or viscous include many of the lipids and sterols such as cholesterol, oils and fats.
Cell Suspensions
Preferably the polymer or density modifying agent is dissolved in an aqueous solution, preferably a 0.1 M potassium phosphate solution, at physiological pH, to a concentration yielding the desired density, for example, for alginate, of between 0.5 to 2% by weight, preferably 1%, alginate. The isolated cells are suspended in the polymer solution to a concentration of between 1 and 100 million cells/ml, most preferably approximately 100 million cells/mi. In a preferred embodiment, the polymer is fibrinogen and the cells are added to one ml of commercially available thrombin to a concentration of 100 million cells, then added to an equivalent volume of fibrinogen for injection into the tumor.
Combinations of materials increasing viscosity and density, as described above, may also be utilized.
Additives
A variety of materials can be added to the polymer-cell solution. Examples of useful materials include proteins, polysaccharides, nucleic acids, vitamins and metals or ions (calcium, sodium and potassium), and synthetic organic molecules. Examples include enzymes such as collagenase inhibitors, hemostatic agents such as thrombin, fibrinogen or calcium ions, growth factors, angiogenic factors and other growth effector molecules, bacteriostatic or bacteriocidal factors, antiinflammatories, anti-angiogenic agents, and vitamins. Growth effector molecules, as used herein, refer to molecules that bind to cell surface receptors and regulate the growth, replication or differentiation of target cells or tissue Preferred growth effector molecules are growth factors and extracellular matrix molecules. Examples of growth factors include epidermal growth factor (EGF), platelet-derived growth factor (PDGF), transforming growth factors (TGFá, TGFâ), hepatocyte growth factor, heparin binding factor, insulin-like growth factor I or II, fibroblast growth factor (FGF), VEGF, LPA, erythropoietin, nerve growth factor, bone morphogenic proteins, muscle morphogenic proteins, and other factors known to those of skill in the art. Additional growth factors are described in “Peptide Growth Factors and Their Receptors I”M. B. Sporn and A. B. Roberts, eds. (Springer-Verlag, New York, 1990), for example, the teachings of which are incorporated by reference herein. Growth factors which are preferred when the material to be injected is fibroblasts, especially skin fibroblasts, are EGF and FGF. Many growth factors are also available commercially from vendors, such as Sigma Chemical Co. of St. Louis, Mo., Collaborative Research, Genzyme, Boehringer, R&D Systems, and GIBCO, in both natural and recombinant forms. Examples of extracellular matrix molecules include fibronectin, laminin, collagens, and proteoglycans. Other extracellular matrix molecules are described in Kleinman et al. (1987) or are known to those skilled in the art. Other growth effector molecules include cytokines, such as the interleukins and GM-colony stimulating factor, and hormones, such as insulin. These are also described in the literature and are commercially available. Collagenase inhibitors, including tissue inhibitor metalloproteinase (TIMP), may also be useful as growth effector molecules. Examples of hemostatic agents include thrombin, Factor Xa, fibrinogen, and calcium ions, typically in the form of calcium chloride or calcium gluconate. Vasoconstrictive agents such as epinephrine can also be used to contract blood vessels and thereby decrease bleeding. Bacteriostatic and bacteriocidal agents include antibiotics and other compounds used for preventing or treating infection in wounds.
The bioactive agents are typically incorporated in a range of nanograms to micrograms in a volume of 0.1 ml, although they can also be applied in dry form, as a paste or suspension.
Modifications and variations of the present invention will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims. | The major problem with current direct delivery techniques of therapeutic reagents into solid tumors, especially of cells or large volumes of recombinant DNA reagents or drugs, has been resistance of the tissues to the influx of the fluid and/or cells, resulting in low quantities of the fluid and/or cells penetrating into and remaining in the tumor tissue to be treated. Increased penetration and/or reduced backflow and diversion through the point of entry, so that more material is introduced into and remains in the tumor, is obtained through the use of a viscous vehicle, most preferably having a similar density to tissue, for the material to be delivered. Preferred materials include solutions or suspensions of a polymeric material which gel or solidify at the time of or shortly after injection or implantation. In the preferred embodiment, the solution is injected via a catheter into regions of the tumor to be treated. | 0 |
TECHNICAL FIELD
The present invention relates to a key input device identifying an operated key in a plurality of keys.
BACKGROUND ART
Conventional electronic equipment has a number of keys for performing various setup and switching of operation with respect to the equipment at a front or a side thereof. In such electronic equipment, when any key is operated, a signal (voltage signal) corresponding to the key is supplied to, for example, a microcomputer provided in the electronic equipment. The microcomputer identifies the operated key based on the supplied signal (voltage signal) and controls the operation of the electronic equipment based on a result of identification.
Patent literatures No. 1 to No. 3 mentioned below describe common means for identifying the operated key based on the signal (voltage signal) supplied to the microcomputer.
Patent literature No. 1 describes a key matrix circuit. In this circuit, when any selection key is pressed in a keyboard with a plurality of selection keys arranged in a matrix, two pairs of voltage levels corresponding to the pressed selection key are detected, and the pressed selection key is identified based on the detection result.
Patent literature No. 2 describes a key switch circuit comprising a plurality of switch groups and a hold switch for holding an operation command by a key switch. The key switch circuit is provided with a hold circuit. When no key switch in the key switch groups is operated, the hold circuit holds a voltage at a particular value different from a value of an output voltage generated in the key switch circuit, whereby it is capable of determining whether the key switch circuit is connected or not, without increasing the number of input ports for such as CPU (Central Processing Unit).
Patent literature No. 3 describes a key input device. In this key input device, each one end of a plurality of resistor string parts to produce the resistance value corresponding to the input key is connected electrically to a power supply, and a selection part electrically connects one of the plurality of resistor string parts to ground in response to a selection command from a control unit. Further, one of the resistor string parts corresponding to the selection command from the control unit is electrically connected to the power supply and, when a value of the voltage corresponding to the input key at the resistor string part is generated at a connecting node, the control unit identifies the input key based on the value of the voltage generated at the connecting node and the selection command given to the selection part.
CITATION LIST
Patent Literature
Patent Literature 1: Japanese Laid-Open Patent Publication No. 2001-51774
Patent Literature 2: Japanese Laid-Open Patent Publication No. 2000-137567
Patent Literature 3: Japanese Laid-Open Patent Publication No. 2007-323295
SUMMARY OF INVENTION
Technical Problems
In the circuits and the device described in the above patent literatures, a plurality of resistors are connected in series as means for identifying the operated key based on the signal (voltage signal) supplied to the microcomputer, and the operated key is identified based on a divided voltage according to the series-connected resistors.
Accordingly, if the number of keys to be identified is increased, the number of resistors required for identifying keys should be also increased. This causes a problem that the cost increases as the number of keys increases. In addition, increase in the number of resistors causes enlargement of circuit and more power consumption.
In view of the above problems, the present invention aims to provide a key input device capable of reducing the cost by suppressing the increase in the number of resistors even if the number of keys to be identified increases.
Solution to Problems
A key input device according to the present invention includes a plurality of keys, a limit resistor whose one end is connected to a power supply and a voltage dividing circuit connected to the other end of the limit resistor to generate different voltages corresponding to each key when any of the plurality of keys is operated, and identifies the operated key based on the voltage generated by the voltage dividing circuit. The voltage dividing circuit includes a plurality of resistors and a plurality of switches each of which is corresponding to each of the plurality of keys. The plurality of switches are composed of a first switch group and a second switch group. A plurality of circuits each of which has one resistor out of the plurality of resistors and one switch in the first switch group are provided, where the resistor and the switch are connected in series. The plurality of circuits are connected in parallel so that one end thereof is connected to the limit resistor and the other end thereof is grounded. Each circuit in the parallel-connected circuits has a connecting point between the resistor and the switch, and one switch in the second switch group is connected between the connecting point in one circuit and the connecting point in another circuit, and each resistor of at least two circuits is connected in parallel by said one switch.
In the above configuration, the circuits having the switch (first group) and the resistor connected in series are connected in parallel, and the switch (second group) is arranged between the connecting points of the switch (first group) and the resistor in each circuit. Thus, compared to the voltage dividing circuit where the plurality of resistors are connected in series, it is possible to generate more various divided voltages of different voltage values. Therefore, if a voltage dividing circuit is configured with the same number of resistors, the device of the present invention can identify more keys than conventional devices. Accordingly, it is possible to reduce the cost by suppressing the increase in the number of resistors even if the number of keys increases.
In the key input device of the present invention, the plurality of resistors may have different resistance values with each other.
According to this, the voltage dividing circuit can generate divided voltages of different values easily, thereby preventing the misidentification of keys due to the voltage values being close to each other.
Advantageous Effects of Invention
According to the present invention, it is possible to provide the key input device capable of reducing the cost by suppressing the increase in the number of resistors, even if the number of keys to be identified increases.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram showing a configuration of a key input device.
FIG. 2 is a diagram showing an example of a configuration of a voltage dividing circuit according to an embodiment of the present invention.
FIG. 3 is a diagram showing another example of a configuration of a voltage dividing circuit according to an embodiment of the present invention.
FIG. 4 is a diagram showing an example of a conversion table.
FIG. 5 is a diagram showing another example of a conversion table.
FIG. 6 is a diagram showing an example of a configuration of a conventional voltage dividing circuit.
FIG. 7 is another example of a configuration of a conventional voltage dividing circuit.
DESCRIPTION OF EMBODIMENTS
An embodiment of the present invention will be described hereinafter with reference to the drawings.
First, a configuration of the general key input device will be described with a block diagram of FIG. 1 . As illustrated in FIG. 1 , a key input device 1 comprises an input circuit 10 having a plurality of keys and an arithmetic processing circuit 20 for identifying keys to which the input operation is performed based on a voltage signal supplied from the input circuit 10 .
The input circuit 10 comprises a key K, a power supply 11 , a voltage dividing circuit 12 , an output port 13 outputting a voltage signal, and a limit resistor 14 whose one end is connected to the power supply 11 and the other end is connected to the voltage dividing circuit 12 through a connecting line 15 . The output port 13 is connected to a connecting point P of the limit resistor 14 and the voltage dividing circuit 12 . The voltage value of the power supply 11 is V 0 and the resistance value of the limit resistor 14 is R 1 .
The arithmetic processing circuit 20 is an LSI (Large Scale Integration) and includes, for example, a control unit 21 , an input port 22 , an A/D converter 23 , a temporary memory 24 , a memory 25 and the output unit 26 .
The control unit 21 is a CPU (Central Processing Unit), and generally controls each part of the arithmetic processing circuit 20 .
The input port 22 receives a voltage signal supplied from the output port 13 of the input circuit 10 , and then supplies the signal to the A/D converter 23 . The A/D converter 23 converts the input voltage signal from an analog signal to a digital signal.
The temporary memory 24 is, for example, a RAM (Random Access Memory) and is provided with a storage area to store the voltage signal outputted from the A/D converter 23 temporarily.
The memory 25 is, for example, a ROM (Read Only Memory) and includes various programs which are executed by the control unit 21 and data which is read when the various programs are executed.
Specifically, the memory 25 includes a identification program 25 a which performs key identification based on the voltage signal (voltage value) supplied from the input circuit 10 , and a conversion table 25 b recording the voltage signal (voltage value) supplied to the input port 22 and the kind of the key to be identified so that they are associated with each other. The conversion table 25 b will be described below in detail.
The output unit 26 supplies information regarding the key (hereinafter, described as “key information”) identified by execution of the identification program 25 a to a device (not illustrated) such as a DVD (Digital Versatile Disc) player connected with the key input device 1 .
In the key input device 1 configured as above, when identification of the key to which the input operation is performed, a voltage which is previously set for every key is generated by the voltage dividing circuit 12 . The generated divided voltage i.e. a voltage signal is supplied to the arithmetic processing circuit 20 through a connecting line 15 and the output port 13 . Then in the arithmetic processing circuit 20 , under control of the control unit 21 , key identification based on the voltage signal inputted to the input port 22 is executed with the identification program 25 a and the conversion table 25 b.
Here, a voltage dividing circuit 12 c indicated in FIG. 6 and a voltage dividing circuit 12 d indicated in FIG. 7 are taken as conventional examples of the voltage dividing circuit 12 .
First, in FIG. 6 , the voltage dividing circuit 12 c includes three resistors 16 c to 18 c and four switches (SW 51 to SW 54 ) corresponding to, respectively, four keys (KEY 51 to KEY 54 ) to which the input operation is performed. Resistance values of the resistors 16 c to 18 c are R 2 to R 4 , respectively.
In the voltage dividing circuit 12 c , the resistors 16 c to 18 c are connected in series. One end of the switch SW 51 is connected to a connecting point P 51 of the connecting line 15 and the resistor 16 c . Similarly, one end of the switch SW 52 is connected to a connecting point P 52 of the resistor 16 c and the resistor 17 c , one end of the switch SW 53 is connected to a connecting point P 53 of the resistor 17 c and the resistor 18 c , and one end of the switch SW 54 is connected to an end of the resistor 18 c.
The other end of the switch SW 51 is connected to a connecting point P 54 provided on one end of a ground line L 21 connecting the switches (SW 51 to SW 54 ) in common. Similarly, the other end of the switch SW 52 is connected to a connecting point P 55 provided on the ground line L 21 , the other end of the switch SW 53 is connected to a connecting point P 56 provided on the ground line L 21 , and the other end of the switch SW 54 is connected to a connecting point P 57 provided on the other end of the ground line L 21 .
Further, since the connecting point P 54 provided on one end of the ground line L 21 is also connected to a ground point G, the other ends of the switches (SW 51 to SW 54 ) are connected to the ground point G in common through the ground line L 21 .
In the above configuration, when the KEY 51 is operated, for example, one end of the connecting line 15 and the ground point G are short-circuited by the switch SW 51 connected between the connecting points P 51 and P 54 . Therefore, a divided voltage generated in the voltage dividing circuit 12 c , that is, an input voltage V 1 which is supplied from the connecting point P to the output port 13 ( FIG. 1 ) is indicated as V 1 =0.
Similarly, when the KEY 52 is operated, for example, one end of the resistor 16 c and the ground point G are short-circuited by the switch SW 52 connected between the connecting points P 52 and P 55 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 /(R 1 +R 2 ).
When the KEY 53 is operated, one end of the resistor 17 c and the ground point G are short-circuited by the switch SW 53 connected between the connecting points P 53 and P 56 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·(R 2 +R 3 )/(R 1 +R 2 +R 3 ).
When the KEY 54 is operated, one end of the resistor 18 c and the ground point G are short-circuited by the switch SW 54 connected between an end of the resistor 18 c and the connecting point P 57 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·(R 2 +R 3 +R 4 )/(R 1 +R 2 +R 3 +R 4 ).
As described above, in the voltage dividing circuit 12 c , four kinds of divided voltages of different values are generated by short-circuiting the predetermined portion in the circuit 12 c with one of the switches SW 51 to SW 54 by key operation. And the divided voltages generated in the circuit 12 c are supplied to the output port 13 through the connecting point P as the input voltage V 1 .
Next, in FIG. 7 , the voltage dividing circuit 12 d includes four resistors 16 d to 19 d and five switches (SW 61 to SW 65 ) corresponding to, respectively, five keys (KEY 61 to KEY 65 ) to which the input operation is performed. Resistance values of the resistors 16 d to 19 d are R 2 to R 5 , respectively.
In the voltage dividing circuit 12 d , the resistors 16 d to 19 d are connected in series. One end of the switch SW 61 is connected to a connecting point P 61 of the connecting line 15 and the resistor 16 d . Similarly, one end of the switch SW 62 is connected to a connecting point P 62 of the resistors 16 d and 17 d , one end of the switch SW 63 is connected to a connecting point P 63 of the resistors 17 d and 18 d , one end of the switch SW 64 is connected to a connecting point P 64 of the resistors 18 d and 19 d , and one end of the switch SW 65 is connected to an end of the resistor 19 d.
The other end of the switch SW 61 is connected to a connecting point P 65 provided on one end of a ground line L 31 connecting the switches (SW 61 to SW 65 ) in common. Similarly, the other end of the switch SW 62 is connected to a connecting point P 66 provided on the ground line L 31 , the other end of the switch SW 63 is connected to a connecting point P 67 provided on the ground line L 31 , the other end of the switch SW 64 is connected to a connecting point P 68 provided on the ground line L 31 , and the other end of the switch SW 65 is connected to a connecting point P 69 provided on the other end of the ground line L 31 .
Further, since the connecting point P 65 provided on one end of the ground line L 31 is also connected to the ground point G, the other ends of the switches (SW 61 to SW 65 ) are connected to the ground point G in common through the ground line L 31 .
In the above configuration, when the KEY 61 is operated, for example, one end of the connecting line 15 and the ground point G are short-circuited by the switch SW 61 connected between the connecting points P 61 and P 65 . Therefore, a divided voltage generated in the voltage dividing circuit 12 d , that is, an input voltage V 1 supplied from the connecting point P to the output port 13 is indicated as V 1 =0.
When the KEY 62 is operated, one end of the resistor 16 d and the ground point G are short-circuited by the switch SW 62 connected between the connecting points P 62 and P 66 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 /(R 1 +R 2 ).
When the KEY 63 is operated, one end of the resistor 17 d and the ground point G are short-circuited by the switch SW 63 connected between the connecting points P 63 and P 67 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·(R 2 +R 3 )/(R 1 +R 2 +R 3 ) When the KEY 64 is operated, one end of the resistor 18 d and the ground point G are short-circuited by the switch SW 64 connected between the connecting points P 64 and P 68 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·(R 2 +R 3 +R 4 )/(R 1 +R 2 +R 3 +R 4 ).
When the KEY 65 is operated, an end of the resistor 19 d and the ground point G are short-circuited by the switch SW 65 connected between the end of the resistor 19 d and the connecting point P 69 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·(R 2 +R 3 +R 4 +R 5 )/(R 1 +R 2 +R 3 +R 4 +R 5 ).
As described above, in the voltage dividing circuit 12 d , five kinds of divided voltages of different values are generated by short-circuiting the predetermined portion in the circuit 12 d with one of the switches SW 61 to SW 65 by key operation. And the divided voltages generated in the circuit 12 d are supplied to the output port 13 through the connecting point P as the input voltage V 1 .
When no key is operated in the voltage dividing circuits 12 c and 12 d , the above-mentioned divided voltages are not generated in each voltage dividing circuit. Therefore, the input voltage V 1 having voltage value of V 0 is supplied from the power supply 11 to the output port 13 through the limit resistor 14 .
Consequently, if the voltage dividing circuit 12 in FIG. 1 is the conventional voltage dividing circuit 12 c ( FIG. 6 ) having three resistors 16 c to 18 c , five kinds of input voltages V 1 of different values are supplied to the arithmetic processing circuit 20 through the output port 13 . Therefore, the arithmetic processing circuit 20 can identify five different kinds of keys by performing a predetermined process based on the input voltage V 1 .
Similarly, if the voltage dividing circuit 12 in FIG. 1 is the conventional voltage dividing circuit 12 d ( FIG. 7 ) having four resistors 16 d to 19 d , six kinds of input voltages V 1 of different values are supplied to the arithmetic processing circuit 20 through the output port 13 . Therefore, the arithmetic processing circuit 20 can identify six different kinds of keys by performing a predetermined process based on the input voltage V 1 .
However, in such configuration as the voltage dividing circuits 12 c and 12 d where resistors are connected in series, if the number of keys to be identified increases, a large number of resistors should be provided and the cost increases as the number of components increases.
Therefore, in the present embodiment, the circuit configurations such as the voltage dividing circuit 12 a in FIG. 2 and the voltage dividing circuit 12 b in FIG. 3 are employed to solve the above problem.
First, the voltage dividing circuit 12 a in FIG. 2 includes three resistors, i.e. a resistor 16 a whose resistance value is R 2 , a resistor 17 a whose resistance value is R 3 and a resistor 18 a whose resistance value is R 4 . The voltage dividing circuit 12 a is composed of a circuit L 1 where only a switch SW 1 is connected, a circuit L 2 where the resistor 16 a and a switch SW 2 are connected in series, a circuit L 3 where the resistor 17 a and a switch SW 3 are connected in series, and a circuit L 4 where the resistor 18 a and a switch SW 4 are connected in series. The resistance values R 2 to R 4 are different from each other. For example, R 2 =0.8 kΩ, R 3 =1.5 kΩ and R 4 =3.0 kΩ. With such different resistance values, divided voltages of different voltage values can be easily generated.
Specifically, the circuits L 1 to L 4 are connected in parallel. One end of this parallel circuit is connected to the limit resistor 14 through the connecting line 15 , and the other end of the parallel circuit is connected to the ground point G.
Also, between the resistor 16 a and the switch SW 2 of the circuit L 2 , three connecting points P 1 to P 3 are provided in order from the resistor 16 a side. Similarly, between the resistor 17 a and the switch SW 3 of the circuit L 3 , three connecting points P 4 to P 6 are provided in order from the resistor 17 a side, and between the resistor 18 a and the switch SW 4 of the circuit L 4 , three connecting points P 7 to P 9 are provided in order from the resistor 18 a side.
Further, a switch SW 5 for short-circuiting the resistors 16 a and 17 a is provided between the connecting points P 1 and P 4 . Similarly, a switch SW 6 for short-circuiting the resistors 16 a and 18 a is provided between the connecting points P 2 and P 8 , a switch SW 7 for short-circuiting the resistors 17 a and 18 a is provided between the connecting points P 5 and P 7 , and a switch SW 8 for short-circuiting the resistors 16 a , 17 a and 18 a is provided between the connecting points P 3 and P 6 (P 9 ).
The above four switches SW 5 to SW 8 have three contacts respectively and the middle contacts thereof are connected to the ground point G in common.
In the voltage dividing circuit 12 a having above-described configuration, the switches SW 1 to SW 8 correspond to, respectively, eight keys (KEY 1 to KEY 8 ) to which the input operation is performed. The switches SW 1 to SW 4 compose the first switch group in the present invention and the switches SW 5 to SW 8 compose the second switch group in the present invention.
Thus, when the KEY 1 is operated, for example, one end of the connecting line 15 and the ground point G are short-circuited by the switch SW 1 . Therefore, a divided voltage generated in the voltage dividing circuit 12 a , that is, the input voltage V 1 supplied from the connecting point P to the output port 13 is indicated as V 1 =0.
When the KEY 2 is operated, one end of the resistor 16 a and the ground point G are short-circuited by the switch SW 2 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 /(R 1 +R 2 ).
When the KEY 3 is operated, one end of the resistor 17 a and the ground point G are short-circuited by the switch SW 3 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 3 /(R 1 +R 3 ).
When the KEY 4 is operated, one end of the resistor 18 a and the ground point G are short-circuited by the switch SW 4 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 4 /(R 1 +R 4 ).
When the KEY 5 is operated, one end of the resistor 16 a and one end of the resistor 17 a are short-circuited by the switch SW 5 and connected to the ground point G through the switch SW 5 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 ·R 3 /(R 1 ·R 2 +R 1 ·R 3 +R 2 ·R 3 ).
When the KEY 6 is operated, one end of the resistor 16 a and one end of the resistor 18 a are short-circuited by the switch SW 6 and connected to the ground point G through the switch SW 6 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 ·R 4 /(R 1 ·R 2 +R 1 ·R 4 +R 2 ·R 4 ).
When the KEY 7 is operated, one end of the resistor 17 a and one end of the resistor 18 a are short-circuited by the switch SW 7 and connected to the ground point G through the switch SW 7 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 3 ·R 4 /(R 1 ·R 3 +R 1 ·R 4 +R 3 ·R 4 ).
When the KEY 8 is operated, one end of the resistor 16 a , one end of the resistor 17 a and one end of the resistor 18 a are short-circuited by the switch SW 8 and connected to the ground point G through the switch SW 8 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 ·R 3 ·R 4 /(R 1 ·R 2 ·R 3 +R 1 ·R 2 ·R 4 +R 1 ·R 3 ·R 4 +R 2 ·R 3 ·R 4 ).
As described above, in the voltage dividing circuit 12 a , eight kinds of divided voltages of different values are generated by short-circuiting the predetermined portion in the circuit 12 a with one of the switches SW 1 to SW 8 by key operation. And the divided voltages generated in the voltage dividing circuit 12 a are supplied to the output port 13 through the connecting point P as the input voltage V 1 .
Next, the voltage dividing circuit 12 b in FIG. 3 includes four resistors, i.e. a resistor 16 b whose resistance value is R 2 , a resistor 17 b whose resistance value is R 3 , a resistor 18 b whose resistance value is R 4 and a resistor 19 b whose resistance value is R 5 . The voltage dividing circuit 12 b is composed of a circuit L 11 where only a switch SW 11 is connected, a circuit L 12 where the resistor 16 b and a switch SW 12 are connected, a circuit L 13 where the resistor 17 b and a switch SW 13 are connected, a circuit L 14 where the resistor 18 b and a switch SW 14 are connected, and a circuit L 15 where the resistor 19 b and a switch SW 15 are connected.
Specifically, the circuits L 11 to L 15 are connected in parallel. One end of this parallel circuit is connected to the limit resistor 14 through the connecting line 15 , and the other end of the parallel circuit is connected to the ground point G.
Also, between the resistor 16 b and the switch SW 12 of the circuit L 12 , seven connecting points P 11 to P 17 are provided in order from the resistor 16 b side. Similarly, between the resistor 17 b and the switch SW 13 of the circuit L 13 , seven connecting points P 18 to P 24 are provided in order from the resistor 17 b side. Between the resistor 18 b and the switch SW 14 of the circuit L 14 , seven connecting points P 25 to P 31 are provided in order from the resistor 18 b side. Between the resistor 19 b and the switch SW 15 of the circuit L 15 , seven connecting points P 32 to P 38 are provided in order from the resistor 19 b side.
Further, between the connecting points P 11 and P 18 , a switch SW 16 for short-circuiting the resistors 16 b and 17 b is provided. Similarly, between the connecting points P 12 , and P 27 , a switch SW 17 for short-circuiting the resistors 16 b and 18 b is provided, and between the connecting points P 13 and P 33 , a switch SW 18 for short-circuiting the resistors 16 b and 19 b is provided.
Between the connecting points P 19 and P 25 , a switch SW 19 for short-circuiting the resistors 17 b and 18 b is provided. Between the connecting points P 20 and P 34 , a switch SW 20 for short-circuiting the resistors 17 b and 19 b is provided. Between the connecting points P 26 and P 32 , a switch SW 21 for short-circuiting the resistors 18 b and 19 b is provided.
Between the connecting points P 14 and P 21 (P 28 ), a switch SW 22 for short-circuiting the resistors 16 b , 17 b and 18 b is provided. Between the connecting points P 15 and P 22 (P 35 ), a switch SW 23 for short-circuiting the resistors 16 b , 17 b and 19 b is provided.
Between the connecting points P 16 and P 30 (P 37 ), a switch SW 24 for short-circuiting the resistors 16 b , 18 b and 19 b is provided. Between the connecting points P 23 and P 29 (P 36 ), a switch SW 25 for short-circuiting the resistors 17 b , 18 b and 19 b is provided.
Finally, between the connecting points P 17 and P 24 (P 31 , P 38 ), a switch SW 26 for short-circuiting the resistors 16 b , 17 b , 18 b and 19 b is provided.
The above eleven switches SW 16 to SW 26 have three contacts respectively and the middle contacts thereof are connected to the ground point G in common.
In the voltage dividing circuit 12 b having above-described configuration, the switches SW 11 to SW 26 correspond to, respectively, sixteen keys (KEY 11 to KEY 26 ) to which the input operation is performed. The switches SW 11 to SW 15 compose the first switch group in the present invention and the switches SW 16 to SW 26 compose the second switch group in the present invention.
Thus, when the KEY 11 is operated, for example, one end of the connecting line 15 and the ground point G are short-circuited by the switch SW 11 . Therefore, the divided voltage generated in the voltage dividing circuit 12 b , that is, the input voltage V 1 supplied from the connecting point P to the output port 13 is indicated as V 1 =0.
Similarly, when the KEY 12 is operated, for example, one end of the resistor 16 b and the ground point G are short-circuited by the switch SW 12 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 /(R 1 +R 2 ).
Similarly, when any key of the KEY 13 to KEY 26 is operated, the predetermined input voltage V 1 is generated according to the circuit state produced by short-circuiting a resistor (resistors) with the switch corresponding to the operated key.
For example, when the KEY 16 is operated, one end of the resistor 16 b and one end of the resistor 17 b are short-circuited by the switch SW 16 and connected to the ground point G through the switch SW 16 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 ·R 3 /(R 1 ·R 2 +R 1 ·R 3 +R 2 ·R 3 ).
Further, when the KEY 22 is operated, for example, one end of the resistor 16 b , one end of the resistor 17 b and one end of the resistor 18 b are short-circuited by the switch SW 22 and connected to the ground point G through the switch SW 22 . Therefore, the input voltage V 1 is indicated as V 1 =V 0 ·R 2 ·R 3 ·R 4 /(R 1 ·R 2 ·R 3 +R 1 ·R 2 ·R 4 +R 1 ·R 3 ·R 4 +R 2 ·R 3 ·R 4 .
As described above, in the voltage dividing circuit 12 b , sixteen kinds of divided voltages of different values are generated by short-circuiting the predetermined portion in the circuit 12 b with one of the switches SW 11 to SW 26 by key operation. And the divided voltages generated in the voltage dividing circuit 12 b are supplied to the output port 13 through the connecting point P as the input voltage V 1 .
When no key is operated in the voltage dividing circuits 12 a and 12 b , the above-mentioned divided voltages are not generated in each voltage dividing circuit. Therefore, the input voltage V 1 having voltage value of V 0 is supplied from the power supply 11 to the output port 13 through the limit resistor 14 .
Consequently, if the voltage dividing circuit 12 in FIG. 1 is the voltage dividing circuit 12 a ( FIG. 2 ) including three resistors 16 a to 18 a , nine kinds of input voltages V 1 of different values are supplied to the arithmetic processing circuit 20 through the output port 13 . Therefore, the arithmetic processing circuit 20 can identify nine different kinds of keys by performing a predetermined process based on the input voltages V 1 . Accordingly, compared to the circuit 12 c in FIG. 6 which can identify only five kinds of keys with three resistors, it is capable of identifying more keys, even though the voltage dividing circuit 12 a has just the same three resistors as the circuit 12 c in FIG. 6 .
Similarly, if the voltage dividing circuit 12 in FIG. 1 is the voltage dividing circuit 12 b ( FIG. 3 ) including four resistors 16 b to 19 b , seventeen kinds of input voltages V 1 of different values are supplied to the arithmetic processing circuit 20 through the output port 13 . Therefore, the arithmetic processing circuit 20 can identify seventeen different kinds of keys by performing a predetermined process based on the input voltages V 1 . Accordingly, compared to the circuit 12 d in FIG. 7 which can identify only six kinds of keys with four resistors, it is capable of identifying more keys, even though the voltage dividing circuit 12 b has just the same four resistors as the circuit 12 d in FIG. 7 .
Next, the key identification will be described in detail. The key identification is executed using the conversion table 25 b ( FIG. 1 ). Specifically, if the voltage dividing circuit 12 is the above-described voltage dividing circuit 12 a , the conversion table 25 b has a table format illustrated in FIG. 4 . If the voltage dividing circuit 12 is the above-described voltage dividing circuit 12 b , the conversion table 25 b has a table format illustrated in FIG. 5 .
In the conversion table 25 b in FIG. 4 , column 25 e indicates keys to which the input operation is performed (hereinafter, described as “operation key”) and column 25 f indicates a divided voltage generated in the voltage dividing circuit 12 a when a corresponding key is operated, that is, the voltage value of the input voltage V 1 supplied to the output port 13 . Column 25 g indicates key information outputted to the output unit 26 by the identification program 25 a based on each voltage value of column 25 f.
Similarly, in the conversion table 25 b in FIG. 5 , column 25 q indicates the operation key, column 25 r indicates the divided voltage generated in the voltage dividing circuit 12 b when a corresponding key is operated, that is, the voltage value of the input voltage V 1 supplied to the output port 13 . Column 25 s indicates key information outputted to the output unit 26 by the identification program 25 a based on the each voltage value of column 25 r.
When the voltage value of the input voltage V 1 which is supplied from the input circuit 10 having the voltage dividing circuit 12 a to the arithmetic processing circuit 20 is, for example, V 1 =V 0 ·R 2 ·R 3 /(R 1 ·R 2 +R 1 ·R 3 +R 2 ·R 3 ), the identification program 25 a executes the key identification under control of the control unit 21 with reference to the conversion table 25 b in FIG. 4 and determines that the KEY 5 , which is corresponding to the above voltage value V 1 , has been operated. Then, the identification program 25 a outputs “CH UP”, which is key information of the KEY 5 , to the output unit 26 .
Similarly, when the voltage value of the input voltage V 1 which is supplied from the input circuit 10 having the voltage dividing circuit 12 b to the arithmetic processing circuit 20 is, for example, V 1 =V 0 ·R 2 ·R 3 ·R 4 /(R 1 ·R 2 ·R 3 +R 1 ·R 2 ·R 4 +R 1 ·R 3 ·R 4 +R 2 ·R 3 ·R 4 ), the identification program 25 a executes the key identification under control of the control unit 21 with reference to the conversion table 25 b in FIG. 5 and determines that the KEY 12 , which is corresponding to the above voltage value V 1 , has been operated. Then, the identification program 25 a outputs “TILT DOWN”, which is key information of the KEY 12 , to the output unit 26 .
In this manner, in the voltage dividing circuits 12 a and 12 b of the present embodiment described above, a plurality of resistors included in the voltage dividing circuits are connected in parallel, and a plurality of switches for producing a short-circuit between each resistor and the ground point G or between a plurality of resistors and the ground point G are provided. Therefore, more switches are provided in comparison with the conventional voltage dividing circuits 12 c and 12 d where a plurality of resistors are connected in series.
Consequently, even if a voltage dividing circuit employs the same number of resistors as the conventional circuit, it is possible to generate more kinds of divided voltages than the conventional circuit. Therefore, it is capable of identifying more keys even though the voltage dividing circuit has just the same number of resistors as the conventional circuit. As a result, if the number of keys to be identified increases, it is possible to reduce the cost by suppressing the increase in the number of resistors.
The present invention can employ not only the aforementioned embodiment but also other various embodiments. For example, although the key input device 1 is described as a single device in the above embodiment, it is not limited thereto and the key input device 1 may be incorporated in the equipment such as DVD (Digital Versatile Disc) player as a part thereof.
In addition, in the above embodiment, although the conversion table 25 b is formed as shown in FIGS. 4 and 5 , it is not limited thereto and the key information may be set arbitrarily with respect to each voltage value.
Furthermore, in the above embodiment, resistance value of each resistor may be set arbitrarily as long as voltage values of the divided voltages (input voltages V 1 ) generated in the voltage dividing circuits 12 a and 12 b in FIGS. 2 and 3 are not identical mutually.
Reference Signs List
1
key input device
10
input circuit
11
power supply
12
voltage dividing circuit
12a, 12b
voltage dividing circuits
13
output port
14
limit resistor
15
connecting line
16a-18a, 16b-19b
resistors
20
arithmetic processing circuit
21
control unit
22
input port
23
A/D converter
24
temporary memory
25
memory
25a
identification program
25b
conversion table
26
output unit
P1-P9, P11-P38
connecting points
L1-L4, L11-L15
circuits
SW1-SW8, SW11-SW26
switches
G
ground point
K
key | In a voltage dividing circuit, a first circuit where only a first switch is connected, a second circuit where a first resistor and a second switch are connected in series, a third circuit where a second resistor and a third switch are connected in series and a fourth circuit where a third resistor and a fourth switch are connected in series are connected in parallel. One end of the parallel circuit is connected to a limit resistor and the other end of the parallel circuit is connected to a ground point. One switch is provided between a connecting point in one circuit and a connecting point in another circuit, and each resistor of at least two circuits is connected in parallel by said one switch. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims is a continuation application and claims benefit under 35 USC 120 of U.S. patent application Ser. No. 10/866,460 filed Jun. 10, 2004 which claimed priority to U.S. Provisional Patent Application No. 60/532,427, filed Dec. 23, 2003, and entitled “Recursive Hierarchical Motion Compensated Frame Rate Conversion,” all of which are hereby incorporated by reference herein.
[0002] This application is also related to U.S. patent application entitled: “Motion Vector Computation For Video Sequences” by Nair et al., filed Apr. 26, 2004, which is hereby incorporated by reference herein in its entirety.
BACKGROUND
[0003] This invention relates to improving video and graphics processing.
[0004] At low display refresh rates (for example, 50 fields/sec for interlaced video material, and 24 frames/sec for film-originated material) on digital display devices, a display artifact referred to as “area flicker” can occur. The area flicker becomes more visible as the size of the display increases, due to the high sensitivity to flicker in the human visual peripheral region. A simple solution for reducing the area flicker is to increase the display refresh rate by repeating the input fields or frames at a higher rate (for example, 100 fields/sec for interlaced video). This solves the area flicker problem for static scenes. However, the repetition introduces a new artifact in scenes with motion, known as “motion judder” or “motion smear,” particularly in areas with high contrast, due to the human eye's tendency to track the trajectory of moving objects. For this reason, motion compensated frame interpolation is preferred, in which the pixels are computed in an interpolated frame or field at an intermediate point on a local motion trajectory, so that there is no discrepancy between an expected image motion due to eye tracking and a displayed image motion. A motion vector describes the local image motion trajectory from one field or frame to the next.
[0005] Motion vectors can be computed at different levels of spatial resolution, such as at a pixel level, at an image patch level, or at an object level. Computing a motion vector for every pixel independently would theoretically result in an ideal data set, but is unfeasible due to the large number of computations required. Computing a motion vector for each image patch reduces the number of computations, but can result in artifacts due to motion vector discontinuities within an image patch. Computing motion vectors on an object basis can theoretically result in high resolution and lower computational requirements, but object segmentation is a challenging problem.
[0006] Therefore what is needed is a way to determine and use motion vectors efficiently and accurately, such that little or no discrepancy exists between an expected image motion due to eye tracking and a displayed image motion in a digital video.
SUMMARY
[0007] The present invention provides methods and apparatus for determining and using motion vectors efficiently and accurately, such that little or no discrepancy exists between an expected image motion due to eye tracking and a displayed image motion in a digital video.
[0008] In general, in one aspect, the invention provides methods and apparatus, including computer program products, implementing and using techniques for determining motion vectors to be used for interpolation of intermediary frames in a digital video sequence. A first image frame including several image patches is received. Each image patch has a respective first position. A second image frame including one or more image patches corresponding to the image patches in the first image frame is received. Each image patch has a respective second position. For each image patch in the first image frame that has a corresponding image patch in the second frame, the following operations occur: a forward motion vector and a backward motion vector is determined for the image patch in the first image frame; a forward motion vector and a backward motion vector is determined for the image patch in the second image frame; a pair of motion vectors consisting of one motion vector from the first image frame and one motion vector from the second frame is selected; and the selected pair of motion vectors is used to establish an intermediary position of the image patch in an interpolated frame that is intermediary to the first and second frames.
[0009] Advantageous implementations can include one or more of the following features. Selecting a pair of motion vectors can include calculating a weight for one or more pairs of motion vectors consisting of one motion vector from the first image frame and one motion vector from the second frame, and selecting the pair of motion vectors having the lowest weight. Calculating a weight can include calculating an absolute difference of an x-component of the motion vector from the first image frame and an x-component of the motion vector from the second image frame, calculating an absolute difference of an y-component of the motion vector from the first image frame and an y-component of the motion vector from the second image frame, adding the calculated absolute differences for the x- and y-components, and multiplying the added calculated absolute differences with a correlation factor for the motion vector from the first image frame and the motion vector from the second image frame.
[0010] Multiplying can include calculating a correlation value for the motion vector from the first image frame, calculating a correlation value for the motion vector from the second image frame, adding the two calculated correlation values, and multiplying the added correlation values with the added calculated absolute differences of the motion vector components from the motion vector from the first image frame and the motion vector from the second image frame. Calculating a correlation value for the motion vector from the first image frame can include centering a first window on a pixel in the first image frame that forms an origin of the motion vector, centering a second window on a pixel in the second image frame that forms an end point of the motion vector, the second window having the same dimensions as the first window; and calculating a sum of absolute differences of luma values for the pixels in the first window and pixels at corresponding positions in the second window. The dimensions of the first and second windows can be identical to the dimensions of the image patch.
[0011] The pair of motion vectors can consist of one of the following combinations: a forward motion vector from the first image frame and a forward vector from the second image frame, a backward motion vector from the first image frame and a backward vector from the second image frame, and a forward motion vector from the first image frame and a backward vector from the second image frame. Selecting can include selecting any one pair of motion vectors if the image patch is part of a large textured object moving with constant velocity. Selecting can include selecting the forward motion vector from the first image frame and the backward motion vector from the second image frame if the image patch is part of an accelerating object. Selecting can include selecting the forward motion vector from the first image frame and the forward motion vector from the second image frame if the image patch is part of an area being uncovered by a trailing edge of a moving object. Selecting can include selecting the backward motion vector from the first image frame and the backward motion vector from the second image frame if the image patch is part of an area being covered by a leading edge of a moving object. Each image patch can include many pixels.
[0012] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 shows a flowchart of a recursive hierarchical process for determining a motion vector.
[0014] FIG. 2 shows a series of image frames in a digital video of a moving object, and the areas where forward and backward motion vectors can be determined.
[0015] FIG. 3 shows a flowchart of a method for using a pair of motion vectors to interpolate a location of an image patch in an image frame intermediate to two original image frames in a digital video.
[0016] FIG. 4 is a schematic view of a sequence of image frames and associated motion vectors.
[0017] FIG. 5 shows a computer system employed to implement the invention.
[0018] Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention provides methods and apparatus for determining motion vectors and using determined motion vectors efficiently and accurately, such that little or no discrepancy exists between an expected image motion due to eye tracking and a displayed image motion in a digital video. The motion vectors that are used are selected such that the number of visual artifacts is minimized.
Determining Motion Vectors
[0020] First, an exemplary approach of determining motion vectors will be discussed. The motion vector determination described herein uses a recursive hierarchical approach, which has been fully described in the above referenced patent application “Motion Vector Computation for Video Sequences,” which is incorporated herein by reference in its entirety. However, it should be realized that regardless of the approach that is chosen for determining motion vectors, the motion vectors can be used for interpolation as described below in the section “Using the motion vectors.”
[0021] Generally, for motion compensated approaches to work well, including the recursive hierarchical approach described herein, two basic assumptions are made about the nature of the object motion: 1) moving objects have inertia, and 2) moving objects are large. The inertia assumption implies that a motion vector changes only gradually with respect to a temporal vector sampling interval (that is, the frame rate in the digital video). The large objects assumption implies that a motion vector changes only gradually with respect to a spatial vector sampling interval, that is, the vector field is smooth and has only few boundary motion discontinuities.
[0022] The goal of the recursive hierarchical method is to find a motion vector by applying a source correlation window to a first image frame and a target correlation window to a subsequent image frame, and placing the target correlation window such that a best match with the source correlation window is obtained, that is, the contents of the source correlation window and target correlation window are as similar as possible. At the same time, the number of calculations needed to perform the matching between the source correlation window and the target correlation window must be as low as possible, while still searching the entire vector space limit. In order to accomplish these goals, the recursive hierarchical method uses multiple resolution levels of the image frames. A best motion vector is first determined for the lowest resolution level by projecting the previous best motion vector at the highest resolution level down to the lowest resolution level, and testing it and one or more updates. This best motion vector is then propagated up to a higher resolution level, where some adjustments are made and a new best motion vector is determined. This new best motion vector is propagated up to yet another higher resolution level, where more adjustments are made and another new best motion vector is determined. This process is repeated until the highest, original, resolution level has been reached and a best motion vector has been identified.
[0023] FIG. 1 shows one implementation of a recursive hierarchical process ( 100 ). It is assumed that multiple resolution levels of the image frames have already been generated. As can be seen in FIG. 1 , the recursive hierarchical process ( 100 ) for determining a motion vector starts by projecting a motion vector from a previous image frame down to a lowest resolution level (step 102 ). A set of update vectors is generated and tested to find a best motion vector at this lowest resolution level (step 104 ). In one implementation this test is performed by comparing pixels in corresponding positions in a source correlation window centered on the origin of the motion vector and a target correlation window centered on the end point of each respective update vector. The comparison can, for example, be performed by subtracting a luma value for each pixel in the source window from the corresponding pixel in the respective target windows. In this case the best match would be defined by finding a minimum sum of absolute differences (SAD) for a source correlation window and a target correlation window pair, and the best motion vector would be the vector associated with this source correlation window and a target correlation window pair.
[0024] In one implementation, the SAD is computed by letting the candidate vectors for an image patch, which all originate at the same image patch location in the source frame, point to different pixel locations in a target frame. For each candidate vector, a rectangular window is centered in the target frame on the pixel pointed to by the respective candidate vector. A corresponding rectangular window is centered in the source frame on the pixel where the candidate vectors originate. Then a pair-wise absolute difference of the corresponding luma pixels in the two windows, that is, the pixels that have the same relative location within the two windows, is calculated. The sum of all the absolute differences is the SAD value. The SAD decreases as the window matching becomes better and is ideally zero when the pixels are identical. In practice, of course, due to noise and other factors, the best vector will have a non-zero SAD, but will have the minimum SAD of the vectors in the set of candidate vectors.
[0025] After the minimum SAD has been found, the best vector is selected (step 106 ). The process ( 100 ) then examines whether there are any higher resolution levels (step 108 ). If there are higher resolution levels, the process propagates the best vector up to the next higher resolution level (step 110 ) and repeats steps 104 through 108 . If there are no higher resolution levels, the process proceeds to step 112 , where the best vector is selected as the motion vector and is used for motion compensation, which completes the process for the current frame.
[0026] In one implementation, a camera vector is also considered when calculating a best motion vector. The camera vector describes a global movement of the contents of the frame, as opposed to the local vectors at each image patch location that are computed completely independently, and can therefore be used to aid in finding a better true motion vector. In several commonly occurring scenarios a motion vector resulting from camera movements at every location in a frame can be predicted quite easily with a simple model. For example, in the case of a camera lens panning across a distant landscape, all the motion vectors will be identical and equivalent to the velocity of the camera. Another scenario is when a camera lens zooms into an object on a flat surface, such as a picture on a wall. All the motion vectors then have a radial direction and increase from zero at the image center to a maximum value at the image periphery.
[0027] In one implementation, the process tries to fit a mathematical model to the motion vectors that have been computed using a least squares method. A good fit between the camera motion vectors and the mathematical model indicates that one of the scenarios discussed above likely is present, and the camera model predicted vector can then be used as an additional candidate vector in the next recursive hierarchical vector estimation step. Taking the camera vector into consideration is advantageous in that the recursive portion of the recursive hierarchical search is a local search approach, which may converge into a false local minimum instead of the true minimum. The camera predicted vector candidate can potentially help in avoiding detection of false local minima and direct the process towards a true minimum
[0028] The main advantage of the recursive hierarchical approach is that at a lower level, an update of a pixel is equivalent to an update of two or more pixels at the next higher level, depending on the difference in resolution between the two levels. If there are, for example, three resolution levels, say 1:1, 1:2 and 1:4, and an update of +/−1 pixel at each level, the convergence delay is potentially reduced by a factor of four. Expressed differently, effectively the resolution hierarchy is used to accelerate the temporal recursion convergence. This results in significant improvements, in particular for frames containing small objects moving with high velocities.
[0029] As can be seen from the above discussion, a smooth and accurate vector field is provided by using only a fairly small number of calculations. Furthermore, there is reduced convergence delay due to the multiple levels of resolution. Fewer resolution levels can be used compared to conventional approaches, and vector errors in lower levels are not amplified due to resolution changes at higher resolution levels due to safeguarding by use of projected vectors at each resolution.
Using the Motion Vectors
[0030] After the motion vector fields have been estimated for each frame, interpolated frames in between the original frames of the digital video can be computed. The robustness of the interpolation can be increased by using motion vectors from more than one of the original frames. Conventional approaches to generate interpolated frames include generating data values from the candidate vectors followed by a filtering scheme to reduce the visibility of artifacts due to erroneous vectors.
[0031] The present invention instead uses a heuristic algorithm to select the best possible candidates from the available set of motion vectors, which further increases the robustness and decreases the number of artifacts. The heuristic algorithm will be discussed in detail below with reference to FIG. 3 , and is applicable to situations where there are simultaneously available forward and backward vectors from two adjacent original frames. The heuristic scheme uses both the vector correlation values and the distance between candidate vectors to select a pair of forward vectors, a pair of backward vectors, or a pair consisting of a forward and a backward vector. Before discussing the heuristic algorithm in detail, it is useful to discuss some properties of forward and backward vectors
[0032] The above discussion has been focused on determining motion vectors between a current frame and a subsequent frame. These motion vectors are typically referred to as forward motion vectors. However, just as forward motion vectors can be determined, the same methodology can be used to determine a motion vector between a current frame and a previous frame. Since this type of motion vector points to a previous frame, it is often referred to as a backward motion vector. Thus, a pair of vectors consisting of one motion vector from a previous frame and one motion vector from a subsequent frame can be used to determine the location of an image patch in an intermediate interpolated frame.
[0033] It should be noted that there are situations in which it is impossible to determine a forward and a backward motion vector for each of two adjacent frames. One such example is shown in FIG. 2 , which shows a simplified one-dimensional object ( 200 ) moving along a line upwards in FIG. 2 , against a static background in four adjacent image frames ( 202 A- 202 D) in a digital video. Here it is assumed that a location of the object ( 200 ) in an interpolated image frame ( 212 ) is to be determined between the original frames 202 B and 202 C, using one motion vector from frame 202 B and one motion vector from frame 202 C.
[0034] As can be seen in FIG. 2 , frame 202 B contains a background region ( 204 ) that was previously covered by the object ( 200 ) in frame 202 A. Therefore, a backward vector cannot be computed for this background region ( 204 ) in frame 202 B. Similarly, frame 202 C contains a background region ( 206 ) that was previously covered by the object ( 200 ) in frame 202 B, and consequently a backward vector cannot be computed for this background region ( 206 ) in frame 202 C. In other words, for areas that are being uncovered by the trailing edge of a moving object, no backward motion vectors can be determined.
[0035] Considering the leading edge of the object ( 200 ), it can be seen that frame 202 B contains a background region ( 208 ) that will be obscured by the leading edge of the object ( 200 ) in the following frame 202 C. Therefore, a forward vector cannot be computed for this background region ( 208 ) in frame 202 B. Similarly, frame 202 C contains a background region ( 210 ) that will be covered by the object ( 200 ) in frame 202 D, and therefore a forward vector cannot be computed for this background region ( 210 ) in frame 202 C. Stated differently, for areas that are being covered by the leading edge of a moving object in a subsequent frame, no forward motion vectors can be determined. The reader skilled in the art will realize that these two situations are just exemplary, and that other situations, for example, an object moving towards or away from the camera, may occur that make it impossible to determine both forward and backward motion vectors in both adjacent frames. In this situation, the resultant size change of the object from one image frame to a subsequent image frame will cause either visible background to be obscured, or obscured background to be uncovered. Thus, an object moving towards the camera will cause trouble with computation of forward vectors at the object's boundary, whereas an object moving away from the camera will cause trouble with computation of backward vectors at the object's boundary.
[0036] FIG. 3 shows a heuristic motion vector selection process ( 300 ) that can be used to choose a pair of motion vectors. FIG. 4 shows a sequence ( 400 ) of image frames ( 402 ; 406 , 408 ; 410 ), and will be used in conjunction with FIG. 3 to explain the steps of the heuristic motion selection process ( 300 ). As can be seen, the process ( 300 ) starts by determining motion vectors for two frames ( 404 , 406 ) that surround a frame ( 405 ) that will be interpolated (step 302 ). These two frames will be referred to as the previous frame ( 404 ) and the subsequent frame ( 406 ) in relation to the interpolated frame ( 405 ).
[0037] The motion vectors can be determined with the recursive hierarchical method described above, or with any other suitable method for determining motion vectors. For each frame, the process ( 300 ) attempts to determine a forward motion vector ( 414 , 418 ) and a backward motion vector ( 412 , 416 ). In the following discussion, the forward motion vector of the previous frame ( 404 ) will be labeled Fp ( 414 ), the backward motion vector of the previous frame ( 404 ) will be labeled Bp ( 412 ), the forward motion vector of the subsequent frame ( 406 ) will be labeled Fs ( 418 ), and the backward motion vector of the subsequent frame ( 406 ) will be labeled Bs ( 416 ).
[0038] Next, the process ( 300 ) checks whether there are both forward motion vectors ( 414 , 418 ) and backward motion vectors ( 412 , 416 ) available for both the previous frame ( 404 ) and the subsequent frame ( 406 ) (step 304 ). If all vectors are not available, the process ( 300 ) ends and uses only one motion vector. If all vectors are available, the process ( 300 ) selects a pair of vectors to be used for the interpolation of the intermediate frame. As the skilled reader will realize, there are four possible combinations of vector pairs that may be generated from the determined forward vectors ( 414 , 418 ) and backward vectors ( 412 , 416 ). These combinations are:
1. Fp ( 414 ) and Fs ( 418 ) 2. Bp ( 412 ) and Bs ( 416 ) 3. Fp ( 414 ) and Bs ( 416 ) 4. Bp ( 412 ) and Fs ( 418 )
[0043] However, only the first three vector pairs make sense to consider, since both the motion vectors Bp ( 412 ) and Fs ( 418 ) in the last pair both “point away” from the frame that is to be interpolated, that is, both vectors refer to movement that occurs outside the time interval for which the interpolated frame is to be computed.
[0044] Furthermore, different vector pairs among the three remaining vector pairs are more or less suitable in different situations. In the event that the type of object motion can be independently determined, it will often be apparent what vector pair to use when determining the interpolated frame. For example, in the case of a large textured object moving with constant velocity, any one pair of the first three pairs of motion vectors on the above list can be used to generate consistent frame interpolated data, since the object moves the same distance between each image frame.
[0045] For an accelerating object, on the other hand, the Fp ( 414 ) and Fs ( 418 ) vectors are different. For example, if the object ( 410 ) is accelerating in the downward direction of FIG. 4 , the Fp vector ( 414 ) will have a smaller magnitude than the Fs vector ( 418 ). Similarly, the Bp ( 412 ) and Bs ( 416 ) vectors are different. If the same acceleration is assumed, the Bp vector ( 412 ) will have a smaller magnitude than the Bs vector ( 416 ). However, the Fp vector ( 414 ) and the Bs vector ( 416 ) are computed over the same frame interval—the Fp vector ( 414 ) has the opposite direction and magnitude of the Bs vector ( 416 )—and can therefore be used for the interpolation.
[0046] Yet another example is the one discussed above with respect to FIG. 2 , of a background area being uncovered at the trailing edge of a moving object. The forward vectors Fp and Fs can always be determined for a background area that is being uncovered at the trailing edge of a moving object, but the backward vectors Bp and Bs can never be determined, since the background area was covered by the object previous frames. For this reason, the (Fp, Fs) vector pair is the only vector pair that can be used for the interpolation.
[0047] Similarly, in the case of a background area being obscured at the leading edge of a moving object, the (Bp, Bs) vector pair is the only pair that can be used for the interpolation. No forward vectors can be determined, since the leading edge of the moving object will obscure the background area in subsequent image frames.
[0048] If the type of object movement is not known, which is typically the case, the heuristical process continues by determining which vector pair should be used. The process calculates a weight (W1 through W3) for each of the first three motion vector pairs as follows (step 306 ):
W1=dist(Fp,Fs)*(corr(Fp)+corr(Fs)) W2=dist(Bp,Bs)*(corr(Bp)+corr(Bs)) W3=dist(Fp,−Bs)*(corr(Fp)+corr(Bs))
where dist (A,B) is the distance between vectors A and B, and is calculated as the sum of the absolute differences of the x components of vectors A and B, and the absolute differences of the y components of vectors A and B, respectively. The corr (A) measure is the SAD correlation value for the vector. As was discussed above, the SAD is lower as the local image match increases, that is, as the vector confidence increases.
[0052] Next, the process selects the vector pair that gives the lowest determined weight (step 308 ), since this pair provides the highest consistency. Finally, the selected vector pair is used for final data interpolation (step 310 ). This heuristic vector selection process increases the robustness of the frame interpolation and minimizes artifacts, which are often manifested as a “shimmering” effect when viewed on a screen, which would occur if only one motion vector was used in the interpolation.
[0053] The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
[0054] FIG. 5 shows a computer system ( 500 ) employed to implement the invention. The computer system ( 500 ) is only an example of a graphics system in which the present invention can be implemented. The computer system ( 500 ) includes a central processing unit (CPU) ( 510 ), a random access memory (RAM) ( 520 ), a read only memory (ROM) ( 525 ), one or more peripherals ( 530 ), a graphics controller ( 560 ), primary storage devices ( 540 and 550 ), and a digital display unit ( 570 ). As is well known in the art, ROM acts to transfer data and instructions uni-directionally to the CPUs ( 510 ), while the RAM ( 520 ) is used typically to transfer data and instructions in a bi-directional manner. The CPUs ( 510 ) can generally include any number of processors. Both primary storage devices ( 540 and 550 ) can include any suitable computer-readable media. A secondary storage medium ( 580 ), which is typically a mass memory device, is also coupled bi-directionally to the CPUs ( 510 ) and provides additional data storage capacity. The mass memory device ( 580 ) is a computer-readable medium that can be used to store programs including computer code, data, and the like. Typically, the mass memory device ( 580 ) is a storage medium such as a hard disk or a tape which generally slower than the primary storage devices ( 540 , 550 ). The mass memory storage device ( 580 ) can take the form of a magnetic or paper tape reader or some other well-known device. It will be appreciated that the information retained within the mass memory device ( 580 ), can, in appropriate cases, be incorporated in standard fashion as part of the RAM ( 520 ) as virtual memory.
[0055] The CPUs ( 510 ) are also coupled to one or more input/output devices ( 590 ) that can include, but are not limited to, devices such as video monitors, track balls, mice, keyboards, microphones, touch-sensitive displays, transducer card readers, magnetic or paper tape readers, tablets, styluses, voice or handwriting recognizers, or other well-known input devices such as, of course, other computers. Finally, the CPUs ( 510 ) optionally can be coupled to a computer or telecommunications network, e.g., an Internet network or an intranet network, using a network connection as shown generally at ( 595 ). With such a network connection, it is contemplated that the CPUs ( 510 ) might receive information from the network, or might output information to the network in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using the CPUs ( 510 ), can be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave. The above-described devices and materials will be familiar to those of skill in the computer hardware and software arts.
[0056] The graphics controller ( 560 ) generates image data and a corresponding reference signal, and provides both to digital display unit ( 570 ). The image data can be generated, for example, based on pixel data received from the CPU ( 510 ) or from an external encode (not shown). In one embodiment, the image data is provided in RGB format and the reference signal includes the VSYNC and HSYNC signals well known in the art. However, it should be understood that the present invention can be implemented with data and/or reference signals in other formats.
[0057] A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications can be made without departing from the spirit and scope of the invention. For example in addition to the hierarchical and temporal vectors in the intermediate layers, the camera model generated vector projected down can also be used as a candidate for SAD computation. Furthermore, the motion vectors generated as described above can be used for other purposes than frame rate conversion, such as deinterlacing, noise reduction, and so on. The robustness can also be increased further by, for example, using motion vectors determined for frames that are not immediately adjacent, but instead located two frames away on either side of the interpolated frame in the digital video. Accordingly, other embodiments are within the scope of the following claims. | Methods and apparatus, including computer program products, implementing and using techniques for determining motion vectors to be used for interpolation of intermediary frames in a digital video sequence are disclosed. A first image frame including several image patches is received. A second image frame including one or more image patches corresponding to the image patches in the first image frame is received. For each image patch that occurs in both frames, the following operations occur: forward and backward motion vectors are determined for the image patch in the first image frame, forward and backward motion vectors are determined for the image patch in the second image frame, one motion vector from the first image frame and one motion vector from the second frame are selected and the selected motion vectors are used to establish an intermediary position of the image patch in an interpolated frame between the frames. | 7 |
This application is a 371 of International Application No. PCT/US2011/036821, filed 17 May 2011, which claims the benefit of U.S. Provisional Application No. 61/345,224 filed 17 May 2010, which is incorporated herein in its entirety.
AREA OF THE INVENTION
The present invention relates to a process for the preparation of certain pyrimidinone compounds.
BACKGROUND
WO 01/60805 (SmithKline Beecham plc) discloses a novel class of pyrimidinone compounds, inter alia those substituted at N1.
The pyrimidinone compounds described in WO 01/60805 are inhibitors of the enzyme lipoprotein associated phospholipase A 2 (Lp-PLA 2 ) and as such are expected to be of use in therapy, in particular in the primary and secondary prevention of acute coronary events, for instance those caused by atherosclerosis, including peripheral vascular atherosclerosis and cerebrovascular atherosclerosis.
Several processes for the preparation of such pyrimidinone compounds are also disclosed in WO 01/60805, inter alia alkylation of the pyrimidinone nucleus. This process generally suffers from moderate yields due to the poor selectivity seen in the alkylation of the pyrimidinone nucleus. Preparation of such compounds is also disclosed in WO 03/16287. While this process achieves improved selectivity, it generally suffers from modest yield particularly in the disclosed regioselective step.
The present invention provides particularly advantageous processes, not hitherto disclosed, for the preparation of some of the pyrimidinone compounds disclosed in WO 01/60805.
SUMMARY OF THE INVENTION
In a first aspect the instant invention provides a process for preparing a compound of formula (I):
wherein:
R a and R b together with the pyrimidine ring carbon atoms to which they are attached form a cyclopentyl ring;
R 1 is phenyl, unsubstituted or substituted by 1-3 fluoro groups;
R 2 is C (1-3) alkyl substituted by NR 5 R 6 ; or
R 2 is Het-C (0-2) alkyl in which Het is a 5- to 7-membered heterocyclic ring containing N and in which N may be substituted by C (1-6) alkyl;
R 3 is phenyl;
R 4 is phenyl unsubstituted or substituted by C (1-6) alkyl or mono to perfluoro-C (1-4) alkyl; and
R 5 and R 6 which may be the same or different are C (1-6) alkyl;
the process comprising carrying out one or more of the following reaction steps:
(a) treating a C (1-4) alkyl 2-oxocyclopentanecarboxylate with an alkali metal salt of glycine to form a compound of formula (A)
(b) cyclising a compound of formula (A) to form the hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid of formula (B)
by treating a compound of formula (A) with either (i) or (ii):
(i) a thiocyanate salt and
a) a haloalkylsilane and a proton source (such as water or alcohol), with heating, or
b) an anhydrous acid, with heating; or
(ii) trimethylsilylisothiocyanate, with heating;
(c) forming a thio-4-oxo-4,5,6,7-tetrahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid of formula (C)
where n is 0 to 3,
by a treating compound of formula (B) with a thio-alkylating reagent which is a benzyl derivative of formula (D)
where n is 0 to 3 and X is a leaving group, in the presence of an alkali metal base and/or an alkali metal carbonate;
(d) treating an aldehyde of formula (E)
with an amine, a heavy metal catalyst and hydrogen to form a secondary amine of formula (F)
and
(e) forming a compound of formula (I) by treating a compound of formula (C) with carbonyldiimidazole and the secondary amine of formula (F) and heating the mixture.
Also within the scope of this invention are the several intermediates used in the foregoing process for making compounds of formula (I), and processes of making such intermediates comprising one or more of the foregoing steps as indicated.
DETAILED DESCRIPTION OF THE INVENTION
For the purposes of this invention, C (1-6) alkyl (which may be alternatively referred to as (C 1 -C 6 )alkyl, including, e.g., C (1-4) alkyl or C 1 -C 4 alkyl) refers to a straight- or branched-chain hydrocarbon radical having the specified number of carbon atoms. For example, as used herein, the terms “C (1-6) -alkyl” refers to an alkyl group having at least 1 and up to 6 carbon atoms. Examples of such branched or straight-chained alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, isobutyl, n-butyl, t-butyl, n-pentyl, isopentyl, and n-hexyl, and branched analogs of the latter 3 normal alkanes.
Halo refers to fluoro, bromo, chloro or iodo. Where such a moiety is on an alkyl group, there may be 1 or more of any one of these four halo groups, or mixtures of them.
When the term “mono to perfluoro-C (1-4) alkyl” is used it refers to an alkyl group having at least 1 and up to 4 carbon atoms that is substituted with at least one fluoro group on any or all of the carbons, and may have up to 2n+1 fluoro groups where n is the number of carbons. Examples include, but are not limited to, fluoromethyl, difluoromethyl, trifluoromethyl, 2,2,2-trifluoroethyl, pentafluoroethyl, 2-(trifluoromethyl)ethyl, and nonafluoro-tert-butyl. Trifluoromethyl is a particularly useful group, especially when present at the 4 position on the R 4 phenyl ring.
With regards to the phenyl of R 1 , if it is substituted by fluoro there may be 1-3 fluoro groups on the phenyl ring at any combination of positions on the ring. Particularly useful are the 4-fluorophenyl, 3,4-difluorophenyl, 3,4,5-trifluorophenyl, or 2,3-difluorophenyl groups, more particularly the 4-fluorophenyl, 3,4,5-trifluorophenyl, or 2,3-difluorophenyl groups.
In regard to R 2 , suitable 5- to 7-membered heterocyclic rings containing N include pyrrolidine, piperidine and azepane.
C 1-6 (e.g. C 1-4 ) alcohols include branched or straight-chained alkanes having at least 1 and up to 6 carbons, and substituted by 1, 2 or 3 —OH groups. Examples include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, isobutyl, n-butyl, t-butyl, n-pentyl, isopentyl, and n-hexyl alcohols, and branched analogs thereof.
In some embodiments, the process is carried out in accordance with the following description.
In step (a), alkyl esters of 2-oxocyclopentanecarboxylate are available commercially. The methyl ester is particularly useful and readily available. The alkali metal salt of glycine may be the sodium, potassium or lithium salt, which are available commercially or prepared in situ from glycine and a suitable base such as sodium ethoxide. The sodium salt is particularly useful. The reaction is run in a polar solvent such as a low molecular weight aqueous alcohol (e.g. C 1-4 , e.g. ethanol, methanol, and/or isopropanol), an amidic solvent (e.g. N-methylpyrrolidinone) or a carboxylic acid (e.g. acetic acid). The reaction mixture is heated, e.g., to between 50°-70° C. for a sufficient, generally short time, e.g. a couple of hours or so, and is then worked up by conventional means to obtain the alkali metal salt of ({2-[(methyloxy)carbonyl]-1-cyclopenten-1-yl}amino)methyl ester or used in solution as is.
With regards to the cyclization step (b), making the hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid of formula (B), the alkali metal salt of formula (A) is treated with either:
(i) a thiocyanate salt such as ammonium thiocyanate or an alkali metal thiocyanate such as sodium thiocyanate, or potassium thiocyanate, and a) a haloalkylsilane and a proton source such as water or alcohol (e.g., C 1-4 alcohols, including e.g., methanol) in an appropriate solvent, such as an amidic solvent (e.g. N-methylpyrrolidinone) or a carboxylic acid (e.g. acetic acid), for a sufficient time, generally several hours, at elevated temperature such as between 80°-120° C.; or b) an anhydrous acid (inorganic or organic) such as anhydrous hydrochloric acid or methane sulfonic acid, with heating (such as in (a) above); or
(ii) trimethylsilylisothiocyanate, with heating (such as in (i) above).
Methods using the thiocyanate salt are particularly suitable. In such methods, treatment with the thiocyanate salt will generally be followed by treatment with the haloalkylsilane and proton source, or with anhydrous acid, although the reagents may be combined in any order. By any of the cyclization methods, after applying heat to the mixture, generally for several hours, it is cooled and the product isolated and purified by conventional means.
The thiol of formula (C) [step (c)] is prepared by treating the hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid with a thio-alkylating agent which is an unsubstituted or substituted benzyl moiety of formula (D). Formula (D) can have any suitable leaving group (X) which is exemplified by Cl, Br, I or an —OSO 2 R group where R is alkyl (e.g., C 1-6 ), perfluoroalkyl (e.g. trifluoromethyl) or an aromatic group (e.g. phenyl). Acid (B) is stirred in a suitable polar solvent, for example water and a low molecular weight alcohol, and then treated with organic or inorganic base. For example, an alkali metal base such as NaOH or KOH and/or an alkali metal carbonate such as Na 2 CO 3 or K 2 CO 3 is added. This mixture is maintained or heated at low temperature, e.g. 20°-50° C. and the benzyl derivative is added and heating is continued for a suitable time, generally a couple of hours. The product is recovered by conventional means; addition of a low molecular weight organic or inorganic acid (e.g., formic, sulphuric or phosphoric acid) may facilitate crystallization.
In step (d), the secondary amine (F) needed to form the amide group in formula (I) is prepared from an aldehyde (E) by treating the aldehyde with the appropriate substituted amine in the presence of a heavy metal catalyst such as palladium and hydrogen gas, in an appropriate solvent such as an aromatic solvent (e.g. toluene), a ketonic solvent (e.g. methylisobutylketone) or an alkyl acetate solvent (e.g. isopropyl acetate). Suitable amines are alkylene diamines of the formula (C 1-3 )NR 5 R 6 , where R 5 and R 6 are as defined in formula (I), and of the formula Het-C (0-2) alkyl in which Het is a 5- to 7-membered heterocyclic ring containing N and in which N may be substituted by C (1-6) alkyl. When hydrogenation is completed, the product is recovered by conventional means (it may be left and used in solution).
The last step, step (e) will typically comprise treating compound (C) with carbonyldiimidazole in an aprotic solvent, then combining the mixture with the amine (F) and heating the mixture. Thus, step (e) is suitably effected by first treating the thiol (C) prepared in step (c) with carbonyldiimidazole in an appropriate aprotic solvent such as an aromatic solvent (e.g. toluene), a ketonic solvent (e.g. methylisobutylketone) or C 1-6 alkyl acetate solvent (e.g. isopropyl acetate) and heating the solution. Alternatively, thiol (C) may be combined with the reagents in any order. This step forms an imidazole intermediate that is not isolated, but added as is to a solution of the secondary amine (F) prepared in step (d). This solution is heated to e.g., 80°-100° C. or thereabout until conventional testing shows the reaction has gone to completion. Product is isolated by conventional means. In alternative embodiments, the imidazole intermediate may be isolated for subsequent reaction with amine (F). It has been found that combined use of the carbonyldiimidazole and amine in this step desirably reduces or removes residual thio-alkylating agent (e.g. (D)) in the thiol (C) (in some embodiments, to less than 1 ppm (D)). In some embodiments, methanol is used as a solvent during isolation of the product and may improve yield and/or purity. The present invention encompasses a methanol solvate of compounds of formula (I), formed by isolation comprising the use of methanol as a solvent.
In one aspect, the invention relates to novel compounds of formula (A). In another aspect, the invention relates to a method of preparing a compound of formula (A), comprising the aforementioned step (a).
In another aspect, the invention relates to novel compounds of formula (B). In another aspect, the invention relates to a method of preparing a compound of formula (B), comprising the aforementioned steps (a) and (b).
In another aspect, the invention relates to a method of preparing a compound of formula (C), comprising the aforementioned steps (a), (b) and (c).
In another aspect, the invention relates to a method of preparing a compound of formula (I), comprising the aforementioned steps (a)-(c).
In another aspect, the invention relates to a method of preparing a compound of formula (I), comprising the aforementioned steps (a)-(e).
All publications (including but not limited to published patent applications and patents) referred to herein are incorporated by reference in their entirety.
EXAMPLES
Example 1
Preparation of Sodium ({2-[(Methyloxy)carbonyl]-1-cyclopenten-1-yl}amino)acetate
Glycine sodium salt (69.64 g, 1.02 eq) and industrial methylated spirits (“IMS”) (800 mL), a grade of denatured ethanol, were combined and stirred. Then water (40 mL) was added to the slurry. Methyl oxocyclopentanone carboxylate (100 g, 1.00 eq) was then added and the slurry heated to 60° C.±3° C. After 2 hrs the slurry was cooled to 20° C.±3° C. over 40 min, aged for 30 min then filtered. The cake was washed with industrial methylated spirits (2×200 mL), deliquored, then dried further at 70° C. in an oven under reduced pressure to yield the title compound as a white solid (139.8 g, 89%).
1 H NMR (d 4 MeOD) δ 1.80 (2H, quintet), 2.49 (2H, t), 2.56 (2H, t), 3.63 (3H, s), 3.75 (2H, s).
Example 2
Preparation of (4-Oxo-2-thioxo-2,3,4,5,6,7-hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid
Sodium ({2-[(Methyloxy)carbonyl]-1-cyclopenten-1-yl}amino)acetate (60 g) and sodium thiocyanate (26.6 g) were stirred in N-methylpyrrolidinone (240 ml) and water (2.94 ml) under a nitrogen atmosphere. Chlorotrimethylsilane (73.8 g) was added and the mixture heated to 117±3° C. After 3 hours at this temperature the reaction mixture was cooled to 90° C. and water (480 ml) was added. The mixture was cooled to 2° C. and the product isolated by filtration. It was washed with water (2×120 ml) then acetone (2×60 ml) and dried at 60° C. in an oven under reduced pressure to yield the title compound as an off-white solid (50.69 g, 83%). 1 H NMR (d 6 DMSO) δ 2.00 (2H, quintet), 2.60 (2H, t), 2.87 (2H, t), 4.95 (2H, broad s), 12.57 (1H, broad s), 13.26 (1H, broad s).
Example 3
Alternative Method for Making (4-Oxo-2-thioxo-2,3,4,5,6,7-hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid
Methyl 2-oxocyclopentanecarboxylate (750 g) was added to a stirred suspension of glycine, sodium salt (528 g) in N-methylpyrrolidinone (4 L) under a nitrogen atmosphere at 60±3° C. over 45 minutes. The ester was washed in with a further portion of N-methylpyrrolidinone (1.3 L) and the mixture was stirred at this temperature for 2 hours. The mixture was then cooled to 20±3° C. and sodium thiocyanate (599 g) was added. Chlorotrimethylsilane (2.01 kg) was added over 45 minutes and the reaction mixture was heated with a jacket set to raise the temperature to 123° C. over 45 minutes. During this heating up period, the reaction mixture became thicker and some volatiles were distilled out. The temperature of the reaction mixture rose to 117±3° C. This reaction temperature was maintained for 3 hours. The reaction mixture was cooled to 90±3° C. Water (10.5 L) was added and the suspension was cooled to 2±3° C. over 4 hours and the product was collected by filtration. The product was washed twice with water (2×2.3 L) and twice with acetone (2×1.2 L) and dried in vacuo at 60° C. to yield the title compound as an off-white solid (920 g, 77%); 1 H NMR (d 6 DMSO) δ 2.00 (2H, quintet), 2.60 (2H, t), 2.87 (2H, t), 4.95 (2H, broad s), 12.57 (1H, broad s), 13.26 (1H, broad s).
Example 4
Preparation of (2-{[(4-Fluorophenyl)methyl]thio}-4-oxo-4,5,6,7-tetrahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid
(4-oxo-2-thioxo-2,3,4,5,6,7-hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid (30.0 g, 1.0 eq) was slurried in a mixture of water (162 mL) and isopropyl alcohol (30 mL). KOH solution (50% aqueous, 28.3 g, 1.90 eq) was added followed by a water line wash (15 mL) resulting in a solution. Then K 2 CO 3 (2.75 g, 0.15 eq) was charged and the solution was heated to 40±3° C. Thereafter 4-fluorobenzyl chloride (18.2 g, 0.95 eq) was added, followed by a line wash of isopropyl alcohol (18 mL) and the reaction mixture was stirred at 40±3° C. until the reaction was deemed complete (˜2.5 hours). The reaction mixture was cooled to 20±3° C. and formic acid (3.1 g, 0.5 eq) was added resulting in crystallisation of the product within 30 minutes. A second charge of formic acid (10.4 g, 1.7 eq) was added over 1 hour and the slurry was stirred at 20±3° C. for at least one hour. The slurry was filtered to isolate the product, which was washed twice with a mixture of water (48 mL) and isopropyl alcohol (12 mL), then with isopropyl alcohol (60 mL) and dried in vacuo at 50° C. to yield the title compound as an off-white solid (40.6 g, 92%). 1 H NMR (d 6 DMSO) δ 1.95 (2H, m), 2.57 (2H, t), 2.85 (2H, t), 4.4 (2H, s), 4.7 (2H, s), 7.15 (2H, dd), 7.45 (2H, dd), ˜13.6 (1H, vbrs).
Example 5
Preparation of N,N-diethyl-N′-{[4′-(trifluoromethyl)-4-biphenylyl]methyl}-1,2-ethanediamine
A mixture of 4′-(trifluoromethyl)-4-biphenylcarbaldehyde, (43.6 kg, 1.1 eq., see WO 01/60805), N,N-diethylethylenediamine (21.2 kg, 1.15 equiv.) and 5% palladium on charcoal (Degussa E101 N/W, 50% wet paste, 1.7 kg) in toluene (138 Kg) was hydrogenated at 20±3° C. and 50 psi until completion. The reaction mixture was filtered and the catalyst bed washed with toluene (2×36.7 kg). The solution was washed with water (84.8 kg) and concentrated under reduced pressure to ca. 85 L. This concentrate was used in the next step, Example 6, without further purification.
Example 6
Preparation of N-[2-(diethylamino)ethyl]-2-(2-{[(4-fluorophenyl)methyl]thio}-4-oxo-4,5,6,7-tetrahydro-1H-cyclopenta[d]pyrimidin-1-yl)-N-{[4′-(trifluoromethyl)-4-biphenylyl]methyl}acetamide
6a. A stirred slurry of carbonyldiimidazole (30.9 kg, 1.2 equiv.) in methylisobutylketone (255 kg) under nitrogen was heated to 70±3° C. (2-{[(4-fluorophenyl)methyl]thio}-4-oxo-4,5,6,7-tetrahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid (53.0 kg) was added in a portionwise manner and the mixture stirred at 70±3° C. until no starting material remained.
6b. The suspension of imidazolide intermediate from 6a was added to a solution N,N-diethyl-N′-{[4′-(trifluoromethyl)-4-biphenylyl]methyl}-1,2-ethanediamine (see Example 5), washing in with methylisobutylketone (43 kg). The mixture was heated to 92±3° C. until complete conversion to the title compound was established. The reaction mixture was concentrated under reduced pressure to ca. 240 L and then cooled to 40 to 45° C. prior to the addition of methanol (105 kg). The solution was cooled to 20 to 25° C. to give a slurry, which was then heated to 50° C. and held for 30 mins. The slurry was cooled to 2±3° C. at 0.3° C./min and held for a further 30 mins. The product was isolated by filtration and washed with cold methanol (5±3° C., 2×168 kg) before being dried under reduced pressure at 47±3° C. to yield the title compound, intermediate grade as an offwhite solid (97.4 kg uncorrected for methanol; 90.9 kg corrected for methanol, 86%). 1 H NMR (CDCl 3 , ca 1.9:1 rotamer mixture) δ 0.99 (6H, t), 2.10 (2H, m), 2.50 (4H, q), 2.58/2.62 (2H, 2×t), 2.70/2.82 (2H, 2×t), 2.86 (2H, t), 3.28/3.58 (2H, 2×t), 4.45/4.52 (2H, 2×s), 4.68/4.70 (2H, 2×s), 4.61/4.93 (2H, s), 6.95 (2H, m), 7.31 (2H, d), 7.31/7.37 (2H, 2×m), 7.48/7.52 (2H, d), 7.65 (2H, m), 7.72 (2H, m).
Example 7
Alternative method for making (2-{[(4-Fluorophenyl)methyl]thio}-4-oxo-4,5,6,7-tetrahydro-1Hcyclopenta[d]pyrimidin-1-yl)acetic acid)
(4-oxo-2-thioxo-2,3,4,5,6,7-hexahydro-1H-cyclopenta[d]pyrimidin-1-yl)acetic acid (20.0 g, 1.0 eq) was slurried in a mixture of water (112 mL) and isopropyl alcohol (20 mL). NaOH solution (50.9% aqueous, 13.82 g, 1.99 eq) was added followed by a water line wash (10 mL) resulting in a solution. Then Na 2 CO 3 (1.50 g, 0.16 eq) was charged and the solution was heated to 40±3° C. Thereafter 4-fluorobenzyl chloride (13.4 g, 1.05 eq) was added, followed by a line wash of isopropyl alcohol (12 mL) and the reaction mixture was stirred at 40±3° C. until the reaction was deemed complete (˜2.5 hours). The reaction mixture was cooled to 20±3° C. and formic acid (2.4 g, 0.6 eq) was added resulting in crystallisation of the product within 30 minutes. A second charge of formic acid (6.9 g, 1.7 eq) was added over 1 hour and the slurry was stirred at 20±3° C. for at least one hour. The slurry was filtered to isolate the product, which was washed twice with a mixture of water (32 mL) and isopropyl alcohol (8 mL), then with isopropyl alcohol (40 mL) and dried in vacuo at 50° C. to yield the title compound as an off-white solid (28.6 g, 97% th). 1 H NMR (d 6 DMSO) δ 1.95 (2H, m), 2.57 (2H, t), 2.85 (2H, t), 4.4 (2H, s), 4.7 (2H, s), 7.15 (2H, dd), 7.45 (2H, dd), ˜13.6 (1H, vbrs).
These examples are given to illustrate the invention, not to limit it. What is reserved to the inventors can be determined by reference to the claims below. | This invention relates to methods of making a compound of formula (I) and intermediates for same
the compounds of formula (I) being useful for treating cardiovascular and inflammatory diseases such as atherosclerosis. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for the preparation of a phosphonitrile chloride oligomer mixture having a high content of cyclic phosphonitrile chloride trimer which has a wide range of use and is in greatest demand, for example, as a raw material for the preparation of oligomer or polymer obtained by replacing the chlorine atom of phosphonitrile chloride oligomer or polymer thereof with another group which is excellent in heat resistance, cold resistance, inflammability, electric insulation and the like.
2. Description of the Prior Art
Phosponitrile chloride oligcmer can generally be represented by the formula.
(NPCl.sub.2).sub.l (I)
wherein l represents an integer of 3 or greater, and has attracted attention as an industrial material since many of the derivatives and polymers thereof have excellent properties in heat resistance, cold resistance, inflammability, electric insulation and the like. Among the above oligomers, a cyclic phosphonitrile chloride trimer of the above-mentioned formula (I) in which l=3 (hereinafter abbreviated as "3PNC") has a particularly wide range of use and thus is in greatest demand. Accordingly, it has been desired to produce 3PNC with a high yield and a high purity. However, a reaction process for preparing 3PNC alone is not yet known and 3PNC has always been obtained in the form of a mixture with various kinds of oligomers in the conventional production process for phosphonitrile chloride oligomer. Accordingly, it has been attempted so far for the production of 3PNC to improve the reaction yield in the entire mixture of phosphonitrile chloride oligomers as well as increase the ratio of 3PNC formed therein. Several examples of such processes of the prior art are given below. (1) A process for reacting phosphorus pentachloride and ammonium chloride under the presence of a quinoline as the catalyst in a solvent of tetrachloroethane is disclosed in U.S. Pat. No. 2,788,286. Although it has been described therein that 3PNC and the heptamer can be obtained with no substantial formation of the tetramer (hereinafter abbreviated occasionally as "4PNC"), the reaction yield of 3PNC is low in the cited process. (2) Japanese Patent Laid-Open Nos. 3705/1982 and 77012/1982 disclose a process of reacting phosphorus pentachloride and ammonium chloride under the presence of a polyvalent metal compound catalyst, washing a solution of the reaction product in an aliphatic hydrocarbon or an ether with water and recovering a product containing cyclic phosphonitrile chloride oligomers at a high content. Although the yield for 3PNC in this process is relatively high, the process has disadvantages in that the content of 4PNC in the reaction product is high before washing with water and that it takes a long period of time for the reaction. (3) Japanese Patent Publication No. 19604/1983 proposes a process for reacting phosphorus trichloride with chlorine to form phosphorus pentachloride, and reacting the thus formed phosphorus pentachloride with ammonium chloride under the presence of a polyvalent metal compound to produce a phosphonitrile chloride oligomer mixture. However, this publication mentions nothing concerning the individual formation rates for 3PNC and 4PNC. (4) A process for the preparation of phosphonitrile oligomer previously proposed by the inventors of the present invention (U.S. Pat. No. 4,567,028, Japanese Patent Application No. 32525/1984) which comprises reacting phosphorus pentachloride with ammonium chloride in the presence of a catalytic amount of pyridine or its alkyl-substituted derivative and a catalytic amount of a polyvalent metal compound. According to this process, a phosphonitrile chloride oligomer mixture having a high content for 3PNC and a low content for 4PNC which is relatively difficult to isolate from 3PNC and causes trouble in preparing a pure 3PNC can be prepared. For example, a phosphonitrile chloride oligomer mixture comprising at least 65% of 3PNC and less than 10% of 4PNC can be easily prepared.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process for preparing a phosphonitrile chloride oligomer mixture with a high content of 3PNC having the greatest demand, with a low content of 4PNC, which is difficult to isolate from 3PNC and thus causes trouble in producing a pure 3PNC product.
The present invention relates to a process for the preparation of a phosphonitrile chloride oligomer mixture having a high 3PNC content and a low 4PNC content which involves reacting phosphorus pentachloride with ammonium chloride in the presence of a catalytic amount of a nitrogen-containing heterocyclic compound selected from the group consisting of quinoline, isoquinoline and their derivatives represented by the general formulae: ##STR3## wherein R stands for an alkyl group or a halogen atom and n stands for zero or an integer of 1 to 7,
and pyridine derivatives represented by the general formula: ##STR4## wherein Q stands for a halogen atom or a hydroxyl group; R' stands for an alkyl group; m stands for an integer of 1 to 5 and P stands for zero or an integer of 1 to 4 with the proviso that the tota number of m and p is from 1 to 5,
and a catalytic amount of a polyvalent metal compound.
According to the process of the present invention, a phosphonitrile chloride oligomer mixture having a high 3PNC content and a low 4 PNC content can be obtained in a high overall yield similarly to the process of the above-mentined U.S. Pat. No. 4,567,028.
DETAILED DESCRIPTION OF THE INVENTION
The process of the present invention is substantially the same as the one described in the above-mentioned U.S. Pat. No. 4,567,028 except that quinoline, isoquinoline, derivatives thereof, or a pyridine derivative is used instead of pyridine or certain alkyl derivatives thereof.
Therefore, the reaction conditions of the process according to the present invention are also nearly the same as those according to the U.S. Pat. No. 4,567,028.
Accordingly, the inert organic solvent and the polyvalent metal compound to be used in the present invention may be each the same as those used in preparing phosphonitrile chloride oligomer by the reaction of phosphorus pentachloride with ammonium chloride according to the prior art.
Inert Organic Solvent
The inert organic solvent usable in the process according to the present invention is any of the inert organic solvents conventionally known for preparing phosphonitrile chloride oligomer from phosphorus pentachloride and ammonium chloride. They include, for example, tetrachloroethane, tetrachloroethylene, monochlorobenzene, dichlorobenzene and nitrobenzene, among which tetrachloroethane and monochlorobenzene are preferable.
The solvent is used in an amount sufficient to enable the reaction system to be stirred uniformly and from 2 to 5 ml of the solvent per gram of phosphorus pentachloride is advantageously used. If the amount of the solvent used is insufficient, it will cause a difficulty in stirring, while on the other hand an excess amount of the solvent may retard the reaction rate as well as result in an economic disadvantage.
Polyvalent Metal Compound
The polyvalent metal compound usable in the process according to the present invention is any of those polyvalent metal compounds employed in the known processes for preparing a phosphonitrile chloride oligomer mixture from phosphorus pentachloride and ammonium chloride. As such polyvalent metal compounds, compounds of metals capable of acting as Lewis acid are effective. Examples of such metals are zinc, magnesium, tin, titanium, boron, aluminum, iron, cobalt, nickel, manganese, chromium and molybdenum. As the forms of the compounds, oxides, hydroxides, carbonates and organic acid salts that can be converted into chlorides with hydrogen chloride, chlorides, sulfates and nitrates can be mentioned.
In addition to the compounds mentioned above, copper salt may also be used.
It is not always essential to previously add the above-mentioned metal compound as such to the reaction system but, depending on the case, the element of the metal may be used while being converted into its chloride in the reaction system.
The polyvalent metal compound is used in a ratio preferably, of more than 1/200 mol and, of more preferably, more than 1/100 mol, per one mol of phosphorus pentachloride. If the amount of the poyvalent metal compound is lower than the above-specified range, no significant effect can be obtained and, on the other hand, an excessive amount, namely more than 1/2 mol of metal compound per one mol of phosphorus pentachloride, will increase the rate of linear polymers. Quinoline, Isoquinoline or Derivatives thereof and Pyridine Derivatives
The quinoline, isoquinoline or derivatives thereof to be used in the present invention is represented by the above general formula wherein R is an alkyl group or a halogen atom. Particularly, compounds represented by the general formula wherein R is a lower alkyl group or a chlorine atom are preferred, while derivatives having both an alkyl group and a halogen atom can be also used. In the case wherein Q in general formula IV represents halogen atom, the preferred halogen is chlorine.
Examples of derivatives of quinoline or isoquinoline to be used in the present invention include 2-methylquinoline, 3-methylquinoline, 4-methylquinoline, 5-methylquinoline, 6-methylquinoline, 7-methylquinoline, 8-methylquinoline, 2-chloroquinoline, 3-chloroquinoline, 4-chloroquinoline, 5-chloroquinoline, 6-chloroquinoline, 2,3-dichloroquinoline, 2-methyl-4-bromoquinoline, 3-chloroisoquinoline and 8-chloroisoquinoline, while those of the pyridine derivatives include 2-hydroxypyridine, 3-hydroxypyridine, 4-hydroxypyridine, 2,6-dihydroxypyridine, 3-hydroxy-6-methylpyridine, 2-chloropyridine, 3-chloropyridine and 2,6-dichloropyridine, though they are not limited to the above examples.
Details for the action of quinoline, isoquinoline, their derivatives and pyridine derivatives have not yet been analyzed at present. However, since the amount of quinoline, isoquinoline, their derivatives or pyridine derivatives used in the present invention is extremely small, it is apparent that the action is different from that of an acceptor or catcher for hydrogen chloride generated as a by-product in the reaction of phosphorus pentachloride and ammonium chloride as described, for example, in "Gaisetsu Muki Kobunshi" (Outline for Inorganic Polymer) (p 69-71, written by Dr. Meisetsu Kajiwara, published by Chijin Shokan, on Apr. 10, 1978).
Quinoline, isoquinoline, their derivatives or pyridine derivatives may be used alone or in the form of a mixture of at least two of them in this invention.
Ratio of Reactants
In the present invention, it is preferred to use ammonium chloride in excess of an equimolar amount relative to phosphorus pentachloride and, usually, 1.1-1.5 mol of ammonium chloride are used per one mol of phosphorus pentachloride. If the amount of ammonium chloride is lower than the above-specified range, phosphorus pentachloride may remain partially unreacted, while on the other hand no further substantial effects can be obtained if the amount is in excess of the above specified range.
The amount of quinoline, isoquinoline, their derivatives or pyridine derivatives used herein is preferably, between 1/20 mol and one mol, and preferably, between 1/15 and 1/2 mol per one mol of phosphorus pentachloride
If the amount of quinoline and the like is insufficient, no substantial effect can be obtained. On the other hand, if it is used excessively, the reaction temperature does not reach the desired temperature to reduce the yield of cyclic oligomers of phosphonitrile chloride and thus lowers the yield of 3PNC.
By the addition of such a small amount of quinoline or the like, the yield of 3PNC can be remarkably enhanced and the reaction time can be remarkably shortened. Accordingly, it can be presumed that quinoline, isoquinoline, derivatives thereof or pyridine derivatives can act catalytically on the reaction system together with the polyvalent metal compound.
Embodiment of the Invention
According to the present invention, the reaction is carried out, for example, as set forth below. An inert organic solvent, ammonium chloride, the above-mentioned polyvalent metal compound and quinoline, isoquinoline, a derivative thereof or a pyridine derivative are charged in a reaction vessel, to which a solution of phosphorus pentachloride in an inert organic solvent is added dropwise under stirring and heating. Alternatively, instead of the solution of phosphorus pentachloride, a solution of phosphorus trichloride in an inert organic solvent may be added dropwise and gaseous chlorine may be introduced through a separate route at a rate corresponding to the dropping rate of the phosphorus trichloride solution.
The reaction temperature, although not particularly restricted, ranges usually from about 100° to 200° C. and, preferably, from about 120° to 145° C. If the reaction temperature is lower than the above-specified range, the reaction scarcely proceeds. It is convenient to use an inert organic solvent having a boiling point within the above-defined temperature range and to allow the reaction to proceed under the reflux of the solvent.
The reaction terminates at a point when the evolution of hydrogen chloride gas ceases. The reaction mixture is preferably aged further for about 2 hours at the same temperature. Then, the reaction mixture is cooled to room temperature and, after filtering out the excess ammonium chloride, the inert organic solvent is distilled off under reduced pressure whereby a phosphonitrile chloride oligomer mixture can be obtained generally at a high yield of more than 90% based on the amount of phosphorus pentachloride employed. The mixture contains more than 65% and, in most cases, more than 70% of 3PNC, while the rate of 4PNC in the mixture is at most not in excess of 10% and, usually, between 4-5%.
The present invention is more specifically described below by way of examples.
EXAMPLE 1
300 g of monochlorobenzene, 38.6 g (0.72 mol) of ammonium chloride, 0.81 g (9.9×10 -3 mol) of zinc oxide and 9.8 g (7.59×10 -2 mol) of quinoline were placed in a 1-l four-necked flask fitted with a stirrer, a reflux condenser, a dropping funnel and a thermometer. A solution of 125.0 g (0.6 mol) of phosphorus pentachloride in 300 g of monochlorobenzene which had been heated to 80° C. to 100° C. was dropwise added over a period of 5 hours to the flask at a temperature of 125° to 133° C., while heating the solvent under reflux and stirring. The obtained content was stirred under reflux for an additional 2 hours and cooled. The unreacted ammonium chloride was filtered out and the filtrate was distilled under a reduced pressure to distill off monochlorobenzene and quinoline, thus obtaining 69.2 g of a phosphonitrile chloride oligomer mixture as a distillation residue in a yield of 99.5%. The yield here and hereinafter refers to the one based on the phosphorus pentachloride used assuming that all of the phosphonitrile chloride formed is (NPCl 2 ) l . The analysis of this mixture by gas liquid chromatography (GLC) showed that it was a phosphonitrile chloride oligomer mixture containing 70.5% of 3PNC and 1.7% of 4PNC.
EXAMPLE 2
The same procedure as the one described in Example 1 was repeated except that 0.94 g (9.9×10 -3 mol) of anhydrous magnesium chloride and 9.8 g (7.59×10 -2 mol) of isoquinoline were used instead of 0.81 g of zinc oxide and 9.8 g of quinoline, respectively, to obtain 59.0 g (yield: 84.8%) of a phosphonitrile chloride oligomer mixture containing 86.7% of 3PNC and 3.0% of 4PNC.
COMPARATIVE EXAMPLES 1
The same procedure as the one described in Example 1 was repeated except that no quinoline was used to obtain 66.4 g of a phosphonitrile chloride oligomer mixture (yield: 95.4%). The GLC analysis of this mixture showed that it was a phosphonitrile chloride oligomer mixture containing 44.5% of 3PNC and 16.9% of 4PNC.
EXAMPLES 3 TO 4
The same procedure as the one described in Example 1 was repeated except that 10.9 g of 3-methylquinoline and 12.4 g of 8-chloroquinoline, both corresponding to 7.59×10 -2 mol, were each used instead of 9.8 g of quinoline. The results are shown in Table 1.
TABLE 1______________________________________ Reaction ProductEx. 3PNC 4PNCNo. Catalyst Yield content (%) content (%)______________________________________3 3-methylquinoline 98.1 77.7 4.64 8-chloroquinoline 96.2 76.7 7.6______________________________________
EXAMPLE 5
The same procedure as the one described in Example 1 was repeated except that 8.6 g (7.59×10 -2 mol) of 3-chloropyridine was used instead of quinoline and that the amount of zinc oxide used was reduced to 0.41 g (4.95×10 -3 mol) 68.3 g of a product was obtained (yield: 98.1%). This product was a phosphonitrile chloride oligomer mixture containing 70.3% of 3PNC and 8.9% of 4PNC.
EXAMPLE 6
The reaction was carried out in the same manner as in Example 1 except that 7.2 g (7.59×10 -2 mol) of 4-hydroxypyridine was used instead of quinoline and that the amount of zinc oxide was 0.41 g (4.95×10 -3 mol). The reaction mixture was cooled and filtered to remove unreacted ammonium chloride. The filtrate was distilled under reduced pressure to remove monochlorobenzene to obtain 65.3 g of a phosphonitrile chloride oligomer mixture as a distillation residue (yield: 95.2%). This mixture contained 67.3% of 3PNC and 5.7% of 4PNC. | Phosphonitrile chloride oligomer, particularly, phosphonitrile chloride trimer, is produced in high yield while suppressing the formation of by-product phosphonitrile chloride tetramer, by reacting phosphorus pentachloride with ammonium chloride in an inert organic solvent, in the presence of a catalytic amount of a compound selected from the group consisting of quinoline, isoquinoline and their drivatives represented by the general formulae: ##STR1## wherein R stands for an alkyl group or a halogen atom and n stands for zero or an integer of 1 to 7,
and pyridine derivatives represented by the general formula: ##STR2## wherein Q stands for a halogen atom or a hydroxyl group; R' stands for an alkyl group; m stands for an integer of 1 to 5 and p stands for zero of an integer of 1 to 4 with the proviso that the total number of m and p is from 1 to 5,
and in the presence of a catalytic amount of a polyvalent metal compound. | 2 |
FIELD OF INVENTION
[0001] The present invention relates to analog-to-digital converters in general, and to differential analog-to-digital converters in particular.
BACKGROUND OF INVENTION
[0002] The usefulness of Analog-to-Digital Converters (ADCs) is well known. One type of ADC is known as a Successive Approximation (SSA) ADC. An SSA ADC uses a Digital-to-Analog Converter (DAC) in a feedback loop, in combination with a comparator and Successive Approximation Register (SAR). An SSA ADC first sets a Most Significant Bit (MSB) using the SAR. The comparator then compares the analog input to be converted with the DAC feedback to determine whether the input is larger or smaller than ½ the full scale reference voltage. If the input voltage is greater than ½ the reference voltage the MSB is left unchanged, otherwise it is reset to the opposite state. The analog input voltage is then reduced by the compared ½reference voltage and compared with ½ 2 , or ¼, the reference voltage to set the next MSB. The process is continued until a desired Least Significant Bit (LSB) is set.
[0003] Traditional SSA ADCs are undesirably prone to introducing errors though, due to the inclusion of both a comparator and DAC. To address this shortcoming, differential SSA ADCs have been proposed wherein two differential inputs are provided. However, many conventional Differential SSA ADCs are relatively costly and complicated in nature. It is an object of the present invention to provide a simplfied differential SSA ADC.
SUMMARY OF INVENTION
[0004] A method for converting a plurality of input signals being indicative of a signal to be converted to a digital output including: setting a plurality of codes each being indicative of a corresponding reference level; and, for each one of the codes, converting the one code to a first analog signal, and summing the first analog signal with a first of the input signals to provide a first summed signal; complementing the one code to provide a complemented code, converting the complemented code to a second analog signal, and summing the second analog signal with a second of the input signals to provide a second summed signal corresponding to the first summed signal; comparing the corresponding first and second summed signals to provide a comparison signal; and, setting at least a portion of the digital output according to the comparison signal.
BRIEF DESCRIPTION OF THE FIGURES
[0005] [0005]FIG. 1 illustrates a block diagram for a differential input analog-to-digital converter according to one aspect of the invention;
[0006] [0006]FIG. 2 illustrates a block diagram of a differential input analog-to-digital converter according to another aspect of the invention;
[0007] [0007]FIG. 3 illustrates a block diagram of a successive approximation analog-to-digital converter according to yet another aspect of the present invention;
[0008] [0008]FIG. 4 illustrates a block diagram of a successive approximation analog-to-digital converter according to yet another aspect of the present invention;
[0009] [0009]FIG. 5 illustrates a block diagram of a successive approximation analog-to-digital converter according to yet another aspect of the present invention;
[0010] [0010]FIG. 6 illustrates a block diagram of a successive approximation analog-to-digital converter according to yet another aspect of the present invention;
[0011] [0011]FIGS. 7A and 7B illustrate diagrams of circuits suitable for use as the digital-to-analog converter DA 1 of FIG. 6 according to an aspect of the present invention;
[0012] [0012]FIGS. 8A and 8B illustrate diagrams of circuits suitable for use as the digital-to-analog converter DA 2 of FIG. 6 according to an aspect of the present invention;
[0013] [0013]FIGS. 9A and 9B illustrate diagrams of alternative circuits suitable for use as the digital-to-analog converter DA 2 of FIG. 6 according to another aspect of the present invention;
[0014] [0014]FIG. 10A illustrates a diagram of circuit suitable for use as the digital-to-analog converter DA 3 of FIG. 6 according to an aspect of the present invention;
[0015] [0015]FIG. 10B illustrates a diagram of a circuit suitable for use as the digital-to-analog converter DA 4 of FIG. 6 according to an aspect of the present invention; and,
[0016] [0016]FIG. 11 illustrates a diagram of a circuit suitable for use as the resistor ladder of FIG. 6 according to an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] In a single input Analog-to-Digital Converter (ADC), a comparator compares an input signal (V in ) and a Digital-to-Analog Converter (DAC) output indicative of a reference level to decode digital outputs. In an N-bit Successive Approximation ADC (SSA), the comparator firstly compares V in with a first fixed voltage, such as ½ the Full Scale voltage (FS), to determine a first Most Significant Bit (MSB) to be output a (N-1) , secondly compares V in −½(a (N-1) )FS with ¼ FS to determine a second MSB a (N-2) , and so on until comparing V in −½ (N-1) (a (N-1) )FS, where I is from 1 to (N-1), to decide a Least Significant Bit (LSB) a (0) .
[0018] For differential SSA ADC's, two input signals are provided, V in+ and V in− . The relationship between these inputs is characterized by V in− =FS−V in+ . If the full scale value is normalized for sake of discussion, then V in− =1−V in+ . In the case of analog-to-digital conversion, each input signal subtracts with a digital-to-analog feedback signal to enable the comparator to determine the decoded digital output. Assuming DA (+) is a digital-to-analog feedback signal corresponding to the V in+ input and DA (−) is a digital-to-analog feedback signal corresponding to the V in− input, the inputs to the comparator take the form of V in+ −DA (+) and V in− −DA (−) . The present invention takes advantage of the following determined relationship between DA (+) and DA (−) .
[0019] Referring now to the Figures, like references identify like elements of the invention. FIG. 1 illustrates a block diagram of a differential input SSA ADC 5 according to one aspect of the invention. Generally, the ADC 5 includes: a comparator 10 including a (+) input 12 , (−) input 14 and output 16 ; a (+) input 20 for receiving V in+ and a (−) input 30 for receiving V in− . Coupled to the output 16 is a Successive Approximation Register (SAR) 40 . Coupled to an output of the SAR 40 are digital outputs 50 and Digital-to-Analog Converters (DACs) 60 , 70 . A (+) summing circuit or summer 80 includes a (+) input 82 , a (−) input 84 and an output 86 . The input 82 is coupled to input 20 , while input 84 is coupled to output of DAC 60 and output 86 is coupled to comparator 10 input 12 . A (−) summing circuit or summer 90 includes a (+) input 92 , a (−) input 94 and an output 96 . The input 92 is coupled to input 30 , while input 94 is coupled to an output of DAC 70 and output 96 is coupled to comparator 10 input 14 . The DAC 60 produces the DA (+) signal while the DAC 70 produces the DA (−) signal. Hence, comparator 10 input 12 receives V in+ −DA (+) and comparator 10 input 14 receives V in− −DA (−) . DA (+) and DA (−) normalized with digital codes and voltage amplitude such that in the analog domain they do not exceed 1 in normal operation.
[0020] The ADC 5 receives the differential signals V in+ and V in− at the inputs 20 , 30 , i.e.
V in+ − DA (+) =−[V in− −DA (−) ] (1)
[0021] By substituting: V in+ +V in− =1 into Eq. 1 , due to normalization, DA (−) =[1−DA (+) ]=[FS−DA (+) ] in the analog domain, or,
DA (−) =2's complement of DA (+) , in the digital domain. (2)
[0022] In the digital domain, for an N-bit ADC,
DA ( + ) = a ( N - 1 ) 1 2 + a ( N - 2 ) 1 4 + a ( N - 3 ) 1 8 + … + a ( 1 ) ( 1 2 ) N - 1 + a ( 0 ) ( 1 2 ) N ,
or
1 = [ 1 2 + 1 4 + 1 8 + 1 16 + … + ( 1 2 ) N - 1 + ( 1 2 ) N ] + ( 1 2 ) N ,
where a ( 1 ) can be 0 or 1 , so DA ( - ) = 1 - DA ( + ) = 1 - { a ( N - 1 ) 1 2 + a ( N - 2 ) 1 4 + a ( N - 3 ) 1 8 + … + a ( 1 ) ( 1 2 ) N - 1 + a ( 0 ) ( 1 2 ) N } = [ 1 - a ( N - 1 ) ] 1 2 + [ 1 - a ( N - 2 ) ] 1 4 + [ 1 - a ( N - 3 ) ] 1 8 + … + [ 1 - a ( 1 ) ] ( 1 2 ) N - 1 + [ 1 - a ( 0 ) ] ( 1 2 ) N + ( 1 2 ) N = [inverse of DA ( + ) ] + ( 1 2 ) N ( 3 )
[0023] Thus, for a case as DA (+) =0000 0000 0000 0000, the lowest possible voltage in a 12-bit ADC, DA (−) =1111 1111 1111 1111+0000 0000 0000 0001=1 0000 0000 0000 0000, the highest full range voltage, remembering that the 2's complement of a binary number N=(1's complement of N)+1 LSB . And, for a case where DA (+) =1111 1111 1111 1111, the highest code which is one LSB below the full voltage range in a 12-bit ADC, DA (−) =0000 0000 0000 0001, one LSB above the lowest voltage.
[0024] Thus in any N-bit ADC according to the present invention, using Eq. 2, the ADC circuit of FIG. 1 can be realized as is illustrated in FIG. 2 using a simple 2's complementary conversion circuit at the output of SAR 40 in combination with DAC 70 to provide the DA (−) signal according to an aspect of the present invention. Referring now also to FIG. 2, there is shown a block diagram for a differential input SSA ADC 100 according to an aspect of the invention.
[0025] Still referring to FIG. 2, there is shown the ADC of FIG. 1 now also illustrating a 2's complementary conversion circuit 110 coupled between the SAR 40 and DAC 70 . Thus, DA (−) which is the 2's complement of DA (+) , is provided as an input to the DAC 70 . The 2's complementary circuit 110 has a carry out bit as the MSB, i.e. is has (N+1) bits.
[0026] The relationship between DA (+) and DA (−) in Eq. 2 is valid for differential ADC's using different types of digital-to-analog conversion schemes. According to another aspect of the present invention, the digital codes supplied at the output of the SAR 40 are decomposed into groups of DACs and then summed through a network of ratio capacitors and resistor ladders to achieve a correct weighting for the individual components and analog voltage level. Referring now also to FIG. 3, there is shown a 10-bit SSA ADC 200 block diagram according to an aspect of the present invention. Like elements to those described with reference to the previous figures will not be again described. The ADC 200 illustrated therein uses pseudo differential inputs V IN 20 and V INR 30 ′, where V IN 20 is a real analog input signal to be converted and V INR 30 ′ is a DC or zero value at the lowest analog input voltage.
[0027] Referring still to FIG. 3, the DAC 60 is decomposed into four (4) smaller DACs 62 : DA 1 , DA 2 , DA 3 and DA 4 . DA 1 processes four bits, DA 2 processes four bits plus one offset bit, DA 3 processes 1 bit and DA 4 processes 1 bit according to another aspect of the invention. Further, adder 210 is interposed between SAR 40 and digital outputs 50 .
[0028] Referring now to FIG. 4, there is shown a 10-bit SSA ADC 220 according to another aspect of the present invention. Again, like elements to those described with reference to the previous figures will not be again described. Separate decoding circuits 62 and 72 ″ are provided for the differential inputs 20 , 30 , respectively. DA (+) is again decomposed into four DACs 62 : DA 1(+) , DA 2(+) , DA 3(+) and DA 4(+) , analogously to the SSA 200 of FIG. 3. DA (−) is also decomposed into four DACs 72 : DA 1(−) , DA 2(−) , DA 3(−) and DA 4(−) . Again, DA (−) is the 2 's complementary input of DA (+) (See EQ.2).
[0029] Still referring to FIG. 4, an offset bit D 4S is added to DA (+) , such that DA′ (+) =DA (+) +D 4S . Equation (2) remains applicable, such that DA′ (−) =1−DA′ (+) =1−[DA (+) +D 4S ]=[1−DA (+) ]−D 4S . DA 1(+) is a four bit decoder, DA 2(+) is a five bit decoder, while DA 3(+) and DA 4(+) are one bit decoders. DA 1(+) receives the four MSBs: D 9 , D 8 , D 7 , D 6 output from SAR 40 . DA 2(+) receives the next four MSBs: D 5 , D 4 , D 3 , D 2 and the offset bit D 4S output from SAR 40 . DA 3(+) receives the second LSB D 1 , while DA 4(+) receives the LSB D 0 output from SAR 40 . DA 1(−) is a 5 bit decoder, DA 2(−) is a 4 bit decoder, while DA 3(−) and DA 4(−) are one bit decoders. DA 1(−) receives the four MSBs: D 9 , D 8 , D 7 , D 6 and bit D 10 output from SAR 40 . DA 2(−) receives the next four MSBs: D 5 , D 4 , D 3 , D 2 output from SAR 40 . DA 3(−) receives the second LSB D 1 , while DA 4(−) receives the LSB D 0 output from SAR 40 . Adder 210 serves to account for offset bit D 4S being parsed from the output of SAR 40 .
[0030] Referring now to FIG. 5, there is shown an SSA ADC 230 according to yet another aspect of the present invention. Again, like elements to those described with reference to the previous figures will not be again described. A single decoder circuit is used therein for driving the DA (+) and DA (−) DACs 62 , 72 . Basically, the DA (+) DAC is decomposed into four DACs 62 : DA 1(+) , DA 2(+) , DA 3(+) and DA 4(+) 62 ′. In mathematical expression this yields:
DA (+) =( a 9 ,a 8 ,a 7 ,a 6 ,0,0,0,0,0,0)+(0,0,0,0 , a 5 ,a 4 ,a 3 ,a 2 ,0,0)+(0,0,0,0,0,0,0,0, a 1 ,0)+(0,0,0,0,0,0,0,0,0 , a 0 )
= GP 1(+) +GP 2(+) +GP 3(+) +GP 4(+)
[0031] The 2's complement of DA (+) is DA (−) (See EQ.2), and DA (−) =1−DA (+) . Hence,
DA(−)=( 1 −a 9 ,1 −a 8 ,1 −a 7 ,1 −a 6 ,0,0,0,0,0,0)+(0,0,0,0,1−a 5 ,1 −a 4 ,1 −a 3 ,1 −a 2 ,0,0)+(0,0,0,0,0,0,0,0,1 −a 1 ,0)+(0,0,0,0,0,0,0,0,0,1 −a 0 )+(0,0,0,0,0,0,0,0,0,1) (4)
= GP 1(−) +GP 2(−) +GP 3(−) +GP 4(−)
[0032] Where a 0 =0, GP 4(−) =(0,0,0,0,0,0,0,0,1,0). So, GP 4(31 ) has a range of (0,0,0,0,0,0,0,0,0,1) to (0,0,0,0,0,0,0,0,1,0). In the DA 4 decoder, the a 0 =0 selects V=0 for DA 4(+) and V=V 4 (1,0) for DA 4(−) . Further, a 0 =1 selects V=V 4 (0,1) for DA 4 (+) and DA 4 (−). Thus, the same decoder can be used for both DA 4 (+) and DA 4 (−). It should be noted that V 4 (1,0) is twice the value of V 4 (0,1), and V 4 (0,0) is 0V. Further, in this case V 4 (0,1) is {fraction (1/1024)} the full voltage range of the ADC.
[0033] Where a 0 =0 and a 1 =0, GP 3(−) =(0,0,0,0,0,0,0,1,0,0). Where a 0 =0, a 1 =1, GP 3(−) =(0,0,0,0,0,0,0,0,1,0). Accordingly, GP 3(−) ranges from (0,0,0,0,0,0,0,0,1,0) to (0,0,0,0,0,0,0,1,0,0). In the DA 3 decoder, the a 1 =0 selects V=0 for DA 3(+) and V=V 3 (1,0) for DA 3(−) ; while a 1 =1 selects V=V 3 (0,1) for DA 3(+) and DA 3(−) . Thus, a same decoder can be used for both DA 3(+) and DA 3 (−). V 3 (1,0) is twice V 3 (0,1), and V 3 (0,0) is 0V and V 3 (0,1) is {fraction (1/512)} the full voltage range of the ADC.
[0034] Where a 0 =a 1 =0, and a 2 =a 3 =a 4 =a 5 =0, GP 2(−) =(0,0,0,1,0,0,0,0,0,0). Where a 0 =0, a 1 =0, and a 2 =a 3 =a 4 =a 5 =1, GP 2(−)=( 0,0,0,0,0,0,0,1,0,0). Hence, GP 2(−) ranges from (0,0,0,0,0,0,0,1,0,0) to (0,0,0,1,0,0,0,0,0,0). As DA 2 is a four bit decoder, at a 2 =a 3 =a 4 =a 5 =0, the decoded output selects V=0 for DA 2(+) and V=V 2 (1,0,0,0,0) for DA 2(−) . While at a 2 =a 3 =a 4 =a 5 =1, the decoded output selects V=V 2 (1,1,1,1) for DA 2 (+) and V=V 2 (0,0,0,1) for DA 2(−) . Thus, a same decoder can be used for both DA 2(+) and DA 2(−) . V 2 (1,0,0,0,0) is 16 times the value of V 2 (0,0,0,1). V 2 (1,1,1,1) is 15 times the value of V 2 (0,0,0,1), and V 2 (0,0,0,0) is 0V. V 2 (0,0,0,1) is {fraction (1/256)} the full scale voltage range of the ADC.
[0035] It should be noted that when an offset bit a 4S is added into DA 2(+) , the carry bit from this summation does not change the original DA 1(+) , So, the new DA 2′(+) has the same maximum value of (1,0,0,1,1) if a 4S =(0,1,0,0). The new range of new DA 2′(+) in this particular case is (1,0,1,0,0) instead of (1,0,0,0,0). Hence,
DA 2′(−) =[(1,0,1,0,0)− DA 2(+) −a 4S ]
=[(1,0,0,0,0)− DA 2(+) ]+(0,0,0,0)− a 4S
= DA 2(−) +(0,1,0,0)− a 4S ,
[0036] where a 4S is a simplified expression for (0 ,a 4S , 0,0).
[0037] Thus, where a 4S =(0,1,0,0), DA 2′(−) =DA 2(−) , DA 2′(+) =DA 2(+) +(0,1,0,0). And, where a 4S =(0,0,0,0), DA 2′(−) =DA 2(−) +(0,1,0,0), and DA 2′(+) =DA 2(+) . Thus, a decoding circuit used in connection with DA 2(+) with an offset bit can be used for DA 2′(+) and DA 2′(−) as well. In this case, the decoded output of (0,0,0,0) in DA 2′(+) selects V=0, and selects V=V 2 (1,0,1,0,0) in DA 2′(−) . The decoded output of (1,0,0,1,1) selects V=V 2 (1,0,0,1,1) for DA 2′(+) and selects V=V 2 (0,0,0,1) for DA 2′(−) . V 2 (1,0,1,0,0) is 20 times the value of V 2 (0,0,0,1). V 2 (1,0,0,1,1) is 19 times the value of V 2 (0,0,0,1) and V 2 (0,0,0,0) is 0V. V 2 (0,0,0,1) is {fraction (1/256)} the full scale voltage range of the ADC.
[0038] Where a0=a1=a2=a3=a4=a5=0, and a6=a7=a8=a9=0, GP1(−)=(1,1,1,1,1,1,1,1,1,1)+(0,0,0,0,0,0,0,0,0,1)=(1,0,0,0,0,0,0,0,0,0,0), an 11-bit code. Where a0=a1=a2=a3=a4=a5=0 and a6=a7=a8=a9=1, GP1(−)=(0,0,0,1,0,0,0,0,0,0). Accordingly, Gp1(−) ranges from (0,0,0,1,0,0,0,0,0,0) to (1,0,0,0,0,0,0,0,0,0,0). DA 1 uses a four-bit decoder, where a6=a7=a8=a9=0 the decoded output selects V=0 for DA 1 (+) and V=V 1 (1,0,0,0,0) for DA 1 (−). Where a6=a7=a8=a9=1, the decoded output selects V=V 1 (1,1,1,1) for DA 1 (+) and V=V 1 (0,0,0,1) for DA 1 (−). Thus, a same decoder can be used for both DA 1 (+) and DA 1 (−). V 1 (1,0,0,0,0) is {fraction (1/16)} the full scale voltage range of the ADC.
[0039] Referring now also to FIG. 6, there is shown a 10-bit SSA ADC 250 according to yet another aspect of the present invention. Again, the ADC 250 generally includes comparator 10 , (+) differential analog input 20 , (−)differential analog input 30 , SAR 40 , adder 210 and digital outputs 50 . In response to the comparator 10 , SAR 40 provides a 10-bit digital code, having an MSB D 9 , LSB D 0 and offset bit D 4S . Digital-to-analog conversion is performed by four DACs 62 : DA 1 , DA 2, DA 3 and DA 4 . DA 1(+) provides DA 1(+) and DA 1(−) using the four MSBs supplied by the SAR 40 , i.e. D 9 , D 8 , D 7 and D 6 . DA 2 provides DA 2(+) and DA 2(−) using the next four MSBs supplied by the SAR 40 , i.e. D 5 , D 4 , D 3 and D 2 , and the offset bit D 4S . DA 3 and DA 4 provide DA 3(+) , DA 3(−) and DA 4(+) and DA 4(−) using the two LSBs supplied by the SAR 40 , i.e. D 1 , D 0 . A resistor ladder 260 is provided and uses a reference voltage V LHF and span voltage V RHF to supply a plurality of voltages Va (0-16) and Vb (0-20) as will be described in greater detail with regard to FIG. 11. Still referring to FIG. 6, capacitors 252 serve to appropriately weight DA 1(+) , DA 2(+) , DA 3(+) , DA 4(+) , DA 1(−) , DA 2(−) , DA 3(−) and DA 4(−) as they are supplied to the comparator 10 . In the illustrated 10-bit SSA ADC of FIG. 6, if the capacitors 252 corresponding to DA 3(+) , DA 4(+) , DA 3(−) and DA 4(−) have a given capacitance C, the capacitors 252 corresponding to DA 2(+) and DA 2(−) should each have a capacitance fours time the given value, or 4C while the capacitors 252 corresponding to DA 1(+) and DA 1(−) should each have a capacitance eight times the given value of 8C.
[0040] Referring now to FIG. 7A also, there is shown a circuit 255 for generating DA (1+) . Generally, the circuit 255 includes a 4-to-16 decoder 270 which receives the four MSBs provided by the SAR 40 (FIG. 6), i.e. D 9 , D 8 , D 7 and D 6 and provides 16 pairs of outputs, T (0-15) , TN (0-15) in response thereto. The circuit 255 further includes a plurality of switches 256 responsive to the pairs of signals T and TN output from the 4-16 decoder 270 to supply corresponding ones of supplied voltages Va 0 -Va 16 as DA 1(+) . The following Table-1 illustrates which of the voltages Va (0-15) are provided responsively to T (0-15) and TN (0-15) by the switches 256 .
TABLE 1 DA 1(+) Va (0-15) T (0-15) TN (0-15) 0 0 0 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15 15 15
[0041] Thus, a first switch 256 ′, uses signals T (0) and TN (0) to selectively supply voltage Va (0) as DA 1(+) .
[0042] Referring now also to FIG. 7B, there is shown a circuit 280 for generating signal DA 1(−) . The circuit 280 includes a plurality of switches 285 also responsive to the pairs of signals T and TN output from the 4-16 decoder 270 (FIG. 7A) to supply corresponding ones of voltages Va 0 -Va 16 as DA 1(−) . The following Table-2 illustrates which of voltages Va (0-15) are provided responsively to T (0-15) and TN (0-15) by the switches 285 .
TABLE 2 DA 1(−) Va (0-15) T (0-15) TN (0-15) 1 15 15 2 14 14 3 13 13 4 12 12 5 11 11 6 10 10 7 9 9 8 8 8 9 7 7 10 6 6 11 5 5 12 4 4 13 3 3 14 2 2 15 1 1 16 0 0
[0043] Thus one of the switches 280 ′, uses signals T (0) and TN (0) to selectively supply voltage Va (16) as signal DA 1(−) .
[0044] Referring now to FIG. 8A, there is shown a circuit 290 for generating DA 2(+) . Generally, circuit 290 includes a 5-to-20 decoder 300 which receives the four next MSBs provided by the SAR 40 (FIG. 6), i.e. D 5 , D 4 , D 3 and D 2 , as well as the offset bit D 4S , and provides 20 pairs of outputs, T (0-19) , TN (0-19) . The circuit 290 includes a plurality of switches 295 responsive to these pairs of signals T and TN output from the 5-20 decoder 300 to supply corresponding ones of voltages Vb 0 -Vb 19 as DA 2(+) . The following Table-3 illustrates which of voltages Vb (0-20) , are provided responsively to T (0—19) and TN (0-19) by the switches 295 .
TABLE 3 DA 2(+) Vb (0-19) T (0-19) TN (0-19) 0 0 0 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 13 13 14 14 14 15 15 15 16 16 16 17 17 17 18 18 18 19 19 19
[0045] Thus, a first switch 295 ′ uses signals T (0) and TN (0) to selectively supply voltage Vb (0) as DA 2(′) .
[0046] Referring now to FIG. 8B, there is shown a circuit 310 for generating DA 2(−) . Generally, the circuit 310 includes a plurality of switches 315 responsive to these pairs of signals T and TN output from the 5-20 decoder 300 to supply corresponding ones of voltages Vb 0 -Vb 20 as DA 2(−) . The following Table-4 illustrates which of voltages Vb (0-19) are provided as DA 2(−) responsively to T (0-19 ) and TN (0-19) by the switches 315 .
TABLE 4 DA 2(−) Vb (0-20) T (0-19) TN (0-19) 1 19 19 2 18 18 3 17 17 4 16 16 5 15 15 6 14 14 7 13 13 8 12 12 9 11 11 10 10 10 11 9 9 12 8 8 13 7 7 14 6 6 15 5 5 16 4 4 17 3 3 18 2 2 19 1 1 20 0 0
[0047] Thus, a switch 315 ′ uses signals T (0) and TN (0) to selectively supply voltage Vb (20) .
[0048] Referring now to FIGS. 9A and 9B, therein is illustrated circuits 290 ′ and 310 ′ according to another aspect of the present invention. Therein a 5-20 decoder 300 ′ is used to provide signals T (0−19) in response to input of the next four MSBs, i.e. D 5 , D 4 , D 3 and D 2 , and the offset bit D 4S . A plurality of transistors 296 are used to selectively provide voltages Vb( 0-19) as DA 2(+) and DA 2(−) in response to T (0-20) . The following Tables 5 and 6 show which ones of signals T (0-20) are used to selectively activate the transistors 296 to provide DA 2(+) and DA 2(−) , respectively.
TABLE 5 DA 2(+) Vb (0-19) T (0-19) 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19
[0049] [0049] TABLE 6 DA 2(−) Vb (0-19) T (0-19) 1 19 2 18 3 17 4 16 5 15 6 14 7 13 8 12 9 11 10 10 11 9 12 8 13 7 14 6 15 5 16 4 17 3 18 2 19 1 20 0
[0050] Referring now to FIG. 10A, there is shown a circuit 320 for providing DA 3(+) and DA 3(−) . Still referring to FIG. 10A, the circuit 320 receives bit D 1 via an input. The input is coupled to an inverter 321 and a first input of a NOR gate 322 . The inverter 321 outputs to a first input of a second NOR gate 323 . The output of the NOR gate 322 is provided as a second input for NOR gate 323 . Likewise, the output of NOR gate 323 is provided as a second input for NOR gate 322 . In other words, the NOR gates 322 , 323 are cross-coupled similarly as for a conventional S-R latch. The output of NOR gate 322 is also coupled to a gate input for a transistor 324 and a gate input for a transistor 326 . The output of NOR gate 323 is coupled to a gate input of a transistor 325 and a gate input of a transistor 327 . The transistor 324 is provided on a source input with Vb (0) and transistor 325 is provided on a source input with Vb (2) . The drains of transistors 324 and 325 are coupled to a common node to provide DA 3(+) . Accordingly, Vb (0) and Vb (2) are selectively provided as DA 3(+) dependently upon D 1 . Similarly, transistor 326 is provided on a source input with Vb (4) and transistor 327 is provided on a source input with Vb (2) . The drains of transistors 326 and 327 are coupled to a common node to provide DA 3(−) . Accordingly, Vb (4) and Vb (2) are selectively provided as DA 3(−) dependently upon D 1 .
[0051] Referring now to FIG. 10B, there is shown a circuit 330 for providing DA 4(+) and DA 4(31 ) . Still referring to FIG. 10B, the circuit 330 receives D 0 via an input. The input is coupled to an inverter 331 and a first input of a NOR gate 332 . The inverter 331 outputs to a first input of a second NOR gate 333 . The output of the NOR gate 332 is provided as a second input for NOR gate 333 . Likewise, the output of NOR gate 333 is provided as a second input for NOR gate 332 . In other words, the NOR gates 332 , 333 are cross-coupled similarly as for a conventional S-R latch. The output of NOR gate 332 is coupled to a gate input for a transistor 334 and a gate input for a transistor 336 . The output of NOR gate 333 is coupled to a gate input of a transistor 335 and a gate input of a transistor 337 . The transistor 334 is provided on a source input with Vb (0) and transistor 335 is provided on a source input with Vb (1) . The drains of transistors 334 and 335 are coupled to a common node to provide DA 4(+) . Accordingly, Vb (0) and Vb (1) are selectively provided as DA 4(+) dependently upon D 0 . Similarly, transistor 336 is provided on a source input with Vb (2) and transistor 337 is provided on a source input with Vb (1) . The drains of transistors 336 and 337 are coupled to a common node to provide DA 4(−) . Accordingly, Vb (2) and Vb (1) are selectively provided as DA 4(−) dependently upon D 0 .
[0052] Referring finally to FIG. 11, there is shown the resistor ladder 260 discussed with regard to FIG. 6. The resistor ladder 260 provides the voltages Va (0-16) and Vb (0-20) as have been discussed. The resistor ladder 260 includes two serially-connected resistor ladders 261 , 262 . These ladders 261 , 262 are cross-connected to reduce resistivity non-unifornity due to fabrication, for example. Each resistor ladder 261 , 262 , is divided into 16 main sections Va (0-16) by resistors 263 . Between Va 0 and Va 1 , each ladder is subdivided into 8 sections Vb (0-8) . Between Va 1 and Va 2 , each ladder is subdivided into another 8 sections Vb (9-16) . Between Va 2 and Va 3 , each ladder is subdivided into another 5 sections Vb (17-20) . Each Vb section is {fraction (1/128)} of the full range for the analog signal input to an ADC utilizing the ladder 260 . The resistors that make up the ladder 260 are preferably all about the same value, for example 1k ohm, within a degree of accuracy of about 1 ohm, for example.
[0053] Although the invention has been described and pictured in a preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form, has been made only by way of example, and that numerous changes in the details of construction and combination and arrangement of parts may be made without departing from the spirit and scope of the invention as hereinafter claimed. It is intended that the patent shall cover by suitable expression in the appended claims, whatever features of patentable novelty exist in the invention disclosed. | A method and system for converting a plurality of input signals being indicative of a signal to be converted to a digital output including: setting a plurality of codes each being indicative of a corresponding reference level; and, for each one of the codes, converting the one code to a first analog signal, and summing the first analog signal with a first of the input signals to provide a first summed signal; complementing the one code to provide a complemented code, converting the complemented code to a second analog signal; summing the second analog signal with a second of the input signals to provide a second summed signal corresponding to the first summed signal. The corresponding first and second summed signals are compared to provide a comparison signal. At least a portion of the digital output is set according to the comparison signal. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is the US National Stage of International Application No. PCT/EP2003/009236, filed Aug. 20, 2003 and claims the benefit thereof. The International Application claims the benefits of European Patent application No. 02020817.9 EP filed Sep. 17, 2002, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to method for producing a three-dimensional molded body.
BACKGROUND OF THE INVENTION
[0003] DE 199 03 436 C2 discloses a method for producing three-dimensional bodies in which, firstly, an enveloping body is built up and, subsequently, it is filled at least partly with a second material. The enveloping body is an essential prerequisite for the method.
[0004] EP 892 090 A1 shows a method for repairing a three-dimensional body in which a layer is applied only in the superficial region.
[0005] U.S. Pat. Nos. 4,085,415, 3,939,895, 4,543,235 and 4,036,599 show methods for introducing fibers into cast components.
[0006] Casting shells are required for the casting.
[0007] DE 100 24 343 A1 and EP 0 799 904 B1 show methods for producing gradients in a metallic or ceramic microstructure.
SUMMARY OF THE INVENTION
[0008] It is therefore the object of the invention to present a method in which a three-dimensional molded body can be produced in a simple way.
[0009] The object is achieved by a method according to the claims. In this case, various consistencies of at least two partial quantities in the form of layers of at least one starting material are bonded to form a three-dimensional molded body.
[0010] Advantageous developments of the invention emerge from the subclaims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings:
[0012] FIG. 1 shows an apparatus given by way of example, with which the method according to the invention is carried out,
[0013] FIG. 2 shows a further method step of the method according to the invention,
[0014] FIG. 3 shows a cross section of a partial quantity which is processed by means of the method according to the invention and
[0015] FIG. 4 shows a further cross section of a partial quantity,
[0016] FIG. 5 shows a partial quantity with fibers,
[0017] FIG. 6 shows a further apparatus for carrying out the method according to the invention, and
[0018] FIG. 7 shows a further apparatus given by way of example, with which the method according to the invention is carried out.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 shows an apparatus 1 given by way of example for carrying out the method according to the invention.
[0020] Arranged inside an optionally provided heater 34 is for example a starting plate 4 , on which a first partial quantity 7 in the form of a layer of at least a first starting material lies.
[0021] The partial quantity 7 can be displaced with respect to the heater 34 in a building-up direction 25 of the three-dimensional molded body, or the heater 34 is displaced with respect to the partial quantity 7 or the molded body to be built up.
[0022] A three-dimensional molded body, for example a turbine blade, is produced from the partial quantity 7 in the form of a layer.
[0023] The partial quantity 7 is, in terms of consistency, for example a powder compact in the form of a layer, a powder bed 52 to be built up layer by layer ( FIG. 6 ) or a metal sheet or a metal foil (both in the form of a layer).
[0024] In the case of metal foils or metal sheets, at least one laser 16 for example cuts out the desired geometry for the three-dimensional molded body to be produced, unless it is already in this form.
[0025] In one of the first method steps, the first partial quantity 7 in the form of a layer is for example compacted. This is necessary in the case of powder compacts and powder beds, but not necessarily in the case of metal sheets or metal foils.
[0026] This may take place by known thermal methods of compaction (sintering) or with laser beams 13 or electron beams which originate from the laser 16 and act on the partial quantity 7 (laser sintering).
[0027] The laser beams 13 may fully or partially cover the first partial quantity 7 and, if appropriate, even melt the material of the first partial quantity 7 .
[0028] The laser 16 and/or its laser beams 13 may change their position with respect to the first partial quantity 7 in all spatial directions. In a control unit 37 , a CAD model of the three-dimensional molded body is stored, so that the laser 16 /laser beams 13 is/are controlled in such a way that the desired three-dimensional molded body is produced with its outer and inner dimensions in accordance with the CAD model from the first partial quantity 7 and further partial quantities 10 ( FIG. 2 ).
[0029] The laser 16 may have the effect that the partial quantity 7 is compacted, and, if appropriate, a shaping of the first partial quantity 7 takes place. Shaping does not have to take place, for example if the powder compact corresponds in its form to the corresponding part of the three-dimensional molded body already or after shrinkage following compaction.
[0030] As many partial quantities 10 in the form of layers as correspond to the height of the molded body in the building-up direction 25 are required to complete the molded body.
[0031] FIG. 2 shows a further method step of the method according to the invention.
[0032] A second partial quantity 10 in the form of a layer is arranged on the first partial quantity 7 .
[0033] The second partial quantity 10 consists for example, but not necessarily, of a second starting material, in order for example to produce a material gradient in the molded body.
[0034] The second partial quantity 10 is for example likewise compacted, in particular by exposure to laser beams 13 .
[0035] If appropriate, the laser 16 also has the effect of shaping the second partial quantity 10 .
[0036] The thermal treatment, for example the laser treatment, has the effect that the partial quantities 7 , 10 in the form of layers are bonded to one another, for example by sintering or fusion.
[0037] A further possibility for producing a three-dimensional molded body is that the three-dimensional molded body to be produced from the at least two partial quantities 7 , 10 has a directionally solidified structure, i.e. a monocrystalline structure (SX) or grain boundaries (DS) only along one direction (building-up direction 25 ). This may for example take place by the starting plate 4 having for example a desired crystalline structure of the three-dimensional molded body to be produced. For this method, in a first step ( FIG. 1 ), the first partial quantity 7 is melted and cooled in a controlled manner, creating the desired crystalline structure.
[0038] In a second step ( FIG. 2 ), the second partial quantity 10 is placed on and melted, whereby it bonds with the first partial quantity 7 . If appropriate, the first partial quantity 7 is slightly melted at the surface.
[0039] By suitable guidance, for example of the heater 34 , and/or heating by the laser 16 , the solidification front with the desired crystalline structure advances from the first partial quantity 7 into the second partial quantity 10 .
[0040] This method can be repeated as often as desired.
[0041] With respect to the growth conditions for producing crystalline structures by means of epitaxial growth, reference is made here to EP 892 090 A1, which is expressly intended to be included as part of this disclosure.
[0042] The use of the laser 16 , i.e. a corresponding movement of the laser beams over the partial quantities 7 , 10 , has the effect for example that only the regions of the partial quantities 7 , 10 that correspond to the dimensions of the desired three-dimensional molded body to be produced are compacted or melted. The partial quantities 7 , 10 therefore do not have to correspond in their dimensions to the desired three-dimensional molded body.
[0043] An outer mold or envelope, as is necessary for example when casting, is not necessary here.
[0044] The bonding of the partial quantities in the form of layers is repeated as often as it takes to create the molded body.
[0045] The molded body is completely created just from individual layers which are for example 0.1 mm to 1 cm thick.
[0046] In particular, the molded body is longer perpendicularly to a plane in which the partial quantities 7 , 10 in the form of layers extend than the extent of the molded body in this plane, as is the case for example in the case of a turbine blade. Such a turbine blade is produced layer by layer, for example from the blade root to the blade tip.
[0047] FIG. 3 shows a cross section of a partial quantity 7 , 10 perpendicularly to the building-up direction 25 .
[0048] The partial quantity 7 is for example a powder compact which in the interior has a cavity 19 , which is enclosed by a wall 22 . Such hollow components are used in particular as turbine blades (three-dimensional component) which are cooled in the interior 19 and are enclosed by an outer wall 22 .
[0049] The partial quantity 7 , 10 may also be a powder compact which does not have a cavity 19 .
[0050] By suitable guidance of the laser beams 13 , only the regions of the partial quantity 7 , 10 that correspond to the wall 22 of the component to be produced (three-dimensional molded body) are compacted or melted and left to solidify. The pressed powder in the middle remains uncompacted and loose and can be easily removed after production of the three-dimensional molded body.
[0051] Similarly, metal sheets or foils may be used, given their outer and inner form by the laser 16 and then melted.
[0052] FIG. 4 shows further partial quantities 7 , 10 .
[0053] The partial quantity 7 , 10 is for example a powder compact and may have in its composition a gradient or a layer structure in the building-up direction 25 or in the plane perpendicular to the building-up direction 25 . The latter is the case in FIG. 4 .
[0054] In an inner region 31 , the partial quantity 7 , 10 consists for example of one material, for example a powder for a nickel-based or cobalt-based superalloy. In the outer region, the inner region 31 is enveloped by a layer 28 which has a different material composition than the inner region 31 . This is for example a powder for an MCrAlY layer, M standing for an element of the group comprising iron, cobalt or nickel.
[0055] When the partial quantities 7 , 10 , 52 are exposed to the laser beams 13 , the parameters of the latter (intensity, wavelength, size, . . . ) are, if appropriate, adapted to the gradient.
[0056] FIG. 5 shows by way of example a first partial quantity 7 , a second partial quantity 10 , in which fibers 40 are arranged, and a further partial quantity 55 .
[0057] The fibers 40 may be arranged in a directed manner or randomly. Similarly, fiber mats may be used. The fibers 40 may have been incorporated in the powder compacts 7 , 10 or be already present in the metal sheets.
[0058] The next partial quantity 55 in the form of a layer may likewise have no fibers, but by no means has to, because for example no mechanical reinforcement is necessary there. The three-dimensional molded body consequently has a material gradient, as also exists in principle in FIG. 4 .
[0059] FIG. 6 shows a further apparatus 1 for carrying out the method according to the invention.
[0060] The laser 16 acts with its laser beams 13 on a powder bed 52 , which represents a further consistency of the at least one starting material.
[0061] The method is started with a specific quantity of powder of a first starting material, which represents the powder bed 52 (first partial quantity 7 ).
[0062] Further material in the form of powder (second partial quantity 10 ) is added continuously or discontinuously to the powder bed 52 by means of a first and/or also a second material supply 46 , 49 , so that the powder bed 52 increases layer by layer in the building-up direction 25 .
[0063] The composition of the material supplied may change by adding a second starting material to the first starting material, in order to obtain a uniform distribution of a second phase (the material supply for the second starting material is constant in terms of time and location, with respect to the powder bed 52 ) or in order to create a material gradient in the partial quantity (the material supply for the second starting material differs in terms of location, with respect to the powder bed 52 , and, if appropriate, in terms of time).
[0064] The material supplies 46 , 49 may be moved locationally in all directions (x, y, z).
[0065] The first material supply 46 supplies for example a matrix material and the second material supply 49 may supply for example fibers, second phases or other constituents.
[0066] With the laser beams 13 , only the regions of the powder bed 52 that are predetermined in a predetermined CAD model are compacted.
[0067] After the completion of the three-dimensional molded body, the compacted material is removed from the loose powder bed 52 .
[0068] Fibers 40 or other second phases may also be present in the powder bed 52 .
[0069] It is similarly possible, by controlling the first and second material supplies 46 , 49 in terms of time and/or location, to produce material gradients in the lateral plane (perpendicular to the building-up direction 25 ) or in the building-up direction 25 . For example, the matrix material of the component to be produced is supplied by the first material supply 46 . The second material supply 49 may supply fibers, second phases or other constituents in different concentrations in terms of location, in order to create the gradient.
[0070] The material supplies 46 , 49 may be moved in the lateral plane and in the building-up direction 25 , so that a different material composition can occur in an inner region and an outer region, in that for example the first material supply 46 supplies a material of a superalloy in the inner region 31 ( FIG. 4 ) and the second material supply 49 supplies for example the same material enriched for example with aluminum, chromium or MCrAlY ( FIG. 4 ), in the outer region 28 .
[0071] A gradient in the composition may be present in the building-up direction 25 and in the plane perpendicular thereto.
[0072] For example, a turbine blade may have a different composition on its convex side than on the concave side. This kind of gradient cannot be realized by a casting method.
[0073] Similarly, a material gradient can be created by a composition of the material supplied by means of the material supplies 46 , 49 that is changed over time.
[0074] If the material supply 46 , 49 is aligned with respect to the three-dimensional molded body to be produced in such a way that the material is to have a different composition there, the composition in the material supplies 46 , 49 is changed at the corresponding point in time. This can be repeated from time to time.
[0075] The statements made with respect to the production of gradients or second phases in the molded body apply to the various methods which are described in this application ( FIGS. 2, 6 and 7 ).
[0076] FIG. 7 shows a further apparatus 1 for carrying out a method according to the invention.
[0077] A three-dimensional molded body can also be produced without powder compacts 7 , 10 , powder beds 52 . The partial quantities 7 , 10 are supplied in the form of powder by means of the first and/or second material supply 46 , 49 on the starting plate 4 only at the locations where they are required by the geometry of the three-dimensional molded body to be produced. The material supplied is bonded together and compacted, for example by means of electron beams or laser beams 13 , by being exposed to a focal spot 43 of the laser.
[0078] The material supplies 46 , 49 and the laser 16 or its laser beams 13 may be guided in three-dimensional space in a way corresponding to the desired geometry of the molded body. | Methods according to prior art for producing three-dimensional moulded bodies generally require outer moulds which define the geometry of a component to be produced. The inventive method for producing three-dimensional moulded bodies renders one such mould redundant. The geometry of a component to be produced is defined by a pre-determined laser guidance or by the geometry of the partial quantities used. | 1 |
CROSS-RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/511,112, filed Oct. 9, 2014, the disclosure of which is hereby incorporated by reference in its entirety and serves as the basis of a priority and/or benefit claim for the present application.
FIELD OF THE INVENTION
The invention relates to inhibitors of VEGFR2 kinase or VEGFR, PDGFR kinases or PDGFR and Protein Kinase R (EIF2AK2), and methods of using such compounds. The present invention is also directed to methods of regulating, modulating or inhibiting protein kinases, whether of the receptor or non-receptor class, for the prevention and/or treatment of disorders related to unregulated protein kinase signal transduction, including cell growth, metabolic, and blood vessel proliferative disorders.
DESCRIPTION OF THE RELATED ART
Protein kinases (PKs) comprise a large and diverse class of proteins having enzymatic activity which catalyzes the transfer of the terminal phosphate of ATP to the hydroxyl group of a serine, threonine or tyrosine group in a protein. Protein kinases (PKs) are involved in numerous diseases which result from dysregulation of their normal function.
There are numerous examples where protein kinases, have been found to be involved in cellular signaling pathways leading to pathological conditions. In the VEGFR2 kinase protein kinase, which is a receptor tyrosine kinase, pathological conditions involving aberrant angiogenesis include cancer, wet age-related macular degeneration (Ni et al. Opthalmologica 2009 223 401-410; Chappelow et al. Drugs 2008 68 1029-1036), diabetic retinopathy (Zhang et al Int. J. Biochem. Cell Biol. 2009 41 2368-2371), cancer (Aora et al. J. Path. Exp. Ther. 2006, 315, 971), psoriasis (Heidenreich et al Drug News Perspective 2008 21 97-105) and hyper immune response. In ophthalmic diseases such as neovascular age-related macular degeneration and diabetic retinopathy aberrant activation of VEGF receptors can lead to abnormal blood vessel growth. The importance of VEGFR signaling in the neovascular age-related macular degeneration disease process is evident by the clinical success of multiple anti-VEGF targeting agents including Lucentis®, Avastin®, and EYLEA™ (Barakat et al. Expert Opin. Investig. Drugs 2009, 18, 637). Recently it has been suggested that inhibition of multiple protein kinase signaling pathways may provide a greater therapeutic effect than targeting a single signaling pathway. For example in neovascular ocular disorders such as neovascular age-related macular degeneration and diabetic retinopathy the inhibition of both VEGFR and PDGFRβ may provide a greater therapeutic effect in by causing regression of existing neovascular blood vessels present in the disease (Adamis et al. Am. J. Pathol. 2006 168 2036-2053). In cancer inhibition of multiple PK signaling pathways has been suggested to have a greater effect than inhibiting a single PK pathway (DePinho et al. Science 2007 318 287-290; Bergers et al. J. Clin Invest. 2003 111 1287-1295).
It has also been suggested that misregulated protein kinases are involved in neurodegenerative disease. In particular Protein Kinase R has been implicated in neurodegenerative disease. Protein Kinase R (PKR, also known as interferon-induced, double-stranded RNA-activated protein kinase, or eukaryotic translation initiation factor 2-alpha kinase 2) is one of four known mammalian kinases that phosphorylate eukaryotic translation initiation factor 2-alpha (eIF-2α) in response to a variety of stress conditions (Donnelly et al., Cell. Mol. Life Sci. 2013, 70, 3493-3511). PKR plays a central role in the innate immune system and serves to prevent viral replication and viral infection (for a detailed review see Garcia et al., Microbiol. and Mol. Bio. Rev. 2006, 70, 1032-1060). It is proposed that in chronic conditions like AMD, innate immune players respond to modified host derived elements (ROS/Alu) and external particulate matter (drusen) by activation of inflammasome complex. Emerging evidence indicates that PKR has a key role in NLRP3 inflammasome activation (Yim & Williams; J of Interferon & Cytokine Res, 2014, Campbell & Doyle, J Mol Med, 2013, Lu et. al; Nature, 2012).
The binding of double stranded RNA to the double stranded RNA regulatory domains of PKR induces dimerization and autophosphorylation which leads to activation of the kinase (Dever et al., Cell 2005, 122, 901-913). Once activated by dimerization PKR can suppress protein synthesis by phosphorylation of serine-51 on eukaryotic translation initiation factor 2-alpha (eIF-2α). In its phosphorylated form eIF2alpha increases its affinity for eIF-2B by 100-fold effectively converting it into a competitive inhibitor of eIF-2B. By this mechanism a small amount of phosphorylated eIF2alpha can effectively inhibit the guanine nucleotide exchange activity of eIF-2B and shut down protein translation (Ramaiah et al., Biochemistry 2000, 39, 12929-12938).
In addition to PKR's role in regulation of protein synthesis it also plays an important role in signal transduction linked to apoptotic cell death. PKR has been shown to be activated by dsRNA, number of growth factors and cytokines including INF, PDGF, TNF-alpha, and IL-1 and by the activation of Toll receptors. PKR has also been shown to be phosphorylated by JAK1 and Tyk2 kinases (Su et al., EMBO Reports 2007, 3, 265). Activation of PKR leads to the activation of multiple signaling pathways that are involved in inflammation and cell death. PKR is required for phosphorylation of MKK6 (Williams et al., J. Biol. Chem. 2004, 279, 37670-37676) and subsequent p38 MAPK signaling (Williams et al., The EMBO Journal 2000, 19, 4292-4297). PKR induces the expression of the pro apoptotic factor CHOP and has been shown to induce apoptosis by the FADD/Caspase 8 pathway (Barber, G. et al, The EMBO Journal 1998, 17, 6888-6902).
Due to its key role in regulation of apoptotic cell death PKR inhibition may be useful in prevention of the rod and cone photoreceptor cell death and ganglion cell death associated with the atrophic form of macular degeneration (Shimazawa et al, IVOS 2007, 48, 3729-3736).
The identification of effective small compounds which specifically inhibit signal transduction by modulating the activity of receptor and non-receptor protein kinases to regulate and modulate abnormal or inappropriate cell proliferation is therefore desirable and one object of this invention.
Certain small compounds are disclosed in PCT publication No. WO/1999/062890, PCT publication No. WO/2005/082001 and PCT publication No. WO/2006/026034 as useful for the treatment of diseases related to unregulated TKS transduction. These patents disclose starting materials and methods for the preparation thereof, screens and assays to determine a claimed compound's ability to modulate, regulate and/or inhibit cell proliferation, indications which are treatable with said compounds, formulations and routes of administration, effective dosages, etc.
US2009/0163545 refers to methods of using lifespan-altering compounds for altering the lifespan of eukaryotic organisms and screening for such compounds.
WO2009/019504 refers to the preparation of benzoxazoles, benzimidazoles, indoles and their analogs for the treatment of muscular dystrophy and cachexia.
WO2007/091106 refers to the preparation of benzoxazoles, benzimidazoles, indoles and their analogs for the treatment of muscular dystrophy and cachexia.
KR 2011033395 refers to the preparation of benzoxazolyl-pyridine derivatives as protein kinase inhibitors.
WO2009/075874 refers to the preparation of N-[4-pyridin-4-yl)phenyl] amides as gamma-secretase modulators.
SUMMARY OF THE INVENTION
The present invention relates to organic molecules capable of modulating, regulating and/or inhibiting protein kinase signal transduction, useful for treating diseases related to protein kinase signal transduction, for example, cancer, blood vessel proliferative disorders, fibrotic disorders, and neurodegenerative diseases. In particular, the compounds of the present invention are useful for treatment of mesangial cell proliferative disorders and metabolic diseases, lung carcinomas, breast carcinomas, Non Hodgkin's lymphomas, ovarian carcinoma, pancreatic cancer, malignant pleural mesothelioma, melanoma, arthritis, restenosis, hepatic cirrhosis, atherosclerosis, psoriasis, rosacea, diabetic mellitus, wound healing, inflammation and neurodegenerative diseases and preferably ophthalmic diseases, i.e. diabetic retinopathy, retinopathy of prematurity, macular edema, retinal vein occlusion, exudative or neovascular age-related macular degeneration, high-risk eyes (i.e. fellow eyes have neovascular age-related macular degeneration) with dry age-related macular degeneration, neovascular disease associated with retinal vein occlusion, neovascular disease (including choroidal neovascularization) associated with the following: pathologic myopia, pseudoxanthoma elasticum, optic nerve drusen, traumatic choroidal rupture, atrophic macular degeneration, geographic atrophy, central serous retinopathy, cystoid macular edema, diabetic retinopathy, proliferative diabetic retinopathy, diabetic macular edema, rubeosis iridis, retinopathy of prematurity, Central and branch retinal vein occlusions, inflammatory/infectious retinal, neovascularization/edema, corneal neovascularization, hyperemia related to an actively inflamed pterygia, recurrent pterygia following excisional surgery, post-excision, progressive pterygia approaching the visual axis, prophylactic therapy to prevent recurrent pterygia, of post-excision, progressive pterygia approaching the visual axis, chronic low grade hyperemia associated with pterygia, neovascular glaucoma, iris neovascularization, idiopathic etiologies, presumed ocular histoplasmosis syndrome, retinopathy of prematurity, chronic allergic conjunctivitis, ocular rosacea, blepharoconjunctivitis, recurrent episcleritis, keratoconjunctivitis sicca, ocular graft vs host disease, etc.
In one aspect, the invention provides a compound represented by Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
wherein:
W is O, S, N(CO)R 14 , CF 2 , C(CH 3 ) 2 , N(CO)(NH)R 14 or NR 14 ;
R 1 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 2 is —N(R 4 )C(O)N(R 4 R 5 ), —N(R 4 )C(O)R 5 , —C(O)N(R 4 R 5 ), hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 3 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
X is —N(R 4 )C(O)N(R 4 R 5 ), —N(R 4 )C(O)R 5 , —C(O)N(R 4 R 5 ), hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is hydrogen, —C(O)—N═S(O)R 7 R 6 , —N(R 4 )C(O)R 8 , —COOR 9 , —C(O)NHR 10 , —B(OH) 2 , —B(OR 12 )(OR 13 ) or
R 7 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 6 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 8 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 9 is hydrogen, substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 10 is hydrogen, substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Z is —NHR 11 ;
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 12 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 13 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 14 is hydrogen or substituted or unsubstituted C 1-8 alkyl; and
with the proviso that the compound of Formula I is not
In another aspect, the invention provides a compound represented by Formula I wherein:
W is O, S, N(CO)R 14 , CF 2 , C(CH 3 ) 2 , N(CO)(NH)R 14 or NR 14 ;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 ), —N(R 4 )C(O)R 5 , or —C(O)N(R 4 R 5 );
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is hydrogen, —C(O)—N═S(O)R 7 R 6 , —COOR 9 , —C(O)NHR 10 , —B(OH) 2 , or
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
R 9 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 10 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 14 is hydrogen or substituted or unsubstituted C 1-8 alkyl; and
with the proviso that the compound of Formula I is not
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is hydrogen, —C(O)—N═S(O)R 7 R 6 , —COOR 9 , —C(O)NHR 10 , —B(OH) 2 , or
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
R 9 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 10 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is —C(O)—N═S(O)R 7 R 6 ;
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is —C(O)—N═S(O)R 7 R 6 ;
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is —C(O)—N═S(O)R 7 R 6 ;
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is —C(O)—N═S(O)R 7 R 6 ;
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted heterocycle;
Y is —C(O)—N═S(O)R 7 R 6 ;
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)R 5 ;
R 4 is hydrogen;
R 5 is substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is hydrogen, —C(O)—N═S(O)R 7 R 6 , —COOR 9 , —C(O)NHR 10 , —B(OH) 2 , or
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
R 9 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 10 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)R 5 ;
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is hydrogen, —C(O)—N═S(O)R 7 R 6 , —COOR 9 , —C(O)NHR 10 , —B(OH) 2 , or
R 7 is substituted or unsubstituted C 1-8 alkyl;
R 6 is substituted or unsubstituted C 1-8 alkyl;
R 9 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 10 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is —COOR 9 ;
R 7 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 6 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 9 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is —C(O)NHR 10 ;
R 10 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)N(R 4 R 5 );
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is —B(OH) 2 ;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —N(R 4 )C(O)R 5 ;
R 4 is hydrogen;
R 5 is substituted or unsubstituted aryl;
Y is hydrogen;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In another aspect, the invention provides a compound represented by Formula I wherein:
W is S;
R 1 is hydrogen;
R 2 is hydrogen;
R 3 is hydrogen;
X is —C(O)N(R 4 R 5 );
R 4 is hydrogen or substituted or unsubstituted alkyl;
R 5 is substituted or unsubstituted alkyl or substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y is hydrogen;
Z is —NHR 11 ; and
R 11 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
In one aspect, the invention provides a compound represented by Formula II or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
wherein:
R 15 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 16 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 17 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
X a is —N(R 19 )C(O)N(R 19 R 20 );
R 18 is hydrogen, substituted or unsubstituted C 1-8 alkyl, halo or haloalkyl;
R 19 is hydrogen, substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 20 is substituted or unsubstituted alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Y a is hydrogen, —C(O)—N═S(O)R 21 R 22 , —N(R 23 )C(O)R 24 , —COOR 25 , —C(O)NHR 27 , —B(OH) 2 , —B(OR 28 )(OR 29 ) or
R 21 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 22 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 23 is substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
R 24 is hydrogen, substituted or unsubstituted C 1-8 alkyl, substituted or unsubstituted heterocycle or substituted or unsubstituted aryl;
Z a is —NHR 26 ;
R 25 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 26 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 27 is hydrogen or substituted or unsubstituted C 1-8 alkyl;
R 28 is hydrogen or substituted or unsubstituted C 1-8 alkyl; and
R 29 is hydrogen or substituted or unsubstituted C 1-8 alkyl.
The term “alkyl”, as used herein, refers to saturated, monovalent or divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 12 carbon atoms. One methylene (—CH 2 —) group, of the alkyl group can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkyl groups can have one or more chiral centers. Alkyl groups can be independently substituted by halogen atoms, hydroxyl groups, cycloalkyl groups, amino groups, heterocyclic groups, aryl groups, carboxylic acid groups, phosphonic acid groups, sulphonic acid groups, phosphoric acid groups, nitro groups, amide groups, sulfonamide groups, ester groups, ketone groups.
The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be independently substituted by halogen atoms, sulfonyl C 1-8 alkyl groups, sulfoxide C 1-8 alkyl groups, sulfonamide groups, nitro groups, cyano groups, —OC 1-8 alkyl groups, —SC 1-8 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “cycloalkenyl”, as used herein, refers to a monovalent or divalent group of 3 to 8 carbon atoms derived from a saturated cycloalkyl having at least one double bond.
Cycloalkenyl groups can be monocyclic or polycyclic. Cycloalkenyl groups can be independently substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine.
The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. One methylene (—CH 2 —) group, of the alkenyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by alkyl groups, as defined above or by halogen atoms.
The term “alkynyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one triple bond. One methylene (—CH 2 —) group, of the alkynyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, sulfate, sulfonate, amide, sulfonamide, by a divalent C 3-8 cycloalkyl, by a divalent heterocycle, or by a divalent aryl group. Alkynyl groups can be substituted by alkyl groups, as defined above, or by halogen atoms.
The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or unsaturated, containing at least one heteroatom selected form oxygen, nitrogen, sulfur, or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be interrupted by a C═O; the S and N heteroatoms can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by halogen atoms, sulfonyl groups, sulfoxide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-8 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups.
The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms, by removal of one hydrogen atom. Aryl can be substituted by halogen atoms, sulfonyl C 1-6 alkyl groups, sulfoxide C 1-6 alkyl groups, sulfonamide groups, carboxcyclic acid groups, C 1-6 alkyl carboxylates (ester) groups, amide groups, nitro groups, cyano groups, —OC 1-6 alkyl groups, —SC 1-6 alkyl groups, —C 1-6 alkyl groups, —C 2-6 alkenyl groups, —C 2-6 alkynyl groups, ketone groups, aldehydes, alkylamino groups, amino groups, aryl groups, C 3-8 cycloalkyl groups or hydroxyl groups. Aryls can be monocyclic or polycyclic.
The term “hydroxyl” as used herein, represents a group of formula “—OH”.
The term “carbonyl” as used herein, represents a group of formula “—C(O)—”.
The term “ketone” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —C(O)R x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “ester” as used herein, represents an organic compound having a carbonyl group linked to a carbon atom such as —C(O)OR x wherein R x can be alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “amine” as used herein, represents a group of formula “—NR x R y ”, wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “carboxyl” as used herein, represents a group of formula “—C(O)O—”.
The term “sulfonyl” as used herein, represents a group of formula “—SO 2 − ”.
The term “sulfate” as used herein, represents a group of formula “—O—S(O) 2 —O—”.
The term “sulfonate” as used herein, represents a group of the formula “—S(O) 2 —O—”.
The term “carboxylic acid” as used herein, represents a group of formula “—C(O)OH”.
The term “nitro” as used herein, represents a group of formula “—NO 2 ”.
The term “cyano” as used herein, represents a group of formula “—CN”.
The term “amide” as used herein, represents a group of formula “—C(O)NR x R y ,” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfonamide” as used herein, represents a group of formula “—S(O) 2 NR x R y ” wherein R x and R y can be the same or independently H, alkyl, aryl, cycloalkyl, cycloalkenyl, heterocycle as defined above.
The term “sulfoxide” as used herein, represents a group of formula “—S(O)—”.
The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
The term “sulphonic acid” as used herein, represents a group of formula “—S(O) 2 OH”.
The formula “H”, as used herein, represents a hydrogen atom.
The formula “O”, as used herein, represents an oxygen atom.
The formula “N”, as used herein, represents a nitrogen atom.
The formula “S”, as used herein, represents a sulfur atom.
Other defined terms are used throughout this specification:
“Ac” refers to acetyl
“DCE” refers to dichloroethane
“DCM” refers to dichloromethane
“DMAP” refers to dimethylaminopyridine
“EDCI” refers to 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide “Et” refers to ethyl
“iPr” refers to i-propyl
“Me” refers to methyl
“MeOH” refers to methanol
“PDGF” refers to platelet derived growth factor
“Ph” refers to phenyl
“PKs” refers to protein kinase
“RTKs” refers to receptor tyrosine kinase
“rt” refers to room temperature
“tBu” refers to t-butyl.
“THF” refers to tetrahydrofuran
“VEGF” refers to vascular endothelial growth factor
“VEGFR” refers to vascular endothelial growth factor receptor
Compounds of the invention are tabulated in Table 1:
TABLE 1
List of compound names and structures
Example
Structure
Compound Name
1
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinamide
2
6-amino-5-[5-({[(3-chloro-4- fluorophenyl)amino]carbonyl} amino)-1-benzothien-2-yl]-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
3
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-[5-({[(2- fluoro-5- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinamide
4
6-amino-5-{5- [(anilinocarbonyl)amino]-1- benzothien-2-yl}-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
5
6-amino-5-{5-[({[4-chloro-3- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
6
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-{5-[({[2- fluoro-5- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}nicotinamide
7
methyl 6-amino-5-{5-[({[3- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}nicotinate
8
methyl 6-amino-5-{5-[({[2- fluoro-5- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}nicotinate
9
methyl 6-amino-5-{5-[({[4- chloro-3- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}nicotinate
10
methyl 6-amino-5-[5-({[(2- fluoro-5- methylphenyl)amino]carbonyl} amino)-1-benzothien-2-yl]nicotinate
11
methyl 6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinate
12
methyl 6-amino-5-[5-({[(3- chloro-4- fluorophenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinate
13
methyl 6-amino-5-[5-({[(4- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinate
14
methyl 6-amino-5-[5-({[(2- fluorophenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinate
15
methyl 6-amino-5-{5- [(anilinocarbonyl)amino]-1- benzothien-2-yl}nicotinate
16
methyl 6-amino-5-[5-({[(2,4- difluorophenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinate
17
6-amino-5-[5-({[(3-chloro-4- fluorophenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinic acid
18
6-amino-5-[5-({[(2-fluoro-5- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinic acid
19
6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinic acid
20
6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinamide
21
methyl 4-[({6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3- yl}carbonyl)amino]butanoate
22
methyl 6-[({6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3- yl}carbonyl)amino]hexanoate
23
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-[2- fluoro-5- (trifluoromethyl)phenyl]urea
24
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-[3- (trifluoromethyl)phenyl]urea
25
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-[4- chloro-3- (trifluoromethyl)phenyl]ure
26
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-(2- fluoro-5-methylphenyl)urea
27
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-(3- chloro-4-fluorophenyl)urea
28
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-(3- ethylphenyl)urea
29
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3-(3- methylphenyl)urea
30
1-{2-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]-1-benzothien-5-yl}-3- phenylurea
31
{6-amino-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3-yl}boronic acid
32
(6-amino-5-{5- [(anilinocarbonyl)amino]-1- benzothien-2-yl}pyridin-3- yl)boronic acid
33
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-{5-[(3- methyl-2-furoyl)amino]-1- benzothien-2-yl}nicotinamide
34
6-amino-5-(5-{[4-chloro-3- (trifluoromethyl)benzoyl]amino} 1-benzothien-2-yl)-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
35
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-{5-[(2- fluoro-5- methylbenzoyl)amino]-1- benzothien-2-yl}nicotinamide
36
6-amino-5-[5-(benzoylamino)- 1-benzothien-2-yl]-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
37
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-{5-[(3- methylbenzoyl)amino]-1- benzothien-2-yl}nicotinamide
38
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-(5-{[2- fluoro-5- (trifluoromethyl)benzoyl]amino- 1-benzothien-2- yl)nicotinamide
39
methyl 6-amino-5-{5-[(3- methyl-2-furoyl)amino]-1- benzothien-2-yl}nicotinate
40
methyl 6-amino-5-{5-[(3- methylbenzoyl)amino]-1- benzothien-2-yl}nicotinate
41
methyl 6-amino-5-{5-[(2- fluoro-5- methylbenzoyl)amino]-1- benzothien-2-yl}nicotinate
42
6-amino-5-[5-[5 (benzoylamino)-1-benzothien- 2-yl]nicotinate
43
methyl 6-amino-5-{5-[(3- chloro-4- fluorobenzoyl)amino]-1- benzothien-2-yl}nicotinate
44
methyl 6-amino-5-(5-{[2- fluoro-5- (trifluoromethyl)benzoyl]amino- 1-benzothien-2-yl)nicotinate
45
methyl 6-amino-5-{5-[(1- benzofuran-2- ylcarbonyl)amino]-1- benzothien-2-yl}nicotinate
46
N-[2-(2-aminopyridin-3-yl)-1- benzothien-5-yl]-3- methylbenzamide
47
N-[2-(2-aminopyridin-3-yl)-1- benzothien-5-yl]benzamide
48
2-(2-aminopyridin-3-yl)-N-(3- methylphenyl)-1- benzothiophene-5- carboxamide
49
2-(2-aminopyridin-3-yl)-N-(5- tert-butylisoxazol-3-yl)-1- benzothiophene-5- carboxamide
50
2-(2-aminopyridin-3-yl)-N-(3- methylbenzyl)-1- benzothiophene-5- carboxamide
51
2-(2-aminopyridin-3-yl)-N-(2- fluoro-5-methylphenyl)-1- benzothiophene-5- carboxamide
52
2-(2-aminopyridin-3-yl)-N-(3- chloro-4-fluorophenyl)-1- benzothiophene-5- carboxamide
53
methyl 5-[N-({6-amino-5-[5- ({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3-yl}carbonyl)-S- methylsulfonimidoyl]pentanoate
54
methyl 5-[N-({6-amino-5-[5- ({[(2-fluoro-5- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3-yl}carbonyl)-S- methylsulfonimidoyl]pentanoate
55
methyl 5-[N-({6-amino-5-[5- ({[(3-chloro-4- fluorophenyl)amino]carbonyl} amino)-1-benzothien-2- yl]pyridin-3-yl}carbonyl)-S- methylsulfonimidoyl]pentanoate
56
6-amino-N-[bis(3- hydroxypropyl)(oxido)-λ 4 - sulfanylidene]-5-[5-({[(3- methylphenyl)amino]carbonyl} amino)-1-benzothien-2- yl]nicotinamide
57
N-[dimethyl(oxido)-λ 4 - sulfanylidene]-5-{5-[({[2- fluoro-5- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}nicotinamide
58
5-{5-[({[4-chloro-3- (trifluoromethyl)phenyl]amino} carbonyl)amino]-1- benzothien-2-yl}-N- [dimethyl(oxido)-λ 4 - sulfanylidene]nicotinamide
59
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-[4-({[(2- fluoro-5-methylphenyl) amino]carbonyl}amino)phenyl] nicotinamide
60
6-amino-N-[dimethyl(oxido)- λ 4 -sulfanylidene]-5-[4-({[(2- fluoro-5- methylphenyl)amino]carbonyl} amino)phenyl]nicotinamide
61
[6-amino-5-(4-{[(2-fluoro-5- methylphenyl)carbamoyl]amino} phenyl)pyridin-3-yl]boronic acid
62
1-{4-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]phenyl}-3-(2-fluoro-5- methylphenyl)urea
63
1-{4-[2-amino-5-(4,4,5,5- tetramethyl-1,3,2- dioxaborolan-2-yl)pyridin-3- yl]phenyl}-3-phenylurea
64
dimethyl {6-amino-5-[4-({[3- (trifluoromethyl)phenyl]carbamoyl} amino)phenyl]pyridin-3- yl}phosphonate
65
diethyl [6-amino-5-(4-{[(2- fluoro-5- methylphenyl)carbamoyl]amino} phenyl)pyridin-3- yl]phosphonate
66
dimethyl {6-amino-5-[4-({[2- fluoro-5- (trifluoromethyl)phenyl]carbamoyl} amino)phenyl]pyridin-3- yl}phosphonate
67
dimethyl [6-amino-5-(4-{[(2- fluoro-5- methylphenyl)carbamoyl]amino} phenyl)pyridin-3- yl]phosphonate
68
dimethyl (6-amino-5-{4- [(phenylcarbamoyl)amino]phenyl} pyridin-3-yl)phosphonate
69
6-amino-N-[bis(3- hydroxypropyl)(oxido)-λ 6 - sulfanylidene]-5-(4-{[(3- methylphenyl)carbamoyl]amino} phenyl)pyridine-3- carboxamide
70
dimethyl 5,5'-(N-{[6-amino-5- (4-{[(3- methylphenyl)carbamoyl]amino} phenyl)pyridin-3- yl]carbonyl}sulfonimidoyl) dipentanoate
71
dimethyl 5,5'-(N-{[6-amino-5- (4-{[(2-fluoro-5- methylphenyl)carbamoyl]amino} phenyl)pyridin-3- yl]carbonyl}sulfonimidoyl) dipentanoate
72
dimethyl 5,5′[N-({6-amino-5- [4-({[3- (trifluoromethyl)phenyl]carbamoyl} amino)phenyl]pyridin-3- yl}carbonyl)sulfonimidoyl] dipentanoate
73
methyl 6-amino-5-(4-{[(2- fluoro-5- methylphenyl)carbamoyl]amino} phenyl)pyridine-3- carboxylate
74
methyl 6-amino-5-[4-({[2- fluoro-5- (trifluoromethyl)phenyl]carbamoyl} amino)phenyl]pyridine- 3-carboxylate
75
methyl 6-amino-5-[4-({[4- chloro-3- (trifluoromethyl)phenyl]carbamoyl} amino)phenyl]pyridine- 3-carboxylate
76
methyl 6-amino-5-{4- [(phenylcarbamoyl)amino]phenyl} pyridine-3-carboxylate
Compounds of formula I and of formula II are useful as protein kinase inhibitors. As such, compounds of formula I and of formula II will be useful for treating diseases related to unregulated protein kinase signal transduction, for example, cancer, blood vessel proliferative disorders, fibrotic disorders, inflammatory disorders and neurodegenerative diseases. In particular, the compounds of the present invention are useful for treatment of mesangial cell proliferative disorders and metabolic diseases, lung carcinomas, breast carcinomas, Non Hodgkin's lymphomas, ovarian carcinoma, pancreatic cancer, malignant pleural mesothelioma, melanoma, arthritis, restenosis, hepatic cirrhosis, atherosclerosis, psoriasis, rosacea, diabetic mellitus, wound healing, inflammation and neurodegenerative diseases and preferably ophthalmic diseases, i.e. diabetic retinopathy, retinopathy of prematurity, macular edema, retinal vein occlusion, exudative or neovascular age-related macular degeneration, high-risk eyes (i.e. fellow eyes have neovascular age-related macular degeneration) with dry age-related macular degeneration, neovascular disease associated with retinal vein occlusion, neovascular disease (including choroidal neovascularization) associated with the following: pathologic myopia, pseudoxanthoma elasticum, optic nerve drusen, traumatic choroidal rupture, atrophic macular degeneration, geographic atrophy, central serous retinopathy, cystoid macular edema, diabetic retinopathy, proliferative diabetic retinopathy, diabetic macular edema, rubeosis iridis, retinopathy of prematurity, Central and branch retinal vein occlusions, inflammatory/infectious retinal, neovascularization/edema, corneal neovascularization, hyperemia related to an actively inflamed pterygia, recurrent pterygia following excisional surgery, post-excision, progressive pterygia approaching the visual axis, prophylactic therapy to prevent recurrent pterygia, of post-excision, progressive pterygia approaching the visual axis, chronic low grade hyperemia associated with pterygia, neovascular glaucoma, iris neovascularization, idiopathic etiologies, presumed ocular histoplasmosis syndrome, retinopathy of prematurity, chronic allergic conjunctivitis, ocular rosacea, blepharoconjunctivitis, recurrent episcleritis, keratoconjunctivitis sicca, ocular graft vs host disease, etc.
Some compounds of Formula I and of Formula II and some of their intermediates may have at least one asymmetric center in their structure. This asymmetric center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I and of Formula II are able to form.
The acid addition salt form of a compound of Formula I and of Formula II that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic acid, for example, hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic acid, hydroxyacetic acid, propanoic acid, lactic acid, pyruvic acid, malonic acid, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric acid, methylsulfonic acid, ethanesulfonic acid, benzenesulfonic acid, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta-Zürich, 2002, 329-345).
The base addition salt form of a compound of Formula I and of Formula II that occurs in its acid form can be obtained by treating the acid with an appropriate base such as an inorganic base, for example, sodium hydroxide, magnesium hydroxide, potassium hydroxide, calcium hydroxide, ammonia and the like; or an organic base such as for example, L-Arginine, ethanolamine, betaine, benzathine, morpholine and the like. (Handbook of Pharmaceutical Salts, P. Heinrich Stahl & Camille G. Wermuth (Eds), Verlag Helvetica Chimica Acta-Zürich, 2002, 329-345).
Compounds of Formula I and of Formula II and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier thereof. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a patch, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known in the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin or olive oil.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
Pharmaceutical compositions containing invention compounds may be in a form suitable for topical use, for example, as oily suspensions, as solutions or suspensions in aqueous liquids or nonaqueous liquids, or as oil-in-water or water-in-oil liquid emulsions. Pharmaceutical compositions may be prepared by combining a therapeutically effective amount of at least one compound according to the present invention, or a pharmaceutically acceptable salt thereof, as an active ingredient with conventional ophthalmically acceptable pharmaceutical excipients and by preparation of unit dosage suitable for topical ocular use. The therapeutically efficient amount typically is between about 0.0001 and about 5% (w/v), preferably about 0.001 to about 2.0% (w/v) in liquid formulations.
For ophthalmic application, preferably solutions are prepared using a physiological saline solution as a major vehicle. The pH of such ophthalmic solutions should preferably be maintained between 4.5 and 8.0 with an appropriate buffer system, a neutral pH being preferred but not essential. The formulations may also contain conventional pharmaceutically acceptable preservatives, stabilizers and surfactants. Preferred preservatives that may be used in the pharmaceutical compositions of the present invention include, but are not limited to, benzalkonium chloride, chlorobutanol, thimerosal, phenylmercuric acetate and phenylmercuric nitrate. A preferred surfactant is, for example, Tween 80. Likewise, various preferred vehicles may be used in the ophthalmic preparations of the present invention. These vehicles include, but are not limited to, polyvinyl alcohol, povidone, hydroxypropyl methyl cellulose, poloxamers, carboxymethyl cellulose, hydroxyethyl cellulose cyclodextrin and purified water.
Tonicity adjustors may be added as needed or convenient. They include, but are not limited to, salts, particularly sodium chloride, potassium chloride, mannitol and glycerin, or any other suitable ophthalmically acceptable tonicity adjustor.
Various buffers and means for adjusting pH may be used so long as the resulting preparation is ophthalmically acceptable. Accordingly, buffers include acetate buffers, citrate buffers, phosphate buffers and borate buffers. Acids or bases may be used to adjust the pH of these formulations as needed.
In a similar manner an ophthalmically acceptable antioxidant for use in the present invention includes, but is not limited to, sodium metabisulfite, sodium thiosulfate, acetylcysteine, butylated hydroxyanisole and butylated hydroxytoluene.
Other excipient components which may be included in the ophthalmic preparations are chelating agents. The preferred chelating agent is edentate disodium, although other chelating agents may also be used in place of or in conjunction with it.
The ingredients are usually used in the following amounts:
Ingredient
Amount (% w/v)
active ingredient
about 0.001-5
preservative
0-0.10
vehicle
0-40
tonicity adjustor
0-10
buffer
0.01-10
pH adjustor
q.s. pH 4.5-7.8
antioxidant
as needed
surfactant
as needed
purified water
to make 100%
The actual dose of the active compounds of the present invention depends on the specific compound, and on the condition to be treated; the selection of the appropriate dose is well within the knowledge of the skilled artisan.
The ophthalmic formulations of the present invention are conveniently packaged in forms suitable for metered application, such as in containers equipped with a dropper, to facilitate application to the eye. Containers suitable for dropwise application are usually made of suitable inert, non-toxic plastic material, and generally contain between about 0.5 and about 15 ml solution. One package may contain one or more unit doses. Especially preservative-free solutions are often formulated in non-resealable containers containing up to about ten, preferably up to about five units doses, where a typical unit dose is from one to about 8 drops, preferably one to about 3 drops. The volume of one drop usually is about 20-35 μl.
The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
The compounds of the invention may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner. The present invention is further directed to pharmaceutical compositions comprising a pharmaceutically effective amount of one or more of the above-described compounds and a pharmaceutically acceptable carrier or excipient, wherein said compositions are effective for treating the above diseases and conditions; especially ophthalmic diseases and conditions. Such a composition is believed to modulate signal transduction by a protein kinase, either by inhibition of catalytic activity, affinity to ATP or ability to interact with a substrate.
More particularly, the compositions of the present invention may be included in methods for treating diseases comprising proliferation, fibrotic or metabolic disorders, for example cancer, fibrosis, psoriasis, rosacea, atherosclerosis, arthritis, and other disorders related to abnormal vasculogenesis and/or angiogenesis, such as exudative age related macular degeneration and diabetic retinopathy.
The present invention is further directed to pharmaceutical compositions comprising a pharmaceutically effective amount of the above-described compounds and a pharmaceutically acceptable carrier or excipient. Such a composition is believed to modulate signal transduction by a protein kinase, tyrosine kinase, or serine threonine kinase either by inhibition of catalytic activity, affinity to ATP or ability to interact with a substrate.
The present invention relates to compounds capable of regulating and/or modulating protein kinase signal transduction and more particularly receptor and non-receptor protein kinase signal transduction.
Receptor tyrosine kinase mediated signal transduction is initiated by extracellular interaction with a specific growth factor (ligand), followed by receptor dimerization, transient stimulation of the intrinsic protein tyrosine kinase activity and phosphorylation. Binding sites are thereby created for intracellular signal transduction molecules and lead to the formation of complexes with a spectrum of cytoplasmic signaling molecules that facilitate the appropriate cellular response (e.g., cell division, metabolic effects and responses to the extracellular microenvironment).
It has been shown that tyrosine phosphorylation sites in growth factor receptors function as high-affinity binding sites for SH2 (src homology) domains of signaling molecules. Several intracellular substrate proteins that associate with receptor tyrosine kinases have been identified. They may be divided into two principal groups: (1) substrates which have a catalytic domain; and (2) substrates which lack such domain but serve as adapters and associate with catalytically active molecules. The specificity of the interactions between receptors and SH2 domains of their substrates is determined by the amino acid residues immediately surrounding the phosphorylated tyrosine residue. Differences in the binding affinities between SH2 domains and the amino acid sequences surrounding the phosphotyrosine residues on particular receptors are consistent with the observed differences in their substrate phosphorylation profiles. These observations suggest that the function of each receptor tyrosine kinase is determined not only by its pattern of expression and ligand availability but also by the array of downstream signal transduction pathways that are activated by a particular receptor. Thus, phosphorylation provides an important regulatory step which determines the selectivity of signaling pathways recruited by specific growth factor receptors, as well as differentiation factor receptors.
Protein kinase signal transduction results in, among other responses, cell proliferation, differentiation and metabolism. Abnormal cell proliferation may result in a wide array of disorders and diseases, including the development of neoplasia such as carcinoma, sarcoma, leukemia, glioblastoma, hemangioma, psoriasis, arteriosclerosis, arthritis and diabetic retinopathy (or other disorders related to uncontrolled angiogenesis and/or vasculogenesis, e.g. macular degeneration).
This invention is therefore directed to compounds which regulate, modulate and/or inhibit protein kinase signal transduction by affecting the enzymatic activity of the PKs and interfering with the signal transduced by such proteins. More particularly, the present invention is directed to compounds which regulate, modulate and/or inhibit the proteinkinase mediated signal transduction pathways as a therapeutic approach to cure many kinds of solid tumors, including but not limited to carcinoma, sarcoma, leukemia, erythroblastoma, glioblastoma, meningioma, astrocytoma, melanoma and myoblastoma. Indications may include, but are not limited to brain cancers, bladder cancers, ovarian cancers, gastric cancers, pancreas cancers, colon cancers, blood cancers, lung cancers and bone cancers.
The present invention concerns also processes for preparing the compounds of Formula I and of Formula II. The compounds of formula I and of formula II according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. The following Synthetic Schemes set forth below, illustrate how the compounds according to the invention can be made.
At this stage, those skilled in the art will appreciate that many additional compounds that fall under the scope of the invention may be prepared by performing various common chemical reactions. Details of certain specific chemical transformations are provided in the examples.
Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I and of Formula II.
The present invention is not to be limited in scope by the exemplified embodiments which are intended as illustrations of single aspects of the invention only. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a method of regulating, modulating or inhibiting proteinkinases, whether of the receptor or non-receptor class, for the prevention and/or treatment of disorders related to unregulated protein kinase signal transduction, including cell growth, metabolic, and blood vessel proliferative disorders, which comprises administering a pharmaceutical composition comprising a therapeutically effective amount of at least one kinase inhibitor as described herein.
In another aspect, the invention provides the use of at least one kinase inhibitor for the manufacture of a medicament for the treatment of a disease or a condition mediated by tyrosine kinases in a mammal.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of hydrogen 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
Compound names were generated with ACDLabs version 12.5. Some of the intermediate and reagent names used in the examples were generated with software such as Chem Bio Draw Ultra version 12.0 or Auto Nom 2000 from MDL ISIS Draw 2.5 SP1.
In general, characterization of the compounds is performed according to the following methods; NMR spectra are recorded on 300 or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal TMS or to the solvent signal.
All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Combi-blocks, TCI, VWR, Lancaster, Oakwood, Trans World Chemical, Alfa, Fisher, Maybridge, Frontier, Matrix, Ukrorgsynth, Toronto, Ryan Scientific, SiliCycle, Anaspec, Syn Chem, Chem-Impex, MIC-scientific, Ltd; however some known intermediates, were prepared according to published procedures.
Usually the compounds of the invention were purified by medium pressure liquid chromatography, unless noted otherwise.
Preparation 1
tert-butyl {2-[2-amino-5-({[dimethyl(oxido)-λ 4 -sulfanylidene]amino}carbonyl)pyridin-3-yl]-1-benzothien-5-yl}carbamate
To the degassed mixture of 6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-iodonicotinamide (1.19 g, 3.51 mmol, 1 eq), 5-tert-butoxycarbonylaminobenzothiophene-2-boronic acid (1.52 g, 1.15 eq), and aq sodium carbonate (2M, 5.27 mL, 3 eq) in dioxane (7.5 mL) was added Ph 3 P (184 mg, 0.2 eq) and Pd(OAc) 2 (79 mg, 0.1 eq). The mixture was heated to 50° C. with vigorous stirring for 30 minutes. The reaction mixture was then partitioned between aq NH 4 Cl and EtOAc. The organic layer was isolated, washed with sat aq NaHCO 3 , brine, and finally dried with anhydrous sodium sulfate. The upper solution was decanted, concentrated, and the foamy oily residue was subject to a gradient column chromatography (EtOAc-Hex 3:1 to 6:1) yielding tert-butyl {2-[2-amino-5-({[dimethyl(oxido)-λ 4 -sulfanylidene]amino}carbonyl)pyridin-3-yl]-1-benzothien-5-yl}carbamate as a white solid in amount of 1.274 g (79%).
Preparation 2
6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
To the mixture of tert-butyl {2-[2-amino-5-({[dimethyl(oxido)-λ 4 -sulfanylidene]amino}carbonyl)pyridin-3-yl]-1-benzothien-5-yl}carbamate (1.23 g, 2.67 mmol, 1 eq) in dichloromethane (6 mL) at 0° C. was added dropwise trifluoroacetic acid (5.16 mL, 20 eq). During this process the reaction mixture became a brown solution. The reaction was stirred at 0° C. for 15 minutes and then at room temperature for 3 hours. The reaction was partitioned between DCM and cold saturated aq NaHCO 3 . The organic layer was isolated, washed with brine and dried with anhydrous sodium sulfate. The clear layer was decanted, concentrated, and the brown solid residue was treated with EtOAc. An orange colored solid was obtained upon filtration giving 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide in amount of 0.837 g (87%).
Example 1
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide
To the solution of 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide (72 mg, 0.2 mmol. 1 eq) in anhydrous DMF (2 mL) at room temperature was added dropwise m-tolylisocyanate (0.03 mL, 1.2 eq). After the reaction solution was stirred at rt for 2 hours, it was diluted with EtOAc, washed sequentially with saturated aq NaHCO 3 , aq NH 4 Cl, brine, and finally dried with anhydrous sodium sulfate. The organic layer was decanted, concentrated, and the solid residue was triturated with DCM with stirring. A lightly pink solid was obtained upon filtration to yield 6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide in amount of 91 mg (92%).
1 H NMR (DMSO-d 6 ) δ: 8.78 (s, 1H), 8.61 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.10 (dd, J=2.1, 0.3 Hz, 1H), 8.02 (d, J=2.1 Hz, 1H), 7.87 (d, J=8.5 Hz, 1H), 7.59 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.32 (s, 1H), 7.25 (d, J=8.2 Hz, 1H), 7.16 (t, J=7.8 Hz, 1H), 6.80 (d, J=7.3 Hz, 1H), 6.76 (s, 2H), 3.44 (s, 6H), 2.29 (s, 3H).
Example 2
6-amino-5-[5-({[(3-chloro-4-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
In a manner similar to that described in Example 1, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 2-chloro-1-fluoro-4-isocyanatobenzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.91 (d, J=4.7 Hz, 2H), 8.61 (d, J=2.3 Hz, 1H), 8.08 (d, J=2.1 Hz, 1H), 8.02 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.5 Hz, 1H), 7.83 (dd, J=6.7, 2.1 Hz, 1H), 7.59 (s, 1H), 7.38 (dd, J=8.8, 2.1 Hz, 1H), 7.32-7.35 (m, 2H), 6.75 (s, 2H), 3.44 (s, 6H).
Example 3
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-[5-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide
In a manner similar to that described in Example 1, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 1-fluoro-2-isocyanato-4-methylbenzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.18 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.50 (d, J=2.6 Hz, 1H), 8.12 (d, J=2.1 Hz, 1H), 8.01-8.04 (m, 2H), 7.89 (d, J=8.8 Hz, 1H), 7.60 (s, 1H), 7.35 (dd, J=8.5, 2.1 Hz, 1H), 7.11 (dd, J=11.3, 8.4 Hz, 1H), 6.79-6.82 (m, 1H), 6.75 (s, 2H), 3.44 (s, 6H), 2.28 (s, 3H).
Example 4
6-amino-5-{5-[(anilinocarbonyl)amino]-1-benzothien-2-yl}-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
In a manner similar to that described in Example 1, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and isocyanatobenzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.80 (s, 1H), 8.69 (s, 1H), 8.60 (d, J=2.3 Hz, 1H), 8.10 (d, J=2.1 Hz, 1H), 8.02 (d, J=2.3 Hz, 1H), 7.87 (d, J=8.8 Hz, 1H), 7.60 (s, 1H), 7.48 (dd, J=8.5, 0.9 Hz, 2H), 7.37 (dd, J=8.5, 2.1 Hz, 1H), 7.29 (dd, J=8.2, 7.6 Hz, 2H), 6.96-6.99 (m, 1H), 6.75 (s, 2H), 3.44 (s, 6H)
Example 5
6-amino-5-{5-[({[4-chloro-3-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
In a manner similar to that described in Example 1, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 1-chloro-4-isocyanato-2-(trifluoromethyl)benzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.30 (br. s., 1H), 9.08 (br. s., 1H), 8.61 (d, J=2.1 Hz, 1H), 8.16 (d, J=2.3 Hz, 1H), 8.11 (d, J=1.8 Hz, 1H), 8.02 (d, J=2.1 Hz, 1H), 7.89 (d, J=8.8 Hz, 1H), 7.60-7.67 (m, 3H), 7.39 (dd, J=8.8, 2.1 Hz, 1H), 6.76 (s, 2H), 3.44 (s, 6H).
Example 6
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[({[2-fluoro-5-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}nicotinamide
In a manner similar to that described in Example 1, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 1-fluoro-2-isocyanato-4-(trifluoromethyl)benzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.31 (s, 1H), 8.93 (d, J=2.6 Hz, 1H), 8.67 (dd, J=7.3, 2.1 Hz, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.15 (d, J=2.1 Hz, 1H), 8.03 (d, J=2.1 Hz, 1H), 7.91 (d, J=8.5 Hz, 1H), 7.62 (s, 1H), 7.51 (dd, J=10.6, 8.8 Hz, 1H), 7.38-7.41 (m, 1H), 7.36 (dd, J=8.5, 2.1 Hz, 1H), 6.77 (s, 2H), 3.44 (s, 6H).
Example 7
methyl 6-amino-5-{5-[({[3-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-isocyanato-3-(trifluoromethyl)benzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.08 (s, 1H), 8.94 (s, 1H), 8.57 (d, J=2.3 Hz, 1H), 8.13 (d, J=2.1 Hz, 1H), 8.06 (t, J=1.5 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.90 (d, J=8.5 Hz, 1H), 7.63 (s, 1H), 7.59 (d, J=8.8 Hz, 1H), 7.52 (t, J=7.9 Hz, 1H), 7.40 (dd, J=8.5, 2.1 Hz, 1H), 7.32 (d, J=7.6 Hz, 1H), 7.01 (br. s., 2H), 3.81 (s, 3H).
Example 8
methyl 6-amino-5-{5-[({[2-fluoro-5-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-fluoro-2-isocyanato-4-(trifluoromethyl)benzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.31 (s, 1H), 8.93 (d, J=2.6 Hz, 1H), 8.67 (dd, J=7.3, 2.1 Hz, 1H), 8.58 (d, J=2.1 Hz, 1H), 8.16 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.91 (d, J=8.8 Hz, 1H), 7.65 (s, 1H), 7.51 (dd, J=10.7, 8.9 Hz, 1H), 7.38-7.42 (m, 1H), 7.37 (dd, J=8.7, 2.2 Hz, 1H), 7.02 (br. s., 2H), 3.81 (s, 3H).
Example 9
methyl 6-amino-5-{5-[({[4-chloro-3-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-chloro-4-isocyanato-2-(trifluoromethyl)benzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.20 (s, 1H), 9.00 (s, 1H), 8.57 (d, J=2.3 Hz, 1H), 8.16 (d, J=2.3 Hz, 1H), 8.12 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.90 (d, J=8.8 Hz, 1H), 7.61-7.67 (m, 3H), 7.40 (dd, J=8.5, 2.1 Hz, 1H), 7.01 (br. s., 2H), 3.81 (s, 3H).
Example 10
methyl 6-amino-5-[5-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-fluoro-2-isocyanato-4-methylbenzene were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.19 (s, 1H), 8.57 (d, J=2.1 Hz, 1H), 8.50 (d, J=2.6 Hz, 1H), 8.13 (d, J=2.1 Hz, 1H), 8.03 (dd, J=7.9, 1.8 Hz, 1H), 7.94 (d, J=2.1 Hz, 1H), 7.89 (d, J=8.8 Hz, 1H), 7.62 (s, 1H), 7.36 (dd, J=8.5, 2.1 Hz, 1H), 7.11 (dd, J=11.3, 8.4 Hz, 1H), 7.01 (br. s., 2H), 6.79-6.82 (m, 1H), 3.81 (s, 3H), 2.28 (s, 3H)
Preparation 3
methyl 6-amino-5-{5-[(tert-butoxycarbonyl)amino]-1-benzothien-2-yl}nicotinate
To the degassed mixture of methyl 6-amino-5-iodonicotinate (4.17 g, 15 mmol, 1 eq), {[2-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-benzo[b]thiophen-5-yl]-carbamic acid tert-butyl ester} (6.47 g, 1.15 eq), and aq sodium carbonate (2M, 22.5 mL, 3 eq) in dioxane (30 mL) was added Ph 3 P (393 mg, 0.1 eq) and Pd(OAc) 2 (340 mg, 0.1 eq). The mixture was heated to 50° C. with vigorous stirring for 45 minutes. The reaction mixture was then partitioned between aq NH 4 Cl and EtOAc. The organic layer was isolated, washed with sat aq NaHCO 3 , brine, and finally dried with anhydrous sodium sulfate. The upper solution-layer was decanted, concentrated, and the solid residue was treated with EtOAc-Hex (1:4) with stirring at room temperature for 3 hours. methyl 6-amino-5-{5-[(tert-butoxycarbonyl)amino]-1-benzothien-2-yl}nicotinate was obtained upon filtration as a slightly green-yellowish solid.
1 H NMR (DMSO-d 6 ) δ: 9.48 (br. s., 1H), 8.56 (d, J=2.1 Hz, 1H), 8.08 (br. s., 1H), 7.93 (d, J=2.3 Hz, 1H), 7.84 (d, J=8.5 Hz, 1H), 7.59 (s, 1H), 7.41 (dd, J=8.8, 2.1 Hz, 1H), 7.00 (br. s., 2H), 3.81 (s, 3H), 1.50 (s, 9H)
Preparation 4
methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate
To the above obtained crude solid of methyl 6-amino-5-{5-[(tert-butoxycarbonyl)amino]-1-benzothien-2-yl}nicotinate (15 mmol, 1 eq) in dichloromethane (25 mL) at 0° C. was added dropwise trifluoroacetic acid (11.7 mL, 10 eq). During this process the reaction mixture became a brown solution. After the reaction was stirred at 0° C. for 10 minutes and at room temperature for 5 hours, it was slowly poured into an ice-cooled saturated aqueous sodium bicarbonate solution with stirring. When all the bubbling ceased, the mixture was extracted with dichloromethane, which was washed with brine and dried with anhydrous sodium sulfate. The upper brown solution was decanted, concentrated to a lesser amount, and the occurring solid mixture was treated with EtOAc-Hex (1:1). A green-yellowish solid was obtained upon filtration which was further subject to chromatography (MeOH-DCM 1:100 to 1:20). The corresponding product fractions were collected, concentrated, and triturated with EtOAc-Hex (1:4) giving methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate as a slightly yellow solid in amount of 3.48 g upon filtration with a yield of 78% for two steps.
1 H NMR (DMSO-d 6 ) δ: 8.54 (d, J=2.1 Hz, 1H), 7.91 (d, J=2.1 Hz, 1H), 7.58 (d, J=8.5 Hz, 1H), 7.40 (s, 1H), 6.97 (d, J=2.1 Hz, 1H), 6.94 (br. s., 2H), 6.74 (dd, J=8.5, 2.1 Hz, 1H), 5.13 (s, 2H), 3.80 (s, 3H)
Example 11
methyl 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
To the solution of methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate (120 mg, 0.4 mmol. 1 eq) in anhydrous THF (4 mL) at room temperature was added dropwise m-tolylisocyanate (0.051 mL, 1 eq). After the reaction was stirred at room temperature for 4 hours, the solid appeared in the reaction was directly filtered to give methyl 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate as a white solid in amount of 84 mg.
1 H NMR (DMSO-d 6 ) δ: 8.78 (s, 1H), 8.61 (s, 1H), 8.57 (d, J=2.1 Hz, 1H), 8.11 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.8 Hz, 1H), 7.61 (s, 1H), 7.38 (dd, J=8.7, 2.2 Hz, 1H), 7.32 (s, 1H), 7.25 (d, J=8.2 Hz, 1H), 7.16 (t, J=7.8 Hz, 1H), 7.01 (br. s., 2H), 6.80 (d, J=7.3 Hz, 1H), 3.81 (s, 3H), 2.29 (s, 3H).
Example 12
methyl 6-amino-5-[5-({[(3-chloro-4-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 2-chloro-1-fluoro-4-isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.90 (s, 1H), 8.90 (s, 1H), 8.57 (d, J=2.3 Hz, 1H), 8.09 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.1 Hz, 1H), 7.89 (d, J=8.5 Hz, 1H), 7.83 (dd, J=6.9, 1.9 Hz, 1H), 7.62 (s, 1H), 7.39 (dd, J=8.8, 2.1 Hz, 1H), 7.31-7.35 (m, 2H), 7.01 (br. s., 2H), 3.81 (s, 3H).
Example 13
methyl 6-amino-5-[5-({[(4-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-isocyanato-4-methylbenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.75 (s, 1H), 8.57 (d, J=2.1 Hz, 2H), 8.09 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.87 (d, J=8.8 Hz, 1H), 7.61 (s, 1H), 7.34-7.39 (m, 3H), 7.09 (d, J=8.2 Hz, 2H), 7.01 (br. s., 2H), 3.81 (s, 3H), 2.25 (s, 3H).
Example 14
methyl 6-amino-5-[5-({[(2-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 1-fluoro-2-isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.21 (s, 1H), 8.57-8.59 (m, 2H), 8.19 (td, J=8.3, 1.6 Hz, 1H), 8.12 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.1 Hz, 1H), 7.90 (d, J=8.5 Hz, 1H), 7.63 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.25 (ddd, J=11.7, 8.1, 1.3 Hz, 1H), 7.15 (t, J=7.8 Hz, 1H), 6.99-7.04 (m, 3H), 3.81 (s, 3H).
Example 15
methyl 6-amino-5-{5-[(anilinocarbonyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) □: 8.81 (s, 1H), 8.69 (s, 1H), 8.57 (d, J=2.3 Hz, 1H), 8.11 (d, J=2.1 Hz, 1H), 7.94 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.5 Hz, 1H), 7.62 (s, 1H), 7.46-7.49 (m, 2H), 7.38 (dd, J=8.5, 2.1 Hz, 1H), 7.27-7.31 (m, 2H), 7.01 (br. s., 2H), 6.98 (tt, J=7.3, 1.0 Hz, 1H), 3.81 (s, 3H).
Example 16
methyl 6-amino-5-[5-({[(2,4-difluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 11, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 2,4-difluoro-1-isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.15 (s, 1H), 8.57 (d, J=2.3 Hz, 1H), 8.53 (d, J=2.1 Hz, 1H), 8.09-8.14 (m, 2H), 7.94 (d, J=2.1 Hz, 1H), 7.89 (d, J=8.5 Hz, 1H), 7.63 (s, 1H), 7.37 (dd, J=8.5, 2.1 Hz, 1H), 7.32 (ddd, J=11.5, 8.7, 2.9 Hz, 1H), 7.04-7.08 (m, 1H), 7.01 (br. s., 2H), 3.81 (s, 3H).
Example 17
6-amino-5-[5-({[(3-chloro-4-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid
In a manner similar to that described in Example 19, methyl 6-amino-5-[5-({[(3-chloro-4-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate was converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 12.65 (br. s., 1H), 8.96 (d, J=3.5 Hz, 2H), 8.55 (d, J=2.3 Hz, 1H), 8.09 (d, J=2.1 Hz, 1H), 7.95 (d, J=2.3 Hz, 1H), 7.89 (d, J=8.8 Hz, 1H), 7.80-7.86 (m, 1H), 7.62 (s, 1H), 7.39 (dd, J=8.8, 2.1 Hz, 1H), 7.30-7.36 (m, 2H), 6.99 (br. s., 2H).
Example 18
6-amino-5-[5-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid
In a manner similar to that described in Example 19, methyl 6-amino-5-[5-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate was converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 12.73 (br. s., 1H), 9.27 (s, 1H), 8.51-8.58 (m, 2H), 8.14 (d, J=2.1 Hz, 1H), 8.02 (dd, J=7.9, 1.8 Hz, 1H), 7.97 (d, J=2.1 Hz, 1H), 7.90 (d, J=8.5 Hz, 1H), 7.63 (s, 1H), 7.37 (dd, J=8.6, 2.2 Hz, 1H), 7.04-7.20 (m, 3H), 6.80 (ddd, J=7.7, 5.2, 2.1 Hz, 1H), 2.28 (s, 3H)
Example 19
6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid
To the stirring mixture of methyl 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinate (420 mg, 0.972 mmol, 1 eq) in MeOH—H 2 O (3:1, 20 mL) at room temperature was added potassium hydroxide pellets (272 mg, 5 eq) and the reaction mixture was stirred at 65° C. for total of two hours, at which time the reaction mixture became a clear yellow solution. The solution was concentrated under reduced pressure to remove most part of methanol. The mixture was then cooled in an ice-bath, concentrated hydrochloride was added dropwise, and the pH was adjusted to about 3. After the mixture was stirred for about another 30 minutes, it was filtered through a Buchner funnel, rinsed with water, and 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid was obtained as a yellow solid in quantitative yield.
1 H NMR (DMSO-d 6 ) δ: 9.09 (s, 1H), 8.88 (s, 1H), 8.55 (d, J=2.1 Hz, 1H), 8.14 (d, J=2.1 Hz, 1H), 8.01 (d, J=2.1 Hz, 1H), 7.89 (d, J=8.8 Hz, 1H), 7.63 (s, 1H), 7.29-7.45 (m, 4H), 7.26 (d, J=8.2 Hz, 1H), 7.12-7.19 (m, 1H), 6.79 (d, J=7.3 Hz, 1H), 2.28 (s, 3H)
Example 20
6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide
To a seal tube containing 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic (84 mg, 0.2 mmol, 1 eq), DMAP (5 mg, 0.2 eq), and EDCI (46.1 mg, 1.2 eq) in anhydrous THF (3 mL) at room temperature, gaseous ammonia was bubbled through for about 5 minutes. The tube was quickly capped and the reaction was heated at 60° C. for one hour.
TLC indicated the reaction did not proceed.
After the reaction was cooled to room temperature, to the reaction mixture was added anhydrous DMF (3 mL), diisopropylethylamine (0.2 mL, 5 eq), ammonium chloride (32.1 mg, 3 eq), and (benzotriazol-1-yloxy)tris(dimethylamino)phosphonium hexafluorophosphate (97.3 mg, 1.1 eq). After the reaction was stirred at 60° C. for 30 minutes, it was partitioned between ethyl acetate and aqueous ammonium chloride. The organic layer was isolated, washed with saturated aqueous sodium bicarbonate, brine, and dried with anhydrous sodium sulfate. The clear solution was decanted, concentrated, the solid residue was subject to a gradient column chromatography (from DCM to MeOH-DCM 1:1). 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide was obtained as white solid in two portions, 38 mg from the chromatography fractions and 16 mg from a remainder on top of the syringe column. Both were confirmed by proton NMR.
1 H NMR (DMSO-d 6 ) δ: 8.81 (s, 1H), 8.63 (s, 1H), 8.55 (d, J=2.1 Hz, 1H), 8.08 (d, J=1.8 Hz, 1H), 8.03 (d, J=2.3 Hz, 1H), 7.95-6.88 (br. s., 2H), 7.86 (d, J=8.5 Hz, 1H), 7.59 (s, 1H), 7.39 (dd, J=8.8, 2.1 Hz, 1H), 7.32 (s, 1H), 7.23-7.29 (m, 1H), 7.13-7.19 (m, 1H), 6.80 (d, J=7.3 Hz, 1H), 6.48 (s, 2H), 2.29 (s, 3H).
Example 21
methyl 4-[({6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)amino]butanoate
In a manner similar to that described in Example 22, 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid was converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.80 (s, 1H), 8.62 (s, 1H), 8.52 (d, J=2.3 Hz, 1H), 8.33 (t, J=5.6 Hz, 1H), 8.10 (d, J=2.1 Hz, 1H), 8.01 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.8 Hz, 1H), 7.60 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.32 (s, 1H), 7.22-7.28 (m, 1H), 7.13-7.20 (m, 1H), 6.80 (d, J=7.6 Hz, 1H), 6.61 (s, 2H), 3.58 (s, 3H), 3.21-3.30 (m, 2H), 2.37 (t, J=7.3 Hz, 2H), 2.29 (s, 3H), 1.77 (quin, J=7.1 Hz, 2H)
Example 22
methyl 6-[({6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)amino]hexanoate
The reaction mixture of 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid (84 mg, 0.2 mmol, 1 eq), methyl 6-aminohexanoate hydrochloride (43.7 mg, 1.2 eq), DMAP (5 mg, 0.2 eq), and EDCI (46.1 mg, 1.2 eq) in anhydrous 1,2-dichloroethane (3 mL) was stirred and heated at 50° C. for 2 hours. It was then diluted with ethyl acetate, washed sequentially with aqueous NH 4 Cl, saturated aqueous NaHCO 3 , and brine, and dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated, and the solid residue was triturated with EtOAc-Hex (3:1) yielding methyl 6-[({6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)amino]hexanoate as a white solid in amount of 83 mg.
1 H NMR (DMSO-d 6 ) δ: 8.79 (s, 1H), 8.62 (s, 1H), 8.51 (d, J=2.3 Hz, 1H), 8.29 (t, J=5.6 Hz, 1H), 8.10 (d, J=1.8 Hz, 1H), 8.00 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.5 Hz, 1H), 7.60 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.32 (s, 1H), 7.22-7.28 (m, 1H), 7.13-7.20 (m, 1H), 6.80 (d, J=7.3 Hz, 1H), 6.60 (s, 2H), 3.57 (s, 3H), 3.22 (q, J=6.4 Hz, 2H), 2.26-2.35 (m, 5H), 1.53 (tt, J=14.5, 7.3 Hz, 4H), 1.26-1.36 (m, 2H).
Example 23
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-[2-fluoro-5-(trifluoromethyl)phenyl]urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 1-fluoro-2-isocyanato-4-(trifluoromethyl)benzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.30 (s, 1H), 8.92 (d, J=2.6 Hz, 1H), 8.67 (dd, J=7.3, 2.1 Hz, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.12 (d, J=1.8 Hz, 1H), 7.89 (d, J=8.5 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.61 (s, 1H), 7.46-7.55 (m, 1H), 7.33-7.43 (m, 2H), 6.53 (s, 2H), 1.28 (s, 12H).
Example 24
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-[3-(trifluoromethyl)phenyl]urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 1-isocyanato-3-(trifluoromethyl)benzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.07 (s, 1H), 8.92 (s, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.09 (d, J=1.8 Hz, 1H), 8.06 (s, 1H), 7.87 (d, J=8.8 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.56-7.62 (m, 2H), 7.48-7.55 (m, 1H), 7.39 (dd, J=8.6, 2.2 Hz, 1H), 7.31 (d, J=7.6 Hz, 1H), 6.53 (s, 2H), 1.28 (s, 12H)
Example 25
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-[4-chloro-3-(trifluoromethyl)phenyl]urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 1-chloro-4-isocyanato-2-(trifluoromethyl)benzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.19 (s, 1H), 8.98 (s, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.16 (d, J=2.1 Hz, 1H), 8.08 (d, J=2.1 Hz, 1H), 7.87 (d, J=8.5 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.62-7.66 (m, 2H), 7.59 (s, 1H), 7.39 (dd, J=8.5, 2.1 Hz, 1H), 6.53 (s, 2H), 1.28 (s, 12H)
Example 26
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(2-fluoro-5-methylphenyl)urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 1-fluoro-2-isocyanato-4-methylbenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.18 (s, 1H), 8.50 (d, J=2.6 Hz, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.09 (d, J=2.1 Hz, 1H), 8.03 (dd, J=7.9, 1.8 Hz, 1H), 7.87 (d, J=8.8 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.58 (s, 1H), 7.36 (dd, J=8.8, 2.1 Hz, 1H), 7.11 (dd, J=11.4, 8.2 Hz, 1H), 6.77-6.84 (m, 1H), 6.53 (s, 2H), 2.28 (s, 3H), 1.28 (s, 12H)
Example 27
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(3-chloro-4-fluorophenyl)urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 2-chloro-1-fluoro-4-isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.89 (s, 1H), 8.88 (s, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.06 (d, J=2.1 Hz, 1H), 7.81-7.89 (m, 2H), 7.69 (d, J=1.8 Hz, 1H), 7.58 (s, 1H), 7.31-7.41 (m, 3H), 6.52 (s, 2H), 1.28 (s, 12H)
Example 28
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(3-ethylphenyl)urea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and 1-ethyl-3-isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.76 (s, 1H), 8.62 (s, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.08 (d, J=2.1 Hz, 1H), 7.85 (d, J=8.8 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.58 (s, 1H), 7.34-7.39 (m, 2H), 7.23-7.30 (m, 1H), 7.15-7.23 (m, 1H), 6.83 (d, J=7.3 Hz, 1H), 6.52 (s, 2H), 2.58 (q, J=7.5 Hz, 2H), 1.28 (s, 12H), 1.19 (t, J=7.6 Hz, 3H)
Example 29
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(3-methylphenyl)urea
To the solution of 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine (734.6 mg, 2 mmol. 1 eq) in anhydrous THF (10 mL) at room temperature was added dropwise m-tolylisocyanate (0.251 mL, 1 eq). After the reaction was stirred at room temperature for 4 hours, it was partitioned between ethyl acetate and aqueous ammonium chloride. The organic layer was isolated, washed with saturated aqueous sodium bicarbonate, brine, and dried with anhydrous sodium sulfate. The upper solution layer was decanted, concentrated, and the solid residue was subject to a gradient column chromatography (DCM to MeOH-DCM 1:5). The products' fractions were collected, concentrated, the solid was triturated with EtOAc-Hex (1:7) yielding 1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(3-methylphenyl)urea as a white powder upon filtration in amount of 407 mg.
1 H NMR (DMSO-d 6 ) δ: 8.77 (s, 1H), 8.60 (s, 1H), 8.24 (d, J=1.8 Hz, 1H), 8.07 (d, J=1.8 Hz, 1H), 7.85 (d, J=8.5 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.57 (s, 1H), 7.37 (dd, J=8.6, 2.2 Hz, 1H), 7.32 (s, 1H), 7.22-7.28 (m, 1H), 7.13-7.20 (m, 1H), 6.79 (d, J=7.3 Hz, 1H), 6.52 (s, 2H), 2.29 (s, 3H), 1.28 (s, 12H).
Example 30
1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-phenylurea
In a manner similar to that described in Example 29, 3-(5-amino-1-benzothien-2-yl)-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-2-amine and isocyanatobenzene are converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.78 (s, 1H), 8.68 (s, 1H), 8.24 (d, J=1.5 Hz, 1H), 8.07 (d, J=1.5 Hz, 1H), 7.85 (d, J=8.8 Hz, 1H), 7.69 (d, J=1.8 Hz, 1H), 7.58 (s, 1H), 7.48 (d, J=7.6 Hz, 2H), 7.38 (dd, J=8.8, 1.8 Hz, 1H), 7.29 (t, J=7.8 Hz, 2H), 6.94-7.01 (m, 1H), 6.53 (s, 2H), 1.28 (s, 12H).
Example 31
{6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}boronic acid
To the solution of 1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-(3-methylphenyl)urea (500 mg, 1 mmol, 1 eq) in tetrahydrofuran (6 mL) at room temperature was added dropwise aqueous HCl (3 N, 6 mL) and the reaction was stirred at room temperature for 4 hours. The reaction mixture was filtered directly through a Buchner funnel, rinsed with isopropanol, followed by i-PrOH—H 2 O (1:1) to give {6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}boronic acid as a white solid in amount of 384 mg.
1 H NMR (DMSO-d 6 ) δ: 9.26 (s, 1H), 9.02 (s, 1H), 8.54 (br. s., 2H), 8.27 (dd, J=12.0, 1.5 Hz, 2H), 8.20 (d, J=2.1 Hz, 1H), 8.16 (br. s., 2H), 7.94 (d, J=8.8 Hz, 1H), 7.65 (s, 1H), 7.42 (dd, J=8.8, 2.1 Hz, 1H), 7.32 (s, 1H), 7.27 (d, J=8.5 Hz, 1H), 7.12-7.19 (m, 1H), 6.79 (d, J=7.3 Hz, 1H), 2.28 (s, 3H).
Example 32
(6-amino-5-{5-[(anilinocarbonyl)amino]-1-benzothien-2-yl}pyridin-3-yl)boronic acid
In a manner similar to that described in Example 31, 1-{2-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]-1-benzothien-5-yl}-3-phenylurea was converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.13 (s, 1H), 8.97 (s, 1H), 8.52 (br. s., 2H), 8.26 (dd, J=6.4, 1.5 Hz, 2H), 8.19 (d, J=1.8 Hz, 1H), 8.04 (br. s., 2H), 7.94 (d, J=8.8 Hz, 1H), 7.65 (s, 1H), 7.48 (d, J=7.3 Hz, 2H), 7.41 (dd, J=8.8, 2.1 Hz, 1H), 7.29 (t, J=8.1 Hz, 2H), 6.94-7.01 (m, 1H)
Example 33
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[(3-methyl-2-furoyl)amino]-1-benzothien-2-yl}nicotinamide
To the mixture of 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide (72 mg, 0.2 mmol, 1 eq) and 3-methylfuranylcarboxylic acid (25.2 mg, 1 eq) in dichloroethane (2 mL) at 50° C. was added catalytic amount of DMAP and EDCI (46.1 mg, 1.2 eq). The reaction was stirred at that temperature for 1 h and then at room temperature for 20 h. It was then partitioned between EtOAc and saturated aq NaHCO 3 . The organic layer was further washed with brine and then dried with anhydrous sodium sulfate. The organic layer was decanted, concentrated, and the residue was subject to a gradient column chromatography (EtOAc-Hex 2:1 to neat EtOAc) rendering 6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[(3-methyl-2-furoyl)amino]-1-benzothien-2-yl}nicotinamide as white solid in amount of 90 mg (96%).
1 H NMR (DMSO-d 6 ) δ: 10.17 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.41 (d, J=1.8 Hz, 1H), 8.03 (d, J=2.1 Hz, 1H), 7.92 (d, J=8.8 Hz, 1H), 7.81 (d, J=1.5 Hz, 1H), 7.71 (dd, J=8.8, 2.1 Hz, 1H), 7.62 (s, 1H), 6.76 (s, 2H), 6.61 (d, J=1.5 Hz, 1H), 3.44 (s, 6H), 2.37 (s, 3H)
Example 34
6-amino-5-(5-{[4-chloro-3-(trifluoromethyl)benzoyl]amino}-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
In a manner similar to that described in Example 33, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 4-chloro-3-(trifluoromethyl)benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.66 (s, 1H), 8.62 (d, J=2.1 Hz, 1H), 8.43 (d, J=1.8 Hz, 1H), 8.38 (d, J=1.8 Hz, 1H), 8.31 (dd, J=8.2, 1.8 Hz, 1H), 8.04 (d, J=2.1 Hz, 1H), 7.99 (d, J=8.8 Hz, 1H), 7.95 (d, J=8.2 Hz, 1H), 7.70 (dd, J=8.5, 2.1 Hz, 1H), 7.68 (s, 1H), 6.79 (s, 2H), 3.44 (s, 6H)
Example 35
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[(2-fluoro-5-methylbenzoyl)amino]-1-benzothien-2-yl}nicotinamide
In a manner similar to that described in Example 33, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 2-fluoro-5-methylbenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.50 (s, 1H), 8.61 (d, J=2.3 Hz, 1H), 8.39 (d, J=1.8 Hz, 1H), 8.04 (d, J=2.3 Hz, 1H), 7.95 (d, J=8.8 Hz, 1H), 7.66 (s, 1H), 7.62 (dd, J=8.7, 1.9 Hz, 1H), 7.50 (dd, J=6.5, 1.8 Hz, 1H), 7.36-7.40 (m, 1H), 7.22-7.26 (m, 1H), 6.78 (s, 2H), 3.44 (s, 6H), 2.36 (s, 3H)
Example 36
6-amino-5-[5-(benzoylamino)-1-benzothien-2-yl]-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide
In a manner similar to that described in Example 33, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.39 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.42 (d, J=1.8 Hz, 1H), 8.04 (d, J=2.1 Hz, 1H), 8.00 (d, J=7.0 Hz, 2H), 7.95 (d, J=8.8 Hz, 1H), 7.72 (dd, J=8.7, 1.9 Hz, 1H), 7.66 (s, 1H), 7.59-7.63 (m, 1H), 7.53-7.57 (m, 2H), 6.78 (s, 2H), 3.44 (s, 6H)
Example 37
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[(3-methylbenzoyl)amino]-1-benzothien-2-yl}nicotinamide
In a manner similar to that described in Example 33, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 3-methylbenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.34 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.41 (d, J=1.5 Hz, 1H), 8.04 (d, J=2.1 Hz, 1H), 7.95 (d, J=8.5 Hz, 1H), 7.81 (s, 1H), 7.78 (d, J=6.7 Hz, 1H), 7.71 (dd, J=8.5, 1.8 Hz, 1H), 7.65 (s, 1H), 7.40-7.44 (m, 2H), 6.78 (s, 2H), 3.44 (s, 6H), 2.42 (s, 3H)
Example 38
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-(5-{[2-fluoro-5-(trifluoromethyl)benzoyl]amino}-1-benzothien-2-yl)nicotinamide
In a manner similar to that described in Example 33, 6-amino-5-(5-amino-1-benzothien-2-yl)-N-[dimethyl(oxido)-λ 4 -sulfanylidene]nicotinamide and 2-fluoro-5-(trifluoromethyl)benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.73 (s, 1H), 8.61 (d, J=2.3 Hz, 1H), 8.37 (d, J=2.1 Hz, 1H), 8.10 (dd, J=6.2, 2.1 Hz, 1H), 8.04 (d, J=2.1 Hz, 1H), 7.99-8.02 (m, 1H), 7.98 (d, J=8.8 Hz, 1H), 7.68 (s, 1H), 7.64 (t, J=9.1 Hz, 1H), 7.61 (dd, J=8.8, 2.1 Hz, 1H), 6.79 (s, 2H), 3.44 (s, 6H)
Example 39
methyl 6-amino-5-{5-[(3-methyl-2-furoyl)amino]-1-benzothien-2-yl}nicotinate
To the mixture of methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate (120 mg, 0.4 mmol, 1 eq) and 3-methylfuranylcarboxylic acid (50.4 mg, 1 eq) in 1,2-dichloroethane (3 mL) at 60° C. was added catalytic amount of DMAP (10 mg, 0.2 eq) and EDCI (92.2 mg, 1.2 eq). The reaction was stirred at that temperature for 2 h and then partitioned between EtOAc and saturated aq NaHCO 3 . The organic layer was further washed with brine and then dried with anhydrous sodium sulfate. The organic layer was decanted, concentrated, and the solid residue which was treated with ethyl acetate with stirring at room temperature for an hour. Methyl 6-amino-5-{5-[(3-methyl-2-furoyl)amino]-1-benzothien-2-yl}nicotinate was obtained upon filtration as a white solid in amount of 128 mg.
1 H NMR (DMSO-d 6 ) δ: 10.18 (s, 1H), 8.58 (d, J=2.3 Hz, 1H), 8.42 (d, J=2.1 Hz, 1H), 7.95 (d, J=2.1 Hz, 1H), 7.92 (d, J=8.8 Hz, 1H), 7.81 (d, J=1.8 Hz, 1H), 7.72 (dd, J=8.8, 2.1 Hz, 1H), 7.64 (s, 1H), 7.02 (br. s., 2H), 6.61 (d, J=1.5 Hz, 1H), 3.81 (s, 3H), 2.37 (s, 3H)
Example 40
methyl 6-amino-5-{5-[(3-methylbenzoyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 3-methylbenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.34 (s, 1H), 8.58 (d, J=2.1 Hz, 1H), 8.42 (d, J=1.8 Hz, 1H), 7.94-7.97 (m, 2H), 7.81 (s, 1H), 7.78 (d, J=6.7 Hz, 1H), 7.72 (dd, J=8.7, 1.9 Hz, 1H), 7.68 (s, 1H), 7.40-7.45 (m, 2H), 7.03 (br. s., 2H), 3.81 (s, 3H), 2.42 (s, 3H)
Example 41
methyl 6-amino-5-{5-[(2-fluoro-5-methylbenzoyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 2-fluoro-5-methylbenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.51 (s, 1H), 8.58 (d, J=2.1 Hz, 1H), 8.39 (d, J=1.2 Hz, 1H), 7.94-7.97 (m, 2H), 7.68 (s, 1H), 7.63 (dd, J=8.7, 1.9 Hz, 1H), 7.50 (dd, J=6.5, 1.5 Hz, 1H), 7.36-7.40 (m, 1H), 7.24 (t, J=9.2 Hz, 1H), 7.03 (br. s., 2H), 3.81 (s, 3H), 2.36 (s, 3H)
Example 42
methyl 6-amino-5-[5-(benzoylamino)-1-benzothien-2-yl]nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.39 (s, 1H), 8.58 (d, J=2.3 Hz, 1H), 8.43 (d, J=1.8 Hz, 1H), 8.00 (d, J=7.0 Hz, 2H), 7.96 (dd, J=5.6, 3.2 Hz, 2H), 7.73 (dd, J=8.8, 2.1 Hz, 1H), 7.68 (s, 1H), 7.59-7.63 (m, 1H), 7.53-7.58 (m, 2H), 7.04 (br. s., 2H), 3.81 (s, 3H)
Example 43
methyl 6-amino-5-{5-[(3-chloro-4-fluorobenzoyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 3-chloro-4-fluorobenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.49 (s, 1H), 8.58 (d, J=2.1 Hz, 1H), 8.39 (d, J=1.8 Hz, 1H), 8.25 (dd, J=7.2, 2.2 Hz, 1H), 8.04 (ddd, J=8.7, 4.7, 2.2 Hz, 1H), 7.95-7.99 (m, 2H), 7.68-7.72 (m, 2H), 7.62 (t, J=9.0 Hz, 1H), 7.04 (br. s., 2H), 3.81 (s, 3H)
Example 44
methyl 6-amino-5-(5-{[2-fluoro-5-(trifluoromethyl)benzoyl]amino}-1-benzothien-2-yl)nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and 2-fluoro-5-(trifluoromethyl)benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.74 (s, 1H), 8.58 (d, J=2.1 Hz, 1H), 8.38 (d, J=2.1 Hz, 1H), 8.10 (dd, J=6.2, 2.1 Hz, 1H), 7.99-8.02 (m, 1H), 7.98 (d, J=8.5 Hz, 1H), 7.96 (d, J=2.1 Hz, 1H), 7.70 (s, 1H), 7.64-7.67 (m, 1H), 7.62 (dd, J=8.7, 1.9 Hz, 1H), 7.04 (br. s., 2H), 3.81 (s, 3H)
Example 45
methyl 6-amino-5-{5-[(1-benzofuran-2-ylcarbonyl)amino]-1-benzothien-2-yl}nicotinate
In a manner similar to that described in Example 39, methyl 6-amino-5-(5-amino-1-benzothien-2-yl)nicotinate and benzofuran-2-carboxylic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.68 (s, 1H), 8.58 (d, J=2.3 Hz, 1H), 8.45 (d, J=1.8 Hz, 1H), 7.99 (d, J=8.8 Hz, 1H), 7.96 (d, J=2.3 Hz, 1H), 7.85 (d, J=7.6 Hz, 1H), 7.81 (d, J=0.6 Hz, 1H), 7.78 (dd, J=8.7, 1.9 Hz, 1H), 7.75 (d, J=8.2 Hz, 1H), 7.70 (s, 1H), 7.50-7.54 (m, 1H), 7.37-7.40 (m, 1H), 7.05 (br. s., 2H), 3.81 (s, 3H)
Example 46
N-[2-(2-aminopyridin-3-yl)-1-benzothien-5-yl]-3-methylbenzamide
In a manner similar to that described in Example 39, 3-(5-aminobenzo[b]thiophen-2-yl)pyridin-2-amine and 3-methylbenzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.33 (s, 1H), 8.40 (d, J=1.8 Hz, 1H), 8.02 (dd, J=4.7, 1.8 Hz, 1H), 7.93 (d, J=8.8 Hz, 1H), 7.81 (s, 1H), 7.78 (d, J=6.7 Hz, 1H), 7.69 (dd, J=8.7, 1.9 Hz, 1H), 7.64 (s, 1H), 7.60 (dd, J=7.3, 1.8 Hz, 1H), 7.40-7.45 (m, 2H), 6.70 (dd, J=7.3, 5.0 Hz, 1H), 6.06 (s, 2H), 2.42 (s, 3H)
Example 47
N-[2-(2-aminopyridin-3-yl)-1-benzothien-5-yl]benzamide
In a manner similar to that described in Example 39, 3-(5-aminobenzo[b]thiophen-2-yl)pyridin-2-amine and benzoic acid were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.38 (s, 1H), 8.40 (d, J=1.8 Hz, 1H), 7.90-8.04 (m, 4H), 7.70 (dd, J=8.8, 1.8 Hz, 1H), 7.52-7.66 (m, 5H), 6.70 (dd, J=7.5, 4.8 Hz, 1H), 6.07 (s, 2H)
Example 48
2-(2-aminopyridin-3-yl)-N-(3-methylphenyl)-1-benzothiophene-5-carboxamide
In a manner similar to that described in Example 51, 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid and m-toluidine were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.27 (s, 1H), 8.48 (s, 1H), 8.13 (d, J=8.2 Hz, 1H), 8.04 (d, J=4.7 Hz, 1H), 7.95 (d, J=8.5 Hz, 1H), 7.77 (s, 1H), 7.67 (s, 1H), 7.62 (t, J=8.2 Hz, 2H), 7.25 (t, J=7.8 Hz, 1H), 6.94 (d, J=7.6 Hz, 1H), 6.72 (dd, J=7.2, 5.1 Hz, 1H), 6.10 (s, 2H), 2.33 (s, 3H)
Example 49
2-(2-aminopyridin-3-yl)-N-(5-tert-butylisoxazol-3-yl)-1-benzothiophene-5-carboxamide
In a manner similar to that described in Example 51, 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid and 5-(tert-butyl)isoxazol-3-amine were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 11.43 (s, 1H), 8.54 (s, 1H), 8.13 (d, J=8.5 Hz, 1H), 8.04 (dd, J=4.7, 1.5 Hz, 1H), 7.98 (dd, J=8.5, 1.5 Hz, 1H), 7.75 (s, 1H), 7.62 (dd, J=7.3, 1.5 Hz, 1H), 6.77 (s, 1H), 6.71 (dd, J=7.3, 4.7 Hz, 1H), 6.10 (s, 2H), 1.34 (s, 9H).
Example 50
2-(2-aminopyridin-3-yl)-N-(3-methylbenzyl)-1-benzothiophene-5-carboxamide
In a manner similar to that described in Example 51, 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid and m-tolylmethanamine were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.11 (t, J=5.9 Hz, 1H), 8.41 (s, 1H), 8.07 (d, J=8.2 Hz, 1H), 8.03 (dd, J=4.7, 1.5 Hz, 1H), 7.88 (dd, J=8.5, 1.2 Hz, 1H), 7.72 (s, 1H), 7.60 (dd, J=7.6, 1.5 Hz, 1H), 7.20-7.24 (m, 1H), 7.12-7.17 (m, 2H), 7.06 (d, J=7.6 Hz, 1H), 6.70 (dd, J=7.3, 5.0 Hz, 1H), 6.08 (s, 2H), 4.49 (d, J=5.9 Hz, 2H), 2.29 (s, 3H)
Preparation 5
2-(dihydroxyboryl)-1-benzothiophene-5-carboxylic acid
Benzothiophene-5-carboxylic acid (2 g, 11.2 mmol, 1 eq) was dissolved in anhydrous THF (50 mL). To the solution was added dropwise tert-BuLi petane solution (1.7 M, 20 mL, 3 eq) at −78° C. for 5 minutes under nitrogen atmosphere. The reaction mixture was allowed to warm to room temperature, stirred for 30 minutes, and cooled to −78° C. again, followed by an addition of triisopropyl borate (3.97 mL, 1.5 eq). The reaction was then allowed to warm to room temperature and stirred at that temperature for one hour. To the reaction mixture was added saturated aqueous ammonium chloride (50 mL) and 10% aqueous potassium hydrogensulfate solution (50 mL) to adjust pH to 2. After the mixture was stirred at room temperature for 30 minutes, it was extracted with ethyl acetate. The organic layer was washed with saturated brine and dried over anhydrous sodium sulfate. The upper solution was decanted, concentrated, and the residue was suspended in Hexane/CHCl 3 /MeOH (40:4:1). The solid was filtered, rinsed with hexane. 2-(dihydroxyboryl)-1-benzothiophene-5-carboxylic acid was obtained as a grayish solid in amount of 1.325 g (53%).
1 H NMR (DMSO-d 6 ) δ: 12.94 (br. s., 1H), 8.57 (br. s., 2H), 8.49 (s, 1H), 8.05-8.09 (m, 2H), 7.90 (d, J=8.5 Hz, 1H).
Preparation 6
2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid
To the degassed mixture of 2-amino-3-iodpyridine (1.12 g, 5.09 mmol, 1 eq), 2-(dihydroxyboryl)-1-benzothiophene-5-carboxylic acid, [2-(dihydroxyboryl)-1-benzothiophene-5-carboxylic acid (1.3 g, 1.15 eq)], and aqueous sodium carbonate (2M, 7.6 mL, 3 eq) in dioxane (10 mL) was added Ph 3 P (267 mg, 0.2 eq) and Pd(OAc) 2 (114.3 mg, 0.1 eq). The mixture was heated to 50° C. with vigorous stirring for 30 minutes. The yellow mixture was then partitioned between aq NH 4 Cl and MeOH—CHCl 3 (1:5). Some solids precipitation was observed. After the pH was carefully adjusted to around 6, the whole mixture was filtered through a Buchner funnel to obtain a yellow solid. The solid was further triturated with MeOH/H 2 O to give 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid as a white-off solid in amount of 1.18 g after dried in vacuo (86%).
1 H NMR (DMSO-d 6 ) δ: 12.97 (br. s., 1H), 8.46 (s, 1H), 8.09 (d, J=8.5 Hz, 1H), 8.03 (d, J=3.5 Hz, 1H), 7.90 (dd, J=8.4, 1.3 Hz, 1H), 7.77 (s, 1H), 7.60 (dd, J=7.3, 1.2 Hz, 1H), 6.70 (dd, J=7.3, 5.0 Hz, 1H), 6.09 (br. s., 2H)
Example 51
2-(2-aminopyridin-3-yl)-N-(2-fluoro-5-methylphenyl)-1-benzothiophene-5-carboxamide
The reaction mixture of 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid (54 mg, 0.2 mmol, 1 eq), 2-fluoro-5-methylaniline (0.048 mL, 2.1 eq), DMAP (5 mg, 0.2 eq), and EDCI (46.1 mg, 1.2 eq) in anhydrous 1,2-dichloroethane (2 mL) and anhydrous DMF (0.5 mL) was stirred and heated at 60° C. for 1 hour. It was then diluted with ethyl acetate, washed sequentially with aqueous NH 4 Cl, saturated aqueous NaHCO 3 , and brine, and finally dried with anhydrous sodium sulfate. The upper, clear solution-layer was decanted, concentrated, and the solid residue was subject to a gradient column chromatography (EtOAc-Hex 1:4 to 1:1) to yield 2-(2-aminopyridin-3-yl)-N-(2-fluoro-5-methylphenyl)-1-benzothiophene-5-carboxamide as a white solid in amount of 39.8 mg.
1 H NMR (DMSO-d 6 ) δ: 10.14 (s, 1H), 8.49 (s, 1H), 8.13 (d, J=8.5 Hz, 1H), 8.04 (dd, J=4.7, 1.2 Hz, 1H), 7.95 (dd, J=8.5, 0.9 Hz, 1H), 7.77 (s, 1H), 7.62 (dd, J=7.3, 1.2 Hz, 1H), 7.45 (d, J=6.2 Hz, 1H), 7.18 (dd, J=10.0, 8.8 Hz, 1H), 7.06-7.09 (m, 1H), 6.71 (dd, J=7.3, 5.0 Hz, 1H), 6.10 (s, 2H), 2.32 (s, 3H).
Example 52
2-(2-aminopyridin-3-yl)-N-(3-chloro-4-fluorophenyl)-1-benzothiophene-5-carboxamide
In a manner similar to that described in Example 51, 2-(2-aminopyridin-3-yl)-1-benzothiophene-5-carboxylic acid and 3-chloro-4-fluoroaniline were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 10.54 (s, 1H), 8.47 (s, 1H), 8.16 (d, J=8.5 Hz, 1H), 8.13 (dd, J=6.7, 2.6 Hz, 1H), 8.04 (dd, J=4.7, 1.5 Hz, 1H), 7.94 (dd, J=8.5, 1.2 Hz, 1H), 7.76-7.79 (m, 2H), 7.62 (dd, J=7.3, 1.5 Hz, 1H), 7.44 (t, J=9.1 Hz, 1H), 6.71 (dd, J=7.3, 5.0 Hz, 1H), 6.10 (s, 2H)
Example 53
methyl 5-[N-({6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)-S-methylsulfonimidoyl]pentanoate
To 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid (418 mg, 1 mmol, 1 equiv.) and (S)-methyl 5-(S-methylsulfonimidoyl)pentanoate (232 mg, 1.2 equiv.) in anhydrous DMF (6 mL) under nitrogen atmosphere was added diisopropylethylamine (0.348 mL, 2.0 equiv.) and (benzotriazol-1-yloxy)tris(dimethylamino)phosphonium hexafluorophosphate (486.5 mg, 1.1 equiv.). The reaction mixture was heated to 60° C. and stirred for 2 hours. After the reaction was cooled to room temperature, it was diluted with EtOAc and washed sequentially with saturated aqueous NaHCO 3 , brine, aqueous NH 4 Cl, and brine. After the organic layer was dried (anhydrous Na 2 SO 4 ), it was decanted, concentrated, and the brown oily residue was subject to a column chromatography (EtOAc-Hex 1:4 to 6:1). methyl 5-[N-({6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)-S-methylsulfonimidoyl]pentanoate was obtained as a yellow foam in amount of 394 mg (66%).
1 H NMR (DMSO-d 6 ) δ: 8.78 (s, 1H), 8.61 (s, 1H), 8.60 (s, 1H), 8.10 (d, J=2.1 Hz, 1H), 8.02 (d, J=2.3 Hz, 1H), 7.87 (d, J=8.5 Hz, 1H), 7.59 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.33 (s, 1H), 7.22-7.28 (m, 1H), 7.13-7.20 (m, 1H), 6.80 (d, J=7.6 Hz, 1H), 6.75 (s, 2H), 3.55-3.63 (m, 5H), 3.41 (s, 3H), 2.39 (t, J=7.2 Hz, 2H), 2.29 (s, 3H), 1.76-1.87 (m, 2H), 1.63-1.74 (m, 2H)
Example 54
methyl 5-[N-({6-amino-5-[5-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)-S-methylsulfonimidoyl]pentanoate
In a manner similar to that described in Example 53, 6-amino-5-(5-(3-(2-fluoro-5-methylphenyl)ureido)benzo[b]thiophen-2-yl)nicotinic acid and (S)-methyl 5-(S-methylsulfonimidoyl)pentanoate were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 9.19 (s, 1H), 8.61 (d, J=2.1 Hz, 1H), 8.51 (d, J=2.3 Hz, 1H), 8.12 (d, J=1.8 Hz, 1H), 8.00-8.05 (m, 2H), 7.88 (d, J=8.5 Hz, 1H), 7.60 (s, 1H), 7.36 (dd, J=8.8, 2.1 Hz, 1H), 7.11 (dd, J=11.4, 8.2 Hz, 1H), 6.77-6.84 (m, 1H), 6.76 (s, 2H), 3.53-3.65 (m, 5H), 3.41 (s, 3H), 2.40 (t, J=7.0 Hz, 2H), 2.28 (s, 3H), 1.75-1.88 (m, 2H), 1.64-1.74 (m, 2H)
Example 55
methyl 5-[N-({6-amino-5-[5-({[(3-chloro-4-fluorophenyl)amino]carbonyl}amino)-1-benzothien-2-yl]pyridin-3-yl}carbonyl)-S-methylsulfonimidoyl]pentanoate
In a manner similar to that described in Example 53, 6-amino-5-(5-(3-(3-chloro-4-fluorophenyl)ureido)benzo[b]thiophen-2-yl)nicotinic acid and (S)-methyl 5-(S-methylsulfonimidoyl)pentanoate were converted to the title compound.
1 H NMR (DMSO-d 6 ) δ: 8.90 (s, 1H), 8.90 (s, 1H), 8.61 (d, J=2.3 Hz, 1H), 8.08 (d, J=2.1 Hz, 1H), 8.01 (d, J=2.3 Hz, 1H), 7.88 (d, J=8.8 Hz, 1H), 7.81-7.86 (m, 1H), 7.60 (s, 1H), 7.31-7.41 (m, 3H), 6.76 (s, 2H), 3.54-3.63 (m, 5H), 3.41 (s, 3H), 2.39 (t, J=7.2 Hz, 2H), 1.75-1.88 (m, 2H), 1.63-1.74 (m, 2H)
Preparation 7
S(CH 2 CH 2 CH 2 OTBDMS) 2
2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane
To the solution of 3,3′-thiodipropanol (5 g, 32.6 mmol, 1 eq) and tert-butyldimethylsilyl chloride (13.18 g, 2.6 eq) in anhydrous DMF (25 mL) at 0° C. was added imidazole (11.21 g, 5 eq). After the reaction was stirred at room temperature for one hour, it was partitioned between ethyl acetate and water. The organic layer was isolated, washed once more with water, then brine, and lastly dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated, and the oily residue was subject to a column chromatography (EtOC-Hex: from 1:9 to 4:1). 2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane, was obtained as clear oil in 12.32 g.
1 H NMR (DMSO-d 6 ) δ: 3.64 (t, J=6.2 Hz, 4H), 2.49-2.53 (m, 4H), 1.65-1.71 (m, 4H), 0.86 (s, 18H), 0.03 (s, 12H)
Preparation 8
O═S(CH 2 CH 2 CH 2 OTBDMS) 2
2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane 8-oxide
A solution of sodium (meta)periodate (7.751 g, 1.1 eq) in water (40 mL) was slowly poured into a solution of 2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane, (12.32 g, 1 eq) in methanol (150 mL) at 0° C. and the reaction mixture was stirred at room temperature for 2 hours. The reaction mixture was then filtered through a pad of celite and silica gel which was washed with methanol. The filtrate was concentrated under reduced pressure at a temperature below 25° C. The residue was diluted with brine and extracted a couple of times with chloroform. All organic solvents were combined, dried with anhydrous sodium sulfate, and concentrated to give a clear oil as crude 2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane 8-oxide, in amount of 12.84 g.
1 H NMR (DMSO-d 6 ) δ: 3.69 (t, J=6.2 Hz, 4H), 2.59-2.83 (m, 4H), 1.80 (tdd, J=6.8, 6.7, 6.4 Hz, 4H), 0.86 (s, 18H), 0.04 (s, 12H)
Preparation 9
8-imino-2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8λ 4 -thia-3,13-disilapentadecane 8-oxide
To the solution of above obtained crude oil 2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8-thia-3,13-disilapentadecane 8-oxide, in anhydrous dichloromethane (150 mL) was added trifluoroacetamide (7.60 g, 2 eq), magnesium oxide (5.256 g. 4 eq), rhodium acetate dimer (432 mg, 0.03 eq), and (diacetoxyiodo)benzene (15.75 g, 1.5 eq) under nitrogen atmosphere at room temperature. The greenish reaction mixture was stirred at room temperature for 18 hours. Then additional amount of trifluoroacetamide (3.0 g), rhodium acetate dimer (300 mg), (diacetoxyiodo)benzene (5.0 g), and anhydrous dichloromethane (100 mL) was added. The mixture was continued being stirred at room temperature for another 3 hours and then filtered through a pad of celite and silica gel. The pad was washed first with dichloromethane followed by MeOH-DCM (1:5). The filtrate was concentrated and the brown oil was taken up into methanol (200 mL). Potassium carbonate (22.53 g, 5 eq) was added to the newly formed solution. After the mixture was stirred at room temp for 2 hours, it was filtered through a pad of celite and silica gel. The pad was washed first with DCM-EtOAC (1:1) followed by a later 10% (v/v) addition of MeOH with stirring of the sediment on top of the pad. The filtrate was concentrated and the residue mixture was treated with DCM-EtOAc (2:3) with stirring at room temp for 30 minutes. The mixture was filtered again through a pad of celite and silica gel. This filtration and concentration circle may be repeated a couple of times such that most of the solid by-product was removed and a redish oil was obtained. Upon a gradient column chromatography (EtOAc-HEX 1:20 to 1:1) 8-imino-2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8λ 4 -thia-3,13-disilapentadecane 8-oxide, was obtained as a reddish oil in amount of 9.538 g with a total yield of 72% for 4 steps.
1 H NMR (DMSO-d 6 ) δ: 3.67 (t, J=6.3 Hz, 4H), 3.65 (s, 1H), 2.99 (t, J=7.9 Hz, 4H), 1.82-1.88 (m, 4H), 0.86 (s, 18H), 0.04 (s, 12H)
Example 56
6-amino-N-[bis(3-hydroxypropyl)(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide
The reaction mixture of 8-imino-2,2,3,3,13,13,14,14-octamethyl-4,12-dioxa-8λ 4 -thia-3,13-disilapentadecane 8-oxide, (102.25 mg, 0.25 mmol, 1 eq), 6-amino-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinic acid (89 mg, 1 eq), DMAP (6.125 mg, 0.2 eq), and EDCI (57.6 mg, 1.2 eq) in anhydrous DCE (2.5 mL) was heated at 70° C. for 2 hours. It was then diluted with DCM, washed sequentially with aqueous NH 4 Cl, saturated aqueous NaHCO 3 , and brine, and dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated, and the oily residue was subject to gradient column chromatography (EtOAc-Hex 1:30 to 2:1) yielding 6-amino-N-[bis(3-{[tert-butyl(dimethyl)silyl]oxy}propyl)(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide as a white foam in amount of 70 mg.
1 H NMR (DMSO-d 6 ) δ: 8.77 (s, 1H), 8.59-8.61 (m, 2H), 8.10 (d, J=2.1 Hz, 1H), 8.01 (d, J=2.1 Hz, 1H), 7.85 (d, J=8.8 Hz, 1H), 7.57 (s, 1H), 7.37 (dd, J=8.8, 2.1 Hz, 1H), 7.33 (s, 1H), 7.25 (d, J=8.2 Hz, 1H), 7.16 (t, J=7.8 Hz, 1H), 6.80 (d, J=7.6 Hz, 1H), 6.76 (br. s., 2H), 3.71 (t, J=6.2 Hz, 4H), 3.62-3.70 (m, 4H), 2.29 (s, 3H), 1.89-1.98 (m, 4H), 0.85 (s, 18H), 0.03 (s, 12H)
To the solution of 6-amino-N-[bis(3-{[tert-butyl(dimethyl)silyl]oxy}propyl)(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide (70 mg, 0.086 mmol, 1 eq) in anhydrous THF (2 mL) at 0° C. was added dropwise tetrabutylammonium fluoride (0.355 mL, 1.0 M in anhyd. THF, 4.1 eq) and the reaction was stirred at that temp for 2 hours. The reaction was then partitioned between saturated aqueous NaHCO 3 and ethyl acetate. The organic layer was further washed with aqueous NH 4 Cl, brine, lastly dried with anhydrous Na 2 SO 4 . The upper solution was decanted, concentrated, and the solid residue was wrapped with silica gel which was subject to a gradient column chromatography (EtOAc-Hex 6:1 to MeOH-EtOAc 1:9) to give 6-amino-N-[bis(3-hydroxypropyl)(oxido)-λ 4 -sulfanylidene]-5-[5-({[(3-methylphenyl)amino]carbonyl}amino)-1-benzothien-2-yl]nicotinamide as a slightly brown solid in amount of 42 mg.
1 H NMR (DMSO-d 6 ) δ: 8.84 (s, 1H), 8.67 (s, 1H), 8.62 (d, J=2.3 Hz, 1H), 8.10 (d, J=1.8 Hz, 1H), 8.01 (d, J=2.1 Hz, 1H), 7.87 (d, J=8.8 Hz, 1H), 7.59 (s, 1H), 7.37 (dd, J=8.5, 2.1 Hz, 1H), 7.33 (s, 1H), 7.25 (d, J=8.2 Hz, 1H), 7.16 (t, J=7.8 Hz, 1H), 6.79 (d, J=7.3 Hz, 1H), 6.76 (s, 2H), 4.74 (t, J=5.3 Hz, 2H), 3.62-3.68 (m, 2H), 3.55-3.60 (m, 2H), 3.52 (q, J=6.1 Hz, 4H), 2.29 (s, 3H), 1.84-1.96 (m, 4H)
Example 57
N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-{5-[({[2-fluoro-5-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}nicotinamide
Synthesized using a procedure similar to Example 1.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.35 (s, 1H) 9.18 (d, J=2.35 Hz, 1H) 9.09 (d, J=2.05 Hz, 1H) 8.94 (d, J=2.93 Hz, 1H) 8.66 (dd, J=7.19, 2.20 Hz, 1H) 8.51 (t, J=2.05 Hz, 1H) 8.19 (d, J=1.76 Hz, 1H) 8.08 (s, 1H) 7.96 (d, J=8.80 Hz, 1H) 7.51 (dd, J=10.56, 8.80 Hz, 1H) 7.38-7.42 (m, 2H) 3.54 (s, 6H)
Example 58
5-{5-[({[4-chloro-3-(trifluoromethyl)phenyl]amino}carbonyl)amino]-1-benzothien-2-yl}-N-[dimethyl(oxido)-Δ 4 -sulfanylidene]nicotinamide
Synthesized using a procedure similar to Example 1.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.22 (s, 1H) 9.18 (d, J=2.35 Hz, 1H) 9.08 (d, J=1.76 Hz, 1H) 9.03 (s, 1H) 8.51 (t, J=2.20 Hz, 1H) 8.15 (dd, J=4.70, 2.35 Hz, 2H) 8.07 (s, 1H) 7.94 (d, J=8.51 Hz, 1H) 7.65-7.68 (m, 1H) 7.61-7.64 (m, 1H) 7.42 (dd, J=8.51, 2.05 Hz, 1H) 3.54 (s, 6H)
The compounds represented by Formula II can be synthesized according to the following example.
Example 60
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-[4-({[(2-fluoro-5-methylphenyl)amino]carbonyl}amino)phenyl]nicotinamide
1-(2-fluoro-5-methylphenyl)-3-(4-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)phenyl)urea (212 mg, 0.6 mmoles) and 6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-iodonicotinamide (170 mg, 0.5 mmoles) was added to a mixture of 6 ml of dioxane and 2 ml of 2M aqueous Sodium Carbonate. Next, Palladium(II) Acetate (˜5 mol %, 6 mg) and Triphenylphosphene (˜20 mol %, 27 mg) was added, followed by 2 ml of dioxane. Dry nitrogen was bubbled through the resulting solution for 15 minutes. Following this, the reaction mixture was set up with a reflux condenser, under nitrogen atmosphere, and heated at 95 C for 2 hours. The reaction was then cooled to room temperature and 40 ml of ethyl acetate was added. The mixture was transferred to a separatory funnel and extracted with saturated Sodium Bicarbonate (3×40 ml) followed by saturated NaCl (3×40 ml). The organic layer was dried with anhydrous Sodium Sulfate, loaded onto silica and columned using ethyl acetate/hexanes, to give 120 mg of the product.
1 H NMR (dmso) δ: 9.18 (s, 1H), 8.55 (d, J=2.0 Hz, 1H), 8.50 (d, J=2.6 Hz, 1H), 8.00 (dd, J=7.8, 1.9 Hz, 1H), 7.75 (d, J=2.3 Hz, 1H), 7.52-7.59 (m, 2H), 7.30-7.38 (m, 2H), 7.10 (dd, J=11.4, 8.2 Hz, 1H), 6.79 (s, 1H), 6.24 (s, 2H), 3.41 (s, 6H), 2.27 (s, 3H)
Example 64
dimethyl (6-amino-5-(4-(3-(3-(trifluoromethyl)phenyl)ureido)phenyl)pyridin-3-yl)phosphonate
The reaction mixture of dimethyl (6-amino-5-(4-aminophenyl)pyridin-3-yl)phosphonate (30 mg, 0.10 mmol, 1 eq) and 1-isocyanato-3-(trifluoromethyl)benzene (0.018 mL, 1.2 eq) in anhydrous DMF (0.5 mL) under anhydrous nitrogen atmosphere was stirred at room temperature for an hour. It was then diluted with ethyl acetate, washed sequentially with aqueous ammonium chloride, saturated aqueous sodium bicarbonate, brine, and lastly dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated, and the solid residue was subject to a gradient column chromatography (EtOAc-Hex 2:1 to MeOH-EtOAc 1:20) to yield dimethyl (6-amino-5-(4-(3-(3-(trifluoromethyl)phenyl)ureido) phenyl)pyridin-3-yl)phosphonate as a white solid in amount of 41 mg.
1 H NMR (300 MHz, DMSO-d 6 ) δ ppm 9.12 (s, 1H) 9.01 (s, 1H) 8.19 (dd, J=6.37, 2.12 Hz, 1H) 8.03 (s, 1H) 7.56-7.64 (m, 3H) 7.49-7.55 (m, 1H) 7.29-7.42 (m, 4H) 6.44 (br. s., 2H) 3.65 (s, 3H) 3.62 (s, 3H).
Example 65
diethyl [6-amino-5-(4-{[(2-fluoro-5-methylphenyl)carbamoyl]amino}phenyl)pyridin-3-yl]phosphonate
Synthesized using a procedure similar to Example 64.
1 H NMR (300 MHz, DMSO-d 6 ) δ ppm 9.22 (s, 1H) 8.51 (d, J=2.49 Hz, 1H) 8.19 (dd, J=6.37, 2.12 Hz, 1H) 8.00 (dd, J=7.84, 1.83 Hz, 1H) 7.57 (d, J=8.64 Hz, 2H) 7.33-7.42 (m, 3H) 7.11 (dd, J=11.28, 8.35 Hz, 1H) 6.77-6.85 (m, 1H) 6.40 (br. s., 2H) 3.93-4.05 (m, 4H) 2.28 (s, 3H) 1.23 (t, J=7.03 Hz, 6H)
Example 66
dimethyl {6-amino-5-[4-({[2-fluoro-5-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridin-3-yl}phosphonate
Synthesized using a procedure similar to Example 64.
1 H NMR (300 MHz, DMSO-d 6 ) δ ppm 9.36 (br. s., 1H) 8.95 (br. s., 1H) 8.63 (dd, J=7.33, 2.20 Hz, 1H) 8.19 (dd, J=6.37, 2.12 Hz, 1H) 7.55-7.61 (m, 2H) 7.51 (dd, J=10.99, 8.94 Hz, 1H) 7.36-7.44 (m, 4H) 6.45 (br. s., 2H) 3.66 (s, 3H) 3.62 (s, 3H)
Example 67
dimethyl [6-amino-5-(4-{[(2-fluoro-5-methylphenyl)carbamoyl]amino}phenyl)pyridin-3-yl]phosphonate
Synthesized using a procedure similar to Example 64.
1 H NMR (300 MHz, DMSO-d 6 ) δ ppm 9.23 (s, 1H) 8.53 (d, J=1.90 Hz, 1H) 8.19 (dd, J=6.30, 2.05 Hz, 1H) 7.97-8.02 (m, 1H) 7.56 (d, J=8.50 Hz, 2H) 7.34-7.42 (m, 3H) 7.11 (dd, J=11.28, 8.50 Hz, 1H) 6.77-6.84 (m, 1H) 6.44 (br. s., 2H) 3.65 (s, 3H) 3.62 (s, 3H) 2.28 (s, 3H)
Example 63
1-{4-[2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl]phenyl}-3-phenylurea
Synthesized using a procedure similar to Example 62.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 8.81 (br. s., 1H) 8.71 (br. s., 1H) 8.18 (d, J=1.76 Hz, 1H) 7.91-7.97 (m, 1H) 7.53-7.57 (m, 2H) 7.47 (d, J=7.92 Hz, 2H) 7.32-7.37 (m, 2H) 7.26-7.31 (m, 2H) 6.97 (t, J=7.34 Hz, 1H) 5.98 (br. s., 2H) 1.27 (s, 12H)
Example 59
6-amino-N-[dimethyl(oxido)-λ 4 -sulfanylidene]-5-[4-({[(2-fluoro-5-methylphenyl) amino]carbonyl}amino)phenyl]nicotinamide
Synthesized using a procedure similar to Example 69.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.22 (s, 1H) 8.56 (d, J=2.20 Hz, 1H) 8.53 (d, J=2.05 Hz, 1H) 8.00 (dd, J=7.78, 1.61 Hz, 1H) 7.74 (d, J=2.05 Hz, 1H) 7.56 (d, J=8.51 Hz, 2H) 7.36 (d, J=8.51 Hz, 2H) 7.11 (dd, J=11.30, 8.36 Hz, 1H) 6.79-6.83 (m, 1H) 6.24 (br. s., 2H) 4.73 (t, J=5.36 Hz, 2H) 3.54-3.66 (m, 4H) 3.51 (q, J=6.02 Hz, 4H) 2.28 (s, 3H) 1.83-1.95 (m, 4H)
Example 70
dimethyl 5,5′-(N-{[6-amino-5-(4-{[(3-methylphenyl)carbamoyl]amino}phenyl)pyridin-3-yl]carbonyl}sulfonimidoyl)dipentanoate
Synthesized using a procedure similar to Example 69.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 8.79 (s, 1H) 8.61 (s, 1H) 8.55 (d, J=2.20 Hz, 1H) 7.73 (d, J=2.05 Hz, 1H) 7.56 (d, J=8.66 Hz, 2H) 7.34 (d, J=8.51 Hz, 2H) 7.31 (s, 1H) 7.24 (d, J=8.36 Hz, 1H) 7.16 (t, J=7.78 Hz, 1H) 6.80 (d, J=7.34 Hz, 1H) 6.23 (br. s., 2H) 3.49-3.63 (m, 10H) 2.38 (t, J=7.26 Hz, 4H) 2.28 (s, 3H) 1.62-1.85 (m, 8H)
Example 71
dimethyl 5,5′-(N-{[6-amino-5-(4-{[(2-fluoro-5-methylphenyl)carbamoyl]amino}phenyl)pyridin-3-yl]carbonyl}sulfonimidoyl)dipentanoate
Synthesized using a procedure similar to Example 69.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.19 (s, 1H) 8.55 (d, J=2.20 Hz, 1H) 8.50 (d, J=2.35 Hz, 1H) 8.00 (dd, J=7.92, 1.76 Hz, 1H) 7.74 (d, J=2.05 Hz, 1H) 7.56 (d, J=8.66 Hz, 2H) 7.35 (d, J=8.51 Hz, 2H) 7.11 (dd, J=11.30, 8.36 Hz, 1H) 6.79-6.83 (m, 1H) 6.24 (br. s., 2H) 3.50-3.62 (m, 10H) 2.38 (t, J=7.26 Hz, 4H) 2.28 (s, 3H) 1.63-1.84 (m, 8H)
Example 72
dimethyl 5,5′-[N-({6-amino-5-[4-({[3-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridin-3-yl}carbonyl)sulfonimidoyl]dipentanoate
Synthesized using a procedure similar to Example 69.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.08 (s, 1H) 8.95 (s, 1H) 8.55 (d, J=2.20 Hz, 1H) 8.03 (s, 1H) 7.74 (d, J=2.20 Hz, 1H) 7.56-7.61 (m, 3H) 7.52 (t, J=8.00 Hz, 1H) 7.36 (d, J=8.51 Hz, 2H) 7.32 (d, J=7.63 Hz, 1H) 6.24 (br. s., 2H) 3.50-3.62 (m, 10H) 2.38 (t, J=7.34 Hz, 4H) 1.72-1.84 (m, 4H) 1.64-1.70 (m, 4H)
Example 68
dimethyl (6-amino-5-{4-[(phenylcarbamoyl)amino]phenyl}pyridin-3-yl)phosphonate
Synthesized using a procedure similar to Example 64.
1 H NMR (300 MHz, DMSO-d 6 ) δ ppm 8.85 (s, 1H) 8.71 (s, 1H) 8.19 (dd, J=6.37, 2.12 Hz, 1H) 7.54-7.60 (m, 2H) 7.44-7.49 (m, 2H) 7.33-7.41 (m, 3H) 7.29 (t, J=7.91 Hz, 2H) 6.94-7.01 (m, 1H) 6.43 (br. s., 2H) 3.65 (s, 3H) 3.62 (s, 3H)
Example 62
1-(4-(2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl)phenyl)-3-(2-fluoro-5-methylphenyl)urea
To the nitrogen bubbled mixture of 1-(4-(2-amino-5-bromopyridin-3-yl)phenyl)-3-(2-fluoro-5-methylphenyl)urea (487 mg, 1.17 mmol, 1 eq), bis(pinacolato)diboron (0.36 g, 1.2 eq), and potassium acetate (0.46 g, 4 eq) in anhydrous 1,4-dioxane (6 mL) was added [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II) complex with dichloromethane (1:1) (0.14 g, 0.15 eq) and the mixture was heated at 120° C. for one and half hours. After the reaction was cooled to room temperature, it was filtered through a celite pad and washed with ethyl acetate. The filtrate was collected, washed sequentially with aqueous ammonium chloride, saturated aqueous sodium bicarbonate, brine, and lastly dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated, and the brown oily residue was subject to a gradient column chromatography (EtOAc-Hex 1:4 to 4:1) to yield 1-(4-(2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl)phenyl)-3-(2-fluoro-5-methylphenyl)urea as a brown oil which solidified in vacuo in amount of 101 mg.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.17 (s, 1H) 8.49 (br. s., 1H) 8.18 (d, J=1.76 Hz, 1H) 8.00 (d, J=7.92 Hz, 1H) 7.51-7.57 (m, 2H) 7.42 (d, J=1.76 Hz, 1H) 7.33-7.37 (m, 2H) 7.11 (dd, J=11.30, 8.36 Hz, 1H) 6.78-6.84 (m, 1H) 5.99 (s, 2H) 2.28 (s, 3H) 1.27 (s, 12H).
Example 61
(6-amino-5-(4-(3-(2-fluoro-5-methylphenyl)ureido)phenyl)pyridin-3-yl)boronic acid
To the solution of 1-(4-(2-amino-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridin-3-yl)phenyl)-3-(2-fluoro-5-methylphenyl)urea (AGN-227971, 108 mg, 0.234 mmol, 1 eq) in anhydrous tetrahydrofuran (2 mL) was added aq HCl (3 N, 2 mL) and the reaction was first stirred at room temperature for two hours. Additional conc. HCl (0.5 mL) was dropwise added to the reaction and the mixture was stirred at 50° C. for further four hours. The reaction was then poured into saturated aqueous sodium bicarbonate and extracted with ethyl acetate. The organic layer was isolated, washed with brine, and dried with anhydrous sodium sulfate. The upper clear solution was decanted, concentrated to lesser amount, and the solid crashed-out was filtered. This solid was further purified by a reversed phase chromatography (from WATER-CH 3 CN 9:1 to CH 3 CN) to give (6-amino-5-(4-(3-(2-fluoro-5-methylphenyl)ureido)phenyl)pyridin-3-yl)boronic acid as a grey solid in amount of 7 mg.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 9.15 (s, 1H) 8.48 (d, J=2.49 Hz, 1H) 8.31 (d, J=1.76 Hz, 1H) 8.00 (dd, J=7.85, 1.83 Hz, 1H) 7.80 (s, 2H) 7.68 (d, J=1.91 Hz, 1H) 7.52-7.56 (m, 2H) 7.34-7.38 (m, 2H) 7.11 (dd, J=11.30, 8.36 Hz, 1H) 6.78-6.83 (m, 1H) 5.71 (s, 2H) 2.28 (s, 3H)
Example 69
6-amino-N-[bis(3-hydroxypropyl)(oxido)-λ 4 -sulfanylidene]-5-[4-({[(3-methylphenyl)amino]carbonyl}amino)phenyl]nicotinamide
To the solution of 6-amino-5-(4-aminophenyl)-N-[bis(3-hydroxypropyl)(oxido)-λ 4 -sulfanylidene]nicotinamide (39 mg, 0.1 mmol, 1.0 eq) in anhydrous THF (1 mL) was added 1-isocyanato-3-methylbenzene (0.013 mL, 1.0 eq) dropwise. The reaction was stirred at room temperature for 1 hour and then diluted with EtOAc. The organic layer was washed sequentially with saturated aq NaHCO 3 , aq NH 4 Cl, brine, and finally dried with anhydrous Na 2 SO 4 . The supernatant liquid was decanted, concentrated, and the oily residue was subject to a gradient column chromatography (EtOAc-Hex 7:1 to MeOH-EtOAc 1:9) yielding 6-amino-N-[bis(3-hydroxypropyl)(oxido)-λ 4 -sulfanylidene]-5-[4-({[(3-methylphenyl)amino]carbonyl}amino)phenyl]nicotinamide as a white solid in amount of 30 mg.
1 H NMR (600 MHz, DMSO-d 6 ) δ ppm 8.82 (br. s., 1H) 8.64 (br. s., 1H) 8.56 (d, J=2.05 Hz, 1H) 7.74 (d, J=2.05 Hz, 1H) 7.56 (d, J=8.51 Hz, 2H) 7.34 (d, J=8.22 Hz, 2H) 7.31 (s, 1H) 7.24 (d, J=7.63 Hz, 1H) 7.16 (t, J=7.78 Hz, 1H) 6.80 (d, J=7.34 Hz, 1H) 6.23 (br. s., 2H) 4.72 (t, J=5.28 Hz, 2H) 3.49-3.66 (m, 8H) 2.28 (s, 3H) 1.82-1.95 (m, 4H)
Example 74
methyl 6-amino-5-[4-({[2-fluoro-5-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridine-3-carboxylate
To methyl 6-amino-5-(4-aminophenyl)nicotinate (0.18 mmoles) in 3 ml of tetrahydrofuran (THF) under nitrogen atmosphere was added a solution of 1-fluoro-2-isocyanato-4-(trifluoromethyl)benzene (0.22 mmoles, 1.2 equivalents) in 1 ml THF. The reaction was stirred at room temperature under nitrogen atmosphere for 30 minutes. Following this, the reaction was loaded onto silica and columned using ethyl acetate-hexanes, to give 25 mg of the product.
1 H NMR (dmso-d 6 ) δ: 9.29-9.34 (m, 1H), 8.92 (br. s., 1H), 8.60-8.65 (m, 1H), 8.51 (d, J=2.4 Hz, 1H), 7.68 (d, J=2.2 Hz, 1H), 7.57 (d, J=8.6 Hz, 2H), 7.46-7.52 (m, 1H), 7.38 (d, J=8.6 Hz, 3H), 6.52 (br. s., 2H), 3.78 (s, 3H)
Example 75
methyl 6-amino-5-[4-({[4-chloro-3-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridine-3-carboxylate
Synthesized using a procedure similar to methyl 6-amino-5-[4-({[2-fluoro-5-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridine-3-carboxylate.
1 H NMR (dmso-d6) δ: 9.20-9.25 (m, 1H), 9.04 (s, 1H), 8.50 (d, J=2.2 Hz, 1H), 8.11 (d, J=2.4 Hz, 1H), 7.59-7.68 (m, 3H), 7.57 (d, J=8.6 Hz, 2H), 7.37 (d, J=8.6 Hz, 2H), 6.51 (br. s., 2H), 3.77 (s, 3H)
Example 73
methyl 6-amino-5-(4-{[(2-fluoro-5-methylphenyl)carbamoyl]amino}phenyl)pyridine-3-carboxylate
Synthesized using a procedure similar to methyl 6-amino-5-[4-({[2-fluoro-5-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridine-3-carboxylate.
1 H NMR (dmso-d 6 ) δ: 9.21 (s, 1H), 8.50 (d, J=2.2 Hz, 2H), 7.97-8.01 (m, 1H), 7.67 (d, J=2.2 Hz, 1H), 7.54-7.57 (m, 2H), 7.36 (d, J=8.6 Hz, 2H), 7.10 (dd, J=11.5, 8.3 Hz, 1H), 6.77-6.82 (m, 1H), 6.51 (br. s., 2H), 3.78 (s, 3H), 2.27 (s, 3H).
Example 76
methyl 6-amino-5-{4-[(phenylcarbamoyl)amino]phenyl}pyridine-3-carboxylate
Synthesized using a procedure similar to methyl 6-amino-5-[4-({[2-fluoro-5-(trifluoromethyl)phenyl]carbamoyl}amino)phenyl]pyridine-3-carboxylate.
1 H NMR (dmso-d 6 ) δ: 8.81 (s, 1H), 8.68 (s, 1H), 8.50 (d, J=2.2 Hz, 1H), 7.66-7.68 (m, 1H), 7.54-7.57 (m, J=8.6 Hz, 2H), 7.46 (dd, J=8.6, 1.0 Hz, 2H), 7.35 (d, J=8.6 Hz, 2H), 7.28 (t, J=7.9 Hz, 2H), 6.97 (t, J=7.4 Hz, 1H), 6.51 (br. s., 2H), 3.77 (s, 3H).
Biological data for the compounds of the present invention was generated by use of the following assays.
VEGFR2 Kinase Assay
Biochemical KDR kinase assays were performed in 96 well microtiter plates that were coated overnight with 75 μg/well of poly-Glu-Tyr (4:1) in 10 mM Phosphate Buffered Saline (PBS), pH 7.4. The coated plates were washed with 2 mls per well PBS+0.05% Tween-20 (PBS-T), blocked by incubation with PBS containing 1% BSA, then washed with 2 mls per well PBS-T prior to starting the reaction. Reactions were carried out in 100 μL reaction volumes containing 2.7 μM ATP in kinase buffer (50 mM Hepes buffer pH 7.4, 20 mM MgCl 2 , 0.1 mM MnCl 2 and 0.2 mM Na 3 VO 4 ). Test compounds were reconstituted in 100% DMSO and added to the reaction to give a final DMSO concentration of 5%. Reactions were initiated by the addition 20 ul per well of kinase buffer containing 200-300 ng purified cytoplasmic domain KDR protein (BPS Bioscience, San Diego, Calif.). Following a 15 minute incubation at 30° C., the reactions were washed 2 mls per well PBS-T. 100 μl of a monoclonal anti-phosphotyrosine antibody-peroxidase conjugate diluted 1:10,000 in PBS-T was added to the wells for 30 minutes. Following a 2 mls per well wash with PBS-Tween-20, 100 μl of O-Phenylenediamine Dihydrochloride in phosphate-citrate buffer, containing urea hydrogen peroxide, was added to the wells for 7-10 minutes as a colorimetric substrate for the peroxidase. The reaction was terminated by the addition of 100 μl of 2.5N H 2 SO 4 to each well and read using a microplate ELISA reader set at 492 nm. IC 50 values for compound inhibition were calculated directly from graphs of optical density (arbitrary units) versus compound concentration following subtraction of blank values.
VEGFR2 Cellular Assay
Automated FLIPR (Fluorometric Imaging Plate Reader) technology was used to screen for inhibitors of VEGF induced increases in intracellular calcium levels in fluorescent dye loaded endothelial cells. HUVEC (human umbilical vein endothelial cells) (Clonetics) were seeded in 384-well fibronectin coated black-walled plates overnight @ 37° C./5% CO2. Cells were loaded with calcium indicator Fluo-4 for 45 minutes at 37° C. Cells were washed 2 times (Elx405, Biotek Instruments) to remove extracellular dye. For screening, cells were pre-incubated with test agents for 30 minutes, at a single concentration (10 uM) or at concentrations ranging from 0.0001 to 10.0 uM followed by VEGF 165 stimulation (10 ng/mL). Changes in fluorescence at 516 nm were measured simultaneously in all 384 wells using a cooled CCD camera. Data were generated by determining max-min fluorescence levels for unstimulated, stimulated, and drug treated samples. IC 50 values for test compounds were calculated from % inhibition of VEGF stimulated responses in the absence of inhibitor.
PDGFRβ Kinase Assay
Biochemical PDGFRβ kinase assays were performed in 96 well microtiter plates that were coated overnight with 75 μg of poly-Glu-Tyr (4:1) in 10 mM Phosphate Buffered Saline (PBS), pH 7.4. The coated plates were washed with 2 mls per well PBS+0.05% Tween-20 (PBS-T), blocked by incubation with PBS containing 1% BSA, then washed with 2 mls per well PBS-T prior to starting the reaction. Reactions were carried out in 100 μL reaction volumes containing 36 μM ATP in kinase buffer (50 mM Hepes buffer pH 7.4, 20 mM MgCl 2 , 0.1 mM MnCl 2 and 0.2 mM Na 3 VO 4 ). Test compounds were reconstituted in 100% DMSO and added to the reaction to give a final DMSO concentration of 5%. Reactions were initiated by the addition 20 μl per well of kinase buffer containing 200-300 ng purified cytoplasmic domain PDGFR-b protein (Millipore). Following a 60 minute incubation at 30° C., the reactions were washed 2 mls per well PBS-T. 100 μl of a monoclonal anti-phosphotyrosine antibody-peroxidase conjugate diluted 1:10,000 in PBS-T was added to the wells for 30 minutes. Following a 2 mls per well wash with PBS-Tween-20, 100 μl of O-Phenylenediamine Dihydrochloride in phosphate-citrate buffer, containing urea hydrogen peroxide, was added to the wells for 7-10 minutes as a colorimetric substrate for the peroxidase. The reaction was terminated by the addition of 100 μl of 2.5N H 2 SO 4 to each well and read using a microplate ELISA reader set at 492 nm. IC 50 values for compound inhibition were calculated directly from graphs of optical density (arbitrary units) versus compound concentration following subtraction of blank values.
PDGFRβ Cellular Assay
Automated FLIPR (Fluorometric Imaging Plate Reader) technology was used to screen for inhibitors of PDGF-induced increases in intracellular calcium levels in fluorescent dye loaded endothelial cells. NHDF-Ad (Normal Human Dermal Fibroblasts, Adult; Lonza) were seeded in 384-well fibronectin coated black-walled plates overnight @ 37° C./5% CO2. Cells were loaded with calcium indicator Fluo-4 for 45 minutes at 37° C. Cells were washed 2 times (Elx405, Biotek Instruments) to remove extracellular dye. For screening, cells were pre-incubated with test agents for 30 minutes, at a single concentration (10 uM) or at concentrations ranging from 0.0001 to 10.0 uM followed by PDGF-BB stimulation (30 ng/mL). Changes in fluorescence at 516 nm were measured simultaneously in all 384 wells using a cooled CCD camera. Data were generated by determining max-min fluorescence levels for unstimulated, stimulated, and drug treated samples. IC 50 values for test compounds were calculated from % inhibition of PDGF-BB stimulated responses in the absence of inhibitor.
PKR KinaseGlo Assay
Commercially available recombinant human GST-PKR (SignalChem, Canada; 1.5 uM-2 uM stock) is diluted to 500 nM in assay buffer (20 mM Tris-HCl, pH 7.2, 10 mM KCl, 10 mM MgCl2, 10% glycerol). Preactivated PKR is dispensed to 384/96-well black plates at 3.125/12.5 uls/well using the liquid handler Janus. Appropriate dilutions of inhibitors are added to 384/96-well plate followed by 6.6 uM ATP (final) and incubated for 10 minutes at room temperature. The remaining ATP/well is determined by adding 6.25/25 uls/well Kinase-Glo assay mix (Promega) and luminescence is measured on EnVision luminescence plate reader (integration time, 0.2 sec; Perkin-Elmer, Massachusetts, USA). The % inhibition for the compounds is calculated using ATP only (100% inhibition) and PKR+ATP (0% inhibition). IC50 values are determined by plotting % activity versus inhibitor concentration. Curves are fitted using Activity base XLfit (IDBS, UK) using the formula—
4 Parameter Logistic Model
fit=( A +(( B−A )/(1+(10^(( C−x )* D )))))
inv=( C −(log((( B−A )/( y−A ))−1)/ D ))
res=( y −fit)
The biological results for the various compounds are shown in Tables 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12 below.
For preparing pharmaceutical compositions from the compounds described by this invention, inert, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets and suppositories. The powders and tablets may be comprised of from about 5 to about 95 percent active ingredient. Suitable solid carriers are known in the art, e.g., magnesium carbonate, magnesium stearate, talc, sugar or lactose. Tablets, powders, cachets and capsules can be used as solid dosage forms suitable for oral administration. Examples of pharmaceutically acceptable carriers and methods of manufacture for various compositions may be found in A. Gennaro (ed.), Remington's Pharmaceutical Sciences, 18 th Edition, (1990), Mack Publishing Co., Easton, Pa.
Liquid form preparations include solutions, suspensions and emulsions. As an example may be mentioned water or water-propylene glycol solutions for parenteral injection or addition of sweeteners and opacifiers for oral solutions, suspensions and emulsions. Liquid form preparations may also include solutions for intranasal administration.
Aerosol preparations suitable for inhalation may include solutions and solids in powder form, which may be in combination with a pharmaceutically acceptable carrier, such as an inert compressed gas, e.g. nitrogen.
Also included are solid form preparations that are intended to be converted, shortly before use, to liquid form preparations for either oral or parenteral administration. Such liquid forms include solutions, suspensions and emulsions.
The compounds of the invention may also be deliverable transdermally. The transdermal compositions can take the form of creams, lotions, aerosols and/or emulsions and can be included in a transdermal patch of the matrix or reservoir type as are conventional in the art for this purpose.
The compounds of this invention may also be delivered orally, subcutaneously, intravenously, intrathecally or some suitable combination(s) thereof.
In addition to the common dosage forms set out above, the compounds of this invention may also be administered by controlled release means and/or delivery devices such as those described in U.S. Pat. Nos. 3,845,770; 3,916,899; 3,536,809; 3,598,123; 3,630,200; 4,008,719; and 5,366,738.
For use where a composition for intravenous administration is employed, a suitable daily dosage range for anti-inflammatory, anti-atherosclerotic or anti-allergic use is from about 0.001 mg to about 25 mg (preferably from 0.01 mg to about 1 mg) of a compound of this invention per kg of body weight per day and for cytoprotective use from about 0.1 mg to about 100 mg (preferably from about 1 mg to about 100 mg and more preferably from about 1 mg to about 10 mg) of a compound of this invention per kg of body weight per day. For the treatment of diseases of the eye, ophthalmic preparations for ocular administration comprising 0.001-1% by weight solutions or suspensions of the compounds of this invention in an acceptable ophthalmic formulation may be used.
Preferably, the pharmaceutical preparation is in a unit dosage form. In such form, the preparation is subdivided into suitably sized unit doses containing appropriate quantities of the active component, e.g., an effective amount to achieve the desired purpose.
The magnitude of prophylactic or therapeutic dose of a compound of this invention will, of course, vary with the nature of the severity of the condition to be treated and with the particular compound and its route of administration. It will also vary according to the age, weight and response of the individual patient. It is understood that a specific daily dosage amount can simultaneously be both a therapeutically effective amount, e.g., for treatment to slow progression of an existing condition, and a prophylactically effective amount, e.g., for prevention of condition.
The quantity of active compound in a unit dose of preparation may be varied or adjusted from about 0.001 mg to about 500 mg. In one embodiment, the quantity of active compound in a unit dose of preparation is from about 0.01 mg to about 250 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 0.1 mg to about 100 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 100 mg. In another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 50 mg. In still another embodiment, the quantity of active compound in a unit dose of preparation is from about 1.0 mg to about 25 mg.
The actual dosage employed may be varied depending upon the requirements of the patient and the severity of the condition being treated. Determination of the proper dosage regimen for a particular situation is within the skill of the art. For convenience, the total daily dosage may be divided and administered in portions during the day as required.
The amount and frequency of administration of the compounds of the invention and/or the pharmaceutically acceptable salts thereof will be regulated according to the judgment of the attending clinician considering such factors as age, condition and size of the patient as well as severity of the symptoms being treated. A typical recommended daily dosage regimen for oral administration can range from about 0.01 mg/day to about 2000 mg/day of the compounds of the present invention. In one embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 1000 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 500 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 100 mg/day to 500 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 250 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 100 mg/day to 250 mg/day. In still another embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 100 mg/day. In still another embodiment, a daily dosage regimen for oral administration is from about 50 mg/day to 100 mg/day. In a further embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 50 mg/day. In another embodiment, a daily dosage regimen for oral administration is from about 25 mg/day to 50 mg/day. In a further embodiment, a daily dosage regimen for oral administration is from about 1 mg/day to 25 mg/day. The daily dosage may be administered in a single dosage or can be divided into from two to four divided doses.
In one aspect, the present invention provides a kit comprising a therapeutically effective amount of at least one compound of the present invention, or a pharmaceutically acceptable salt of said compound and a pharmaceutically acceptable carrier, vehicle or diluents, and directions for the use of said kit.
The present invention is not to be limited in scope by the specific embodiments disclosed in the examples which are intended as illustrations of a few aspects of the invention and any embodiments that are functionally equivalent are within the scope of this invention. Indeed, various modifications of the invention in addition to those shown and described herein will become apparent to those skilled in the relevant art and are intended to fall within the scope of the appended claims.
TABLE 2
Sulfoximine/Urea
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
1
8
20
20
2
3
25
17
3
8
3
17
4
42
68
73
5
6
11
21
6
6
5
27
TABLE 3
Ester/Urea
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
7
7
22
11
8
10
12
24
9
15
63
45
10
17
27
15
11
20
328
18
12
21
355
26
13
45
941
12
14
81
1595
10
15
137
1352
28
16
NA
NA
9
TABLE 4
Acid or Amide/Urea
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
Y
Z
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
17
41
N/A
N/A
18
38
N/A
N/A
19
120
N/A
431
20
35
N/A
N/A
21
118
N/A
N/A
22
132
N/A
N/A
TABLE 5
Boronate Ester/Urea
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
23
10
N/A
17
24
13
N/A
N/A
25
16
N/A
21
26
25
N/A
10
27
37
N/A
N/A
28
42
N/A
18
29
54
N/A
20
30
301
N/A
130
TABLE 6
Boronic Acid/Urea
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
31
93
N/A
42
32
378
N/A
138
TABLE 7
Sulfoximine/Amide
VEGFR2
VEGFR2
PDGFRβ
Enzyme Assay
Cellular Assay
Enzyme Assay
Example
Q
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
33
17
6
457
34
32
277
36
35
50
45
258
36
51
N/A
N/A
37
53
N/A
131
38
178
1023
128
TABLE 8
Ester/Amide
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay (IC 50
Assay (IC 50
Assay (IC 50
Example
Y
Q
nM)
nM)
nM)
39
31
75
61
40
57
145
25
41
199
1102
38
42
224
3945
503
43
264
2488
25
44
930
8722
29
45
N/A
N/A
936
46
H
1171
5110
1278
47
H
1488
1815
N/A
TABLE 9
Reverse Amides
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
T
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
48
3570
N/A
>10,000
TABLE 10
Other Sulfoximine substituents/Ureas
VEGFR2
VEGFR2
PDGFRβ
Enzyme
Cellular
Enzyme
Assay
Assay
Assay
Example
Y
A
(IC 50 nM)
(IC 50 nM)
(IC 50 nM)
53
5
N/A
16
54
3
N/A
N/A
55
4
N/A
N/A
56
8
N/A
8
TABLE 11
PKR data for Pyridyl Benzothiophenes
PKR KINASEGLO
Enzyme Assay IC50
Example
Structure
(nM)
5
69
6
167
TABLE 12
VEGFR2
PKR
Enzyme
KINASEGLO
Assay
Enzyme Assay
Example
Structure
(IC 50 nM)
IC50 (nM)
57
7
551
58
14
390
TABLE 13
VEGFR2
VEGFR2
PDGFRβ
PDGFRβ
Example
Kinase
Cellular
Kinase
Cellular
Number
Structure
IC 50 nM
IC 50 nM
IC 50 nM
IC 50 nM
59
26
na
100
na
60
6
12
na
na
61
25
na
58
150
62
53
na
24
na
63
206
na
na
na
64
57
10
na
66
65
99
35
82
118
66
115
25
na
na
67
133
30
na
na
68
891
na
na
na
69
13
na
83
na
70
14
3
138
173
71
33
13
88
141
72
42
11
13
192
73
9
14
na
na
74
7
41
na
na
75
7
74
na
na
76
29
115
na
na | This invention is directed to compounds, which are useful as protein kinase (PK) inhibitors and can be used to treat such diseases as cancer, blood vessel proliferative disorders, fibrotic disorders, mesangial cell proliferative disorders, metabolic diseases inflammatory disorders and neurodegenerative disorders. | 2 |
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